LOCAL GOVERNMENT & HTP DEPARTMENT

GOVERNMENT OF SINDH

CONSTRUCTION OF BRIDGE AT KORANGI CAUSEWAY

BIDDING AND CONTRACT DOCUMENTS

VOLUME - IIB
TECHNICAL SPECIFICATIONS (FOR NON - SCHEDULED ITEMS)
(CIVIL & ELECTRICAL WORKS)

February, 2023

National Engineering Services Pakistan (Pvt) Limited

13th Floor, NICL Building, Abbasi Shaheed Road,
Off: Shahrah-e-Faisal, Karachi-74400, Pakistan
Phone: +92-021-99090000 Ext 685 Fax: +92-021-35651994
Email: karachi@nespak.com.pk, nespakkh@gmail.com
http://www.nespak.com.pk

Clearance Code Doc No. Rev No. 00

LOCAL GOVERNMENT & HTP DEPARTMENT GOVERNMENT OF SINDH
CONSTRUCTION OF BRIDGE AT KORANGI CAUSEWAY

VOLUME – IIB
TECHNICAL SPECIFICATIONS
TABLE OF CONTENTS
SEC.NO DESCRIPTION PAGE NO.

SCHEDULE ITEMS

For schedule items, refer NHA specifications (Latest Version)

NON - SCHEDULE ITEMS (CIVIL WORKS)

0100 General Requirements 0100-1 to 20

0120 Contractor’s Camp 0120-1 to 02

0130 Stake-out Survey 0130-1 to 02

0200 Dismantling Works 0200-1 to 04

0400 Geotechnical Investigation 0400-1 to 24

1100 Earthworks 1100-1 to 12

1520 Piling Works 1520-1 to 09

2100 Formwork 2100-1 to 06

2300 Plain and Reinforced Concrete 2300-1 to 44

2315 Expansion Joint 2315-1 to 03

3000 Structural Steel Works 0300-1 to 13

3100 Miscellaneous Steel Works 3100-1 to 05

5100 Plumbing 5100-1 to 16

5180 Testing of Pipeline 5180-1

5190 Hydraulic Model (Physical

& Mathematical Study) 5190-1 to 02
5213 Polyethylene (PE) pipes
and pipe fittings 5213-1 to 04

Bidding and Contract Documents Page No.

Volume-IIB 1
 SEC.NO DESCRIPTION PAGE NO.
5233 Cast Iron Covers with Frames & 5233-1 to 02
Ladder Rungs
5240 Pumping Machinery 5240-1 to 03

6411 Water proofing and Built up Roofing 6411-1 to 06

7190 Miscellaneous Roads Works 7190-1 to 02

7510 Precast Concrete Paving 7510-1 to 04
Blocks

NON - SCHEDULE ITEMS (ELECTRICAL WORKS)

8001 General Specifications for 8001-1 to13

Electrical Works

8132 LT Switchboards / 8132-1 to 10

LT Outdoor Distribution Boards

8150 Light Fixtures 8150-1 to 05

8212 Low Tension Cables 8212-1 to 07

8230 Conduits and Pipes 8230-1 to 08

8240 Earthing / Grounding System 8240-1 to 05

8290 Miscellaneous Items 8290-1 to 07

Bidding and Contract Documents Page No.

Volume-IIB 2
SCHEDULED ITEMS
Refer NHA Specifications (Latest Version)
 SECTION - 0100

GENERAL REQUIREMENTS

01 GENERAL

The Conditions of Contract Part I & II shall form an integral part of these General
Requirements.

The Contractor shall notify all sub-contractors of the provisions of the Conditions of
Contract and the General Requirement of this Specification.

The arrangement and divisions of these Specifications is not to be construed as

establishing the limits of responsibility of sub-trades.

The Contractor is responsible for delineating the scope of Sub-Contracts and for
coordinating all the Works.

All works shall be carried out in accordance with the following specifications, supplemented
by detailed specifications contained in the following sections. Any inconsistencies or
ambiguities shall be brought to the notice of the Engineer for his clarification/decision.
Decision and direction of the Engineer, in all such cases, shall be final and binding.

The Contractor shall make himself thoroughly familiar with the site conditions, foresee any
and all problems likely to be encountered during execution of the works, and shall be able
and ready to solve them effectively. Proposals for solutions to the problems shall be
submitted to the Engineer for approval before proceeding with the work.

02 APPLICABLE CODES AND STANDARDS

In the absence of other Standards being required by the Contract Documents, all work and
materials shall meet the requirement of the Uniform Building Code of the United States,
and/or applicable American Society for Testing Materials (ASTM),American Association of
State Highway and Transportation Officials (AASHTO) Specifications and the latest
American Concrete Institute Manual of Concrete Practice and American Institute of Steel
Construction (AISC) Manual relevant to the Works except in cases where the Pakistan
Building Code requires a higher standard. In such cases the Pakistani Code shall govern.
Where the abbreviations listed below are used, it refers to the latest code, standards, or
publication of the following organizations:

AASHTO American Association of State Highway and Transportation Officials.

ACI American Concrete Institute
AISC American Institute of Steel Construction
ANSI American National Standards Institute
ASA American Standard Association
ASCE American Society of Civil Engineers
ASTM American Society for Testing and Material
AWS American Welding Society
BSI British Standards Institute
ICAO International Civil Aviation Organization
BSICP British Standard Institute Code of Practice
PCA Portland Cement Association
PSI Pakistan Standard Institute
PSQCA Pakistan Standard & Quality Control Authority.
UBC Uniform Building Code
UPS Uniform Plumbing Code
If the Contractor, at any time and for any specific reasons, wish to deviate from the above
standards or desires to use materials or equipment other than those provided for by the

Construction of Bridge at Korangi Causeway 0100-1 General Requirements

 above standards, then he shall state the exact nature of the change giving the reasons for
making the change and shall submit complete specifications of the materials and
descriptions of the equipment for the Engineer's approval, whose decisions shall be
conclusive and binding upon the Contractor.

03 CODES, STANDARDS, CERTIFICATES

The Contractor shall supply and have at his site office:

Copies of all latest editions of codes and standards referred to in these specifications by
number, or equivalent codes and standards approved by the Engineer.

Catalogues and published recommendations from manufacturers supplying products and

materials for the project.

The Contractor shall provide manufacturer's or supplier's certificates to the Engineer for all
products and materials which must meet the requirements of a specific code or standard as
stated in these Specifications.

04 UNITS OF MEASUREMENTS

The International System of Units (SI) shall be used throughout this Project.

05 MANUFACTURER'S RECOMMENDATIONS

Installation of manufactured items shall be in accordance with procedures recommended by

the manufacturer or as approved by the Engineer.

06 EXISTING CONDITION AT SITE

Drawings and information pertaining to existing project conditions are available at

Engineer’s office for reference.

Neither the Employer nor the Engineer warrants the adequacy or correctness of these.

07 PROTECTION AND PRECAUTIONS

The Contractor and his sub-contractors shall afford all necessary protection to existing
structures and will be required to make good at his own expense any damage done to such
structures through his own or his representatives or subcontractors' fault and negligence.

The Contractor and his sub-contractors shall afford all necessary protection to existing
roads in the area. He will clear and make good at his own expense any damage to or debris
on these roads through his own fault and negligence. He must at all time ensure the free
and normal flow of traffic and shall not cause obstruction to the traffic system. The
Contractor and his sub-contractors shall provide and maintain necessary protection and
precautionary measures such as warning signs, warning lamps and barricades etc. to
prevent accidents.

The Contractor shall promptly correct all such damage to original condition at no additional
expense to the Employer.

The Contractor shall cooperate with other Contractors performing work under other
Contracts as necessary for completion.

08 SETTING OUT OF WORK

Construction of Bridge at Korangi Causeway 0100-2 General Requirements

 8.1 Verify accuracy of layout information shown on the Drawings, in relation to the
property survey and existing benchmarks before proceeding to layout the Work.
Locate and protect existing benchmarks and control points. Preserve permanent
reference points during construction.

(a) Do not change or relocate benchmarks or control points without prior written
approval from the Engineer. Promptly report lost or destroyed reference
points or requirements to relocate reference points because of necessary
changes in grade, location or conflicting construction.

(b) Promptly replace lost or damaged project control points with prior approval
of the Engineer. Replacement of project control points shall be based on
original survey control points.

(c) Establish and maintain the required number of permanent benchmarks on

the job site as directed by the Engineer. Benchmarks shall be located from
and referenced to data established from survey control points. Record
benchmark location, with horizontal and vertical data, on Project Record
Documents.

8.2 Existing utilities and equipment:

(a) The existence and location of underground and other utilities and
construction indicated in the Construction Documents as existing are not
guaranteed. Before beginning site work, investigate and verify the existence
and location of underground utilities and other construction and record this
information on the relevant plan.

(b) Prior to construction, verify the location and invert elevation at points of
connection to sanitary sewer, storm drainage and water service piping.
Verify the location of electrical power and communication utilities for
interface.

8.3 PERFORMANCE

(a) Working from lines and levels established by the property survey, establish
benchmarks and reference markers to set lines and levels at each story of
construction and elsewhere as needed to properly locate each element of
the Project. Calculate and measure required dimensions within indicated or
recognized tolerances. Drawings shall not be scaled to determine
dimensions.

(b) Maintain a Surveyor's Log of control and other survey work. Surveyor's
Log shall be made available for The Engineer reference.

Record deviations from required lines and levels, and advise the Engineer
when deviations that exceed indicated or recognized tolerances are
detected. Contractor shall record on Project Record Drawings deviations
that are accepted and not corrected.

8.4 Site Works:

(a) Locate and lay out works, fill and topsoil placement, slopes and invert
elevations by instrumentation and similar appropriate means.

(b) Prior to Substantial Completion, prepare a final property survey showing

significant features (real property) for the Project. Include on the survey a
certification, signed by the Surveyor, to the effect that principal metes,

Construction of Bridge at Korangi Causeway 0100-3 General Requirements

 bounds, lines and levels of Project are accurately positioned as shown on
survey.

09 SEQUENCE OF CONSTRUCTION

The Contractor shall submit his proposal for approval of the Engineer the sequence of
Construction, prior to starting the works. The works shall be executed as per approved
sequence of construction.

10 PARTIAL POSSESSION

Whenever, as determined by the Employer any portion of work performed by the Contractor
is in a condition suitable for use, the Employer may take possession of or use such portion.

Such use by the Employer shall in no instance be construed as constituting final

acceptance, and shall neither relieve the Contractor of any of his responsibilities under the
Contract, nor acts a waiver by the Employer of any of the conditions thereof, provided that
the Contractor shall not be liable for the cost of repairs, re-work, or renewals which may be
required due to ordinary wear and tear resulting from such use. However, if such use
increases the cost or delays to the completion of remaining portions of work, the Contractor
will be entitled to an equitable adjustment.

If, as a result of the Contractor's failure to comply with the provision of the Contract, such
use proves to be unsatisfactory, the Employer will have the right to continue such use until
such portion of the work can, without injury to the Employer, be taken out of service for
correction of defects, errors, omissions, or replacement of unsatisfactory materials or
equipment, as necessary for such work to comply with the Contract; provided that the
period of such operation or use pending completion of appropriate remedial action shall not
exceed twelve months unless otherwise mutually agreed upon in writing between the
parties.

11 EXISTING SERVICES

The Contractor shall search for, find, locate and protect any wiring, cable, duct, pipe work,
etc., within or immediately adjoining the site area.

The Contractor shall take full responsibly for safety of existing service lines, utilities and
utility structures uncovered or encountered during excavation and construction operations.

The Contractor shall take full responsibility for damaging any such service lines, utility/utility
structure and any cost and/or expense that arises or issues from any such damage shall be
borne directly by him. If damage to any such service occur the Contractor shall forthwith
take remedial action, initiate safety precautions, install temporary services and carryout
repair all at his own cost and expense and inform the Engineer and notify all relevant
authorities.

Existing utilities which are to remain in service for or after the works are to be determined
by the Contractor. If any existing service lines, utilities and utility structures which are to
remain in service are uncovered or encountered during these operations, they shall be
safeguarded, protected from damage, and supported.

12 PLANT AND EQUIPMENT

The Contractor shall submit a detailed list of plant and equipment which he shall undertake
to bring to the site to carry out the work. The list shall satisfy the Engineer as to type, size
and quantity. The list shall include for each piece of equipment the type, manufacturer,
model, identification number and year of manufacture. The Contractor shall provide on the
site of the work at his cost all of the equipment listed and all subsequent equipment
required for approval of the detailed programme of work and such equipment which may
be directed by the Engineer. The Contractor shall supply all plant and equipment necessary

Construction of Bridge at Korangi Causeway 0100-4 General Requirements

 for the construction of each phase of the work and it must be on site, inspected and
approved by the Engineer.

13 CONSTRUCTION AREA AND ACCESS

The Contractor shall confine his operations to the areas that are actually required for the
Works and shall fence the area accordingly. Arrangements for access roads, storage areas
and routes for haulage of materials are to be made by the Contractor at his own cost,
subject to the approval of the Engineer.

14 STORAGE & HANDLING FACILITIES

The Employer will provide the Contractor possible space within or nearby the area of site of
works for the storage of plant, equipment and materials and for Contractor's temporary
office, during the currency of the Contract. In case the adjacent area as required by the
Contractor is not available within the Project boundary for storage of plant, equipment and
machines then the Contractor shall arrange at his own expense possible space for storage
of plant, equipment and machines at his own cost and expense. On no account shall such
temporary installations conflict/interfere with any of the permanent installations, services
and any operational function of Employer. The handling and storage of all plants,
equipment and materials at site shall be the sole responsibility of the Contractor and at no
risk and cost to the Employer.

The Contractor shall protect all material against corrosion, mechanical damage or
deterioration during storage and erection on site. The protection methods shall be to the
approval of the Engineer.

15 TEST LABORATORY AND TESTING

15.1 Testing, except as otherwise specified herein, shall be performed by an

approved testing agency as proposed by the Contractor and at no extra cost to the
Employer. The Engineer may require all testing to be carried out under his
supervision only.

15.2 If suitable and adequate material testing laboratory is not available in the vicinity,
then the Contractor shall provide and maintain a materials testing laboratory in the
vicinity of the Contractor's Camp and the laboratory shall have sufficient working
area and shall be equipped with all necessary facilities including a suitable store
room.

15.3 The Contractor shall supply and maintain to the satisfaction of the Engineer or his
representative complete testing equipment, apparatus, tools, gauges, instruments,
etc. in sufficient number and adequate for all tests to be carried out as specified in
these specifications. Valid calibration certificates of gauges / instruments /
equipment shall be provided by the Contractor.

15.4 The Contractor, after the approval by the Engineer for the source of cement and
steel shall make available at the site sufficient stock of the materials in advance in
order to allow sample testing for quality control prior to use.

15.5 The quality control testing shall be performed by the Contractor's competent
personnel in accordance with a site testing and quality control programme to

be established by the Contractor and approved by the Engineer or his

Representative. The Contractor shall keep a complete record of all quality tests
performed on site and submit the same to the Engineer. All quality control and
related tests shall be carried out in accordance with applicable standards and codes.

16 CONSTRUCTION & CHECKING AT SITE

Construction of Bridge at Korangi Causeway 0100-5 General Requirements

 The Contractor shall submit to the Engineer in due time for approval and discussion, his
proposals and plans as to the method and procedure to be adopted for the temporary and
permanent works involved.

The submitting to these suggestions and arrangements, and the approval thereof by the
Engineer shall not relieve the Contractor of his responsibilities and duties under the
Contract.

The carrying out of all work included in the Contract is to be supervised by a sufficient
number of qualified representatives of the Contractor and full facilities and assistance are
to be afforded by the Contractor for the Engineer or his Representative to check & examine
the execution of the work.

The Engineer reserves the right to inspect all parts of the works but may at his discretion
waive inspection on certain items. This shall in no way absolve the Contractor from his
responsibilities. This particularly applies to the checking of materials, the accurate setting
out of foundations, and to the levelling, setting and aligning of the various parts, and to the
proper fitting and adjustment of manufactured and finished materials and fixtures in
position.

If the Engineer or his Representative find that the work progress is slow in such a way that
the works or parts thereof will not be completed in the time specified, then he shall order the
Contractor to work overtime or in shifts and the Contractor shall comply. These
arrangements will be free of all financial encumbrances and at no additional costs to the
Employer.

In the event of night work, the Contractor shall provide sufficient and adequate lighting to
the satisfaction of the Engineer or his Representative and shall supply the necessary
manpower for satisfactory continuation of the work after normal hours.

17 BAR BENDING SCHEDULE

Bar bending (reinforcement bars) schedule of all drawings shall be prepared by the
Contractor and submitted in triplicate to the Engineer for approval.

18 DRAWINGS

18.1 Bidding Drawings: Drawings are provided in Volume III and are referred as Bidding
Drawings. The Drawings show the scope of work to be performed by the Contractor.
Bidding Drawings shall not be used as a basis for fabrication or construction but may
be used as a basis for placing preliminary order for materials, subject to corrections
based on the future issue of Drawings as provided under sub-clause 18.2 Drawings
Issued for Construction. Bidding Drawings are subject to be modified and
supplemented by additional detail by the Engineer.

18.2 Drawings Issued for Construction: After Award of Contract, Bidding Drawings shall
be replaced by Drawings Issued for Construction including supplementary
Specifications as may be necessary. Such drawings and specifications shall be
construed to be included in the expression Custody and Supply of Drawings under
Sub-Clause 6.1 of Conditions of Contract Part I. Drawings Issued for Construction
may include some of the Bidding Drawings with or without modification and additional
drawings as required to express design intent in greater detail. Such drawings may
also be modified from time to time. Drawings Issued for Construction will be the
drawings from which shop, fabrication, erection, installation, concrete placing,
formwork, or other construction detail drawings shall be prepared by the Contractor.
The work shall be executed in conformity with Drawings Issued for Construction. The
Contractor shall prepare a schedule of Drawings Issued for Construction of various
parts of the Works based on Construction programme approved by the Engineer for
issuance to the Contractor from time to time.

Construction of Bridge at Korangi Causeway 0100-6 General Requirements

 18.3 Study of Drawings: The Contractor shall study all Drawings Issued for Construction
carefully as soon as practicable after receipt thereof, and any errors discovered shall
promptly be brought to the knowledge of the Engineer for his instructions.

18.4 Copies of Drawing: Drawings will be issued to the Contractor free of charge as
follows:

Drawings Issued for Construction - Two copies as specified in sub-clause 6.1 of

Conditions of Contract Part - I i.e. Custody and Supply of Drawings.

18.5 Drawings to be furnished by the Contractor:

(a) Shop Drawings.

All shop drawings required for the work including all kinds of fabrication, field
erection, installation, placement and layout drawings shall be furnished by the
Contractor for approval of the Engineer. If additional detail drawings are
necessary to complete any part of the work, such as additional reinforcing steel,
drawings shall be prepared by the Contractor and submitted to the Engineer for
approval. All drawings shall be complete and shall be submitted in due time and
in logical order to facilitate proper coordination.

(b) Lift and placement Drawings.

At least thirty calendar days prior to starting construction of any concrete lift or
other placement, the Contractor shall submit lift or other placement drawings to
the Engineer for approval. Lift or other placement drawings shall be submitted for
each lift or other placement of concrete to be placed. These drawings shall be to
such scale as to clearly show all recesses, openings, and embedded parts,
including embedded structural steel, mechanical and electrical items,
reinforcement placement in each lift in sufficient detail for proper execution of the
work.

(c) Construction Plant Layout Drawings.

Three prints of drawings, showing the layout of construction plant and equipment
the Contractor proposes to use on the work, shall be submitted by the Contractor
for review to the Engineer. The drawings shall show the locations of the principal
components of the construction plant, offices; storage areas and yards which the
Contractor proposes to construct or use at the site of the work and elsewhere.
The drawings shall also show the unloading facilities for materials and equipment
at the work site.

18.6 Submissions and Approvals:

(a) Except as otherwise specified, three copies of each drawing for approval or
review shall be furnished to the Engineer. Within thirty calendar days after
receipt, the Engineer will send one copy to the Contractor marked Approved,
Approved/Except as Noted, or Returned for Correction. The notations
Approved and Approved/Except as Noted will authorize the Contractor to
proceed with the fabrication of the materials and equipment covered by such
drawings subject to the corrections, if any, indicated thereon. Drawings
returned for correction will be resubmitted for approval in the same manner as
for new drawings. Every revision made during the life of the Contract shall be
shown by number, date and subject in a revision block.

(b) Upon receipt of prints which have been Approved or Approved Except as
Noted, the Contractor shall furnish three prints plus one reproducible of each

Construction of Bridge at Korangi Causeway 0100-7 General Requirements

 drawing to the Engineer. If revisions are made after a drawing has been
approved, the Contractor shall furnish 3 additional prints and one reproducible
subsequent to each approved revision.

(c) Shop drawings to be prepared by a Sub-contractor shall be submitted in the

same manner as (a) & (b) above but they will be submitted through the
Contractor.

(d) All of the applicable requirements of this Clause with reference to drawings to
be prepared by the Contractor, including Sub-contractors, shall apply equally to
catalogue cuts, illustrations, printed specifications, or other data submitted for
approval.

(e) Any work done on Contractor's drawings shall be at the Contractor's risk. The
Engineer will have the right to request any additional details and to require
the Contractor to make any changes in the drawings which are necessary to
conform to the provisions and intent of design and specifications without
additional cost to the Employer. The approval of the drawings by the Engineer
shall not be construed as a complete check but will indicate only that the
general method of construction and detailing is satisfactory. Approval by the
Engineer of the Contractor’s drawings shall not be held to relieve the
Contractor of his obligation to meet all the requirements of the Specifications or
of his responsibility for the correctness of the Contractor's drawings or of his
responsibility for correct fit of assembled parts in final position or of his
responsibility for the adequacy of method of construction.

19 AS-BUILT DRAWINGS

The Contractor shall, at all times, keep on the site one copy of all drawings and approved
samples together with copies of all building, mechanical, electrical and public safety codes
and relevant standards applicable to the works. All such material shall be made available
to the Engineer.

In addition, the Contractor shall, at all times, keep on site a separate set of prints on which
shall be noted neatly, accurately and promptly as the work progresses all significant
changes between the work shown on the drawings and that which is actually
constructed. The sub-Contractors shall each keep on site, at all times, a separate set of
prints of the drawings showing their parts of the work on which shall be noted, neatly
accurately and promptly as work progresses the exact physical location and configuration
of the works as actually installed, including any revisions or deviation from the Contract
Documents.

At the completion of the works, the Contractor shall at his expense, supply to the Engineer
six copies and one reproducible copy of all drawings alongwith CD containing all as built
drawings amended to comply with the work "As Built". The Contractor shall provide in the
same format as the original drawings, any additional drawing required to record the work.

20 RESTORATION AND CLEANING

The Contractor shall do regular cleaning and clean away all rubbish and excess materials
that may accumulate from time to time on completion and before handing over. Upon
completion of the works he shall obliterate all signs of temporary construction facilities such
as work areas, structures, foundations of temporary structures, stock piles of excess or
waste materials, or any other vestiges of construction, unless otherwise directed by the
Engineer. The works and site shall be left in a clean and satisfactory state for immediate
use and occupation. Care shall be taken not to use any cleaning materials which may
cause damage to the surface to be cleaned.

Construction of Bridge at Korangi Causeway 0100-8 General Requirements

21 PROTECTION OF THE WORKS

The Contractor shall whenever necessary cover up and protect the works from weather and
damage by his own or other workmen performing subsequent operation. He shall provide
all necessary dust sheets, barriers and guard rails and clear away the same at completion.

The Contractor shall take all proper steps for protection at all places on or about the works
which may be dangerous to his workmen or any other person or to traffic. The Contractor
shall provide and maintain warning signs, warning lamps and barricades as necessary.

22 PRODUCT DATA

Manufacture’s standard schematic drawings shall be modified or deleted to indicate only

information which is applicable to the project. Such standard information shall be
supplemented to provide all additional applicable information.

Manufacturer's catalogue sheets, brochures, diagrams, schedules, performance charts,

illustrations and other standard descriptive literature shall be clearly marked to identify
pertinent materials products or models. Dimensions and required clearances shall be
indicated. Shop performance characteristics and capacities shall be noted.

23 SAMPLES

23.1 The Contractor shall furnish for approval of the Engineer with reasonable promptness
all samples as directed by the Engineer or specifically called for in these
Specifications. The Engineer shall check and approve such samples with reasonable
promptness for compliance with the requirements of Contract Documents. All work
shall be in accordance with approved samples.

23.2 Duplicate final approved samples, in addition to any required for the Contractor's
use, shall be furnished to the Engineer, one for office use and the other for the Site.

23.3 Samples shall be furnished so as not to delay fabrication, allowing the Engineer
reasonable time for consideration of the sample submitted.

23.4 Each sample shall be properly labeled with the name and quality of the material,
manufacturer's name, name of the project, the Contractor's name and the date of
submission, and the Specifications Article number to which the sample refers.

23.5 The manufacturer’s installation directions shall be provided with each sample. The
Contractor shall pay all transportation costs and deliver samples to the Engineer’s
office, Site or testing laboratory as directed by the Engineer.

Samples will not be returned unless return is requested at the time of submission; all
packing and transportation costs for the return of samples shall be paid by the
Contractor.
23.6 Samples shall be of adequate size and number to permit proper evaluation of the
material by the Engineer. Where variations in colour, texture, dimensions or other
characteristics are to be expected, the Contractor shall submit samples showing the
maximum range of variation. Materials exceeding the range of variation of the
approved samples shall not be used on the Work.

23.7 If both Shop Drawings and samples are required for the same item, the
Engineer may require both to be submitted before approving either.

23.8 No acceptance or approval of any Shop Drawings or sample, or any indication or

directions by the Engineer on any Shop Drawings shall constitute an authorization for
any increase in the Contract Sum.

Construction of Bridge at Korangi Causeway 0100-9 General Requirements

24 PRODUCT QUALITY AND HANDLING

Suppliers of local and foreign products and installations specified shall have been regularly
engaged in the business of manufacturing, fabricating, installing and / or servicing work
required for a period not less than 5 years. In addition, the Engineer may request as
appropriate a:

- list of similar installations that describes project, scope and date of completion.

- complete literature, performance data, and technical data.

- list of services record within Pakistan.

- location of service office from which this installation could be maintained.

For the actual fabrication, installation, and testing of the specified work, use only thoroughly
trained and experienced workmen completely familiar with the items required and with the
manufacturers recommended methods of installation. In acceptance or rejection, no
allowance will be made for the lack of skill on the part of workmen.

Use all means necessary to protect materials before, during and after installation and to
protect the installed work and materials of all other trades. In the event of damage,
immediately make all repairs and replacement necessary for approval and at no additional
cost to the Employer.

25 INSPECTION & TESTS REPORTS

All equipment and materials furnished under these specifications and all work performed in
connection therewith will be subject to rigid inspection by the Engineer or the Engineer’s
Representative. Acceptance of equipment and material or the waiving off inspection thereof
shall in no way relieve the Contractor of his responsibility for meeting the requirements of
the Contract.

The Contractor shall furnish the Engineer with certified true copies of test reports of all
materials used in the manufacture and fabrication of equipment and material. The result of
these tests shall be in such form as to show compliance with the applicable Specifications,
standards and codes for the material used.

26 ACCIDENT PREVENTION, PROTECTIVE EQUIPMENT

The Contractor shall comply and enforce compliance by all his sub-Contractors with the
highest standards of safety and accident prevention in accordance with international
standards and in compliance with all applicable laws, ordinances and statutory provisions in
Pakistan.

All requisite barriers, fences, warning signs, lights and other safety precautions as required
for the protection of persons and property on or adjacent to the site shall be provided at the
Contractor's cost.

All warning signs shall be in two languages, English and Urdu, and shall at all times be
maintained in a clean and legible condition, to the satisfaction of the Engineer.

Trash shall be removed at frequent intervals to the satisfaction of the Engineer.

27 HEALTH SAFETY & ENVIROMENTAL REQUIREMENTS

The Contractor during execution of contract / project shall provide all the required, Personal
Protective Equipment (PPE) for the staff working at sites for their Health & safety either they
would be from Employer’s personnel, Consultant’s personnel, Contractor’s personnel, Sub-
Contractor’s personnel & Site visitors. Not limited but minimum requirement would include

Construction of Bridge at Korangi Causeway 0100-10 General Requirements

 helmets, special shoes, gloves, harness belts, nose cover and other proper resources for
their Health & safety. HSE requirements should be included in the Project Execution Plans
prepared at the start of Project. The Contractor shall appoint qualified HSE Engineer
deputed at sites during working hours and make sure for the implementation of HSE
requirements. The cost for providing these Health & safety facilities shall be borne by the
Contractor till the closure of contract and no extra payment would be made in this account
and the cost of providing these facilities deemed to include in the contract rates quoted for
the works.

28 TEMPORARY FACILITIES

The Contractor shall provide, erect or install, maintain, alter as necessary and remove on
completion except as otherwise directed by the Engineer all temporary facilities and
services including access roads as described hereinafter and/or in the Contract Document.

The Contractor's temporary site office shall be available for use not later than one month
after the date of the site handing over.

Installation of temporary services at the site shall be given priority over all other
construction at the site.

28.1 Temporary Road

The Contractor shall prepare and maintain such temporary roads as may be
necessary, from the site to the nearest road and also within the site. Such roads shall
be positioned strictly in accordance with the Engineer’s instructions and the Contractor
shall reduce or control any dust nuisance by spraying with water as directed. The
Contractor shall satisfy himself as to the locations and nature of the proposed access
routes to the site and shall be responsible for preventing any damage whatsoever to
adjacent property and vegetation and keeping the access road free from debris at all
times.

28.2 Temporary Services

(a) Temporary Water Supply

The Contractor shall supply in sufficient quantity all necessary potable and other
water for construction purposes for all trades at point within a reasonable
distance of the work. He shall make arrangements and pay charges for water
service installation, maintenance and removal thereof, and pay the costs of water
for all trades.

When the permanent water supply and distribution system has been installed, it
may be used as the source of water for construction purposes provided that the
Contractor obtains the written approval of the Engineer and the Employer and
assumes full responsibility for the entire water distribution system and pays all
charges/costs for operation and maintenance of the system mutually agreed
between the Employer and the Contractor.

Temporary pipe lines and connections from the permanent service line, whether
outside or within the area of site of works but necessary for the use of Contractor
and his sub-contractor shall be installed, protected and maintained at the expense
of the Contractor.

At completion of the work or at such time as the Contractor makes use of the
permanent water supply installation, the temporary water services equipment and
piping shall be removed by the Contractor at his own expense.

(b) Temporary Electricity

Construction of Bridge at Korangi Causeway 0100-11 General Requirements

 The Contractor shall make all the necessary arrangements for a temporary
electricity service, pay all expense in connection with the installation, operation and
removal thereof and pay the costs of electricity consumed by all trades.

In the event that the site can not be connected to a local electricity
network or where the available power is insufficient the Contractor has to make
his own provision and maintain such installation.

A temporary lighting system shall be furnished, installed and maintained by the

Contractor as required to satisfy the minimum requirements for safety and security.
The temporary lighting system shall afford adequate general illumination to all
building areas. Adequate outdoor lighting shall be provided to illuminate staging
trenches and the like to the satisfaction of the Engineer and general illumination
throughout adequate for watchmen and emergency personnel.

Temporary equipment and wiring for power and lighting shall be in accordance with
the applicable provisions of governing codes. Temporary wiring shall be
maintained in a safe manner and utilised so as not to constitute a hazard to
persons or property.

When the permanent electrical power and lighting systems are in an operating
condition, they may be used for temporary power and lighting for construction
purposes provided that the Contractor obtains the written approval of the Engineer
and the Employer and assumes full responsibility for the entire power and lighting
system and pays all charges/costs for operation and maintenance of the system
mutually agreed between the Employer and the Contractor.

Approval, license etc. if required under local laws will be obtained by the Contractor
on his own responsibility and cost.

At completion of construction work, or at such time as the Contractor makes use of

permanent electrical equipment and devices, temporary electricity services shall be
removed by the Contractor as his own expense.

(b) Waste Disposal

The Contractor shall make such temporary provisions as may be required in order
to dispose of any chemicals, fuels, grease, bituminous materials, waste and soil
waste and the like without causing pollution to either the site or the environment.
Disposal of any materials, wastes, effluents, garbage, oil, grease, chemicals and
the like shall be in areas specified by the concerned local authority proposed by the
Contractor and subject to the approval of the Engineer. If any waste material is
dumped in unauthorized areas the Contractor shall remove the material and restore
the area to the condition of the adjacent undisturbed area. If necessary,
contaminated ground shall be excavated, disposed off as directed by the Engineer
and replaced with suitable fill material compacted and finished with topsoil all at the
expense of the Contractor.

(c) Fire Protection

The Contractor shall provide and maintain adequate fire protection in the form of
barrels of water with buckets, fire bucket tanks, fire extinguishers, or other
effective means ready for instant use, distributed around the project and in and
about temporary inflammable structures during construction of the works.

Gasoline and other flammable liquids shall be stored in and dispensed from
safety containers approved by the Engineer and storage shall not be within
building.

Construction of Bridge at Korangi Causeway 0100-12 General Requirements

 Torch-cutting and welding operations performed by the Contractor shall have the
approval of the Engineer before such work is started and a chemical
extinguisher is to be available at the location where such work is in progress.

The Contractor shall follow the instructions and specifications of the Civil
Defence Department and or other local authority.

29 CONSTRUCTION SCHEDULE

A Construction schedule shall be maintained in accordance with the provisions of the

General Conditions of Contract.

The schedule shall be accompanied with sufficient data and information including all
necessary particulars of constructional plant, equipment, machinery, temporary Works,
arrival of plant, equipment at site and their installation, method of operation, work forces
employed, etc., for activities of the Works.

Should the Engineer consider any alteration or addition in the programme and time
schedule, the Contractor shall conform thereto without any cost to the Employer.

Whenever necessary and wherever the progress of the actual work shows departure, the
programme and time schedule shall be undated and submitted to the Engineer for his
approval.

30 NOTIFICATION TO THE ENGINEER

The Engineer’s Representative shall be notified daily in writing of the nature and location of
the Works the Contractor intends to perform the next day so as to enable necessary
inspection and measurement to be carried out. The Engineer may, if necessary, direct that
longer notice be given of certain operations.

31 NIGHT WORK

When work is done at night the Contractor shall maintain from sunset to sunrise such
lights on or about his work and plant as the Engineer may deem necessary for the proper
observations of the work and the efficient prosecution hereof.

32 WEATHER

No work is to be undertaken when, in the opinion of the Engineer, the weather is so

unsuitable that proper protection of the work cannot be ensured.
33 CO-ORDINATION WITH OTHER CONTRACTORS

The Contractor shall make all necessary coordination with other Contractor and shall make
sure that all embedding components such as pipes, steel bases etc. (as required for
completion of electrical and other works) are properly, accurately and timely installed.

The Contractor shall inform other contractors if any, the schedule of any construction
activity well in advance giving him sufficient time to finish his part of job, before any
compaction/concreting etc. The Contractor shall get the signature of the authorized
representative of the other contractor, before carrying out any construction activity.

If any part of existing work is damaged or has to be dismantled or redone due to

negligence/omissions/incorrect position of the embedding etc. on part of the Contractor, all
such losses/expenses shall be borne by the Contractor.

All expenses incurred for the above works including coordination are deemed to be covered
in his Bid cost and no separate/extra payment shall be paid against such item.

Construction of Bridge at Korangi Causeway 0100-13 General Requirements

34 SUBMISSION REQUIREMENTS

33.1 Schedule submission at least sixty days before the dates when reviewed submittals
will be needed.

33.2 Submit Shop Drawings as per provision given in Sub-Clause 18.5 (a) of this General
Requirements and number of copies of Product Data which the Contractor requires
for distribution plus four copies which will be retained by the Engineer.

33.3 Submit three samples unless otherwise specified.

33.4 Accompany submittals with transmittal letter, in duplicate, containing:

• Date

• Project title and number

• Contractor’s name and address

• The number of each Shop Drawing, Product Data and the Sample submitted.

• Notification of deviations from Contract Documents.

• Other pertinent data.

35 RESUBMISSION REQUIREMENTS

Shop Drawings:

- Revise initial drawings as required and resubmit as specified for initial submittal.

- Indicate on drawings any changes which have been made by the Engineer.

- Product Data and Samples: Submit new data and samples as required for initial
submittal.

36 SURVEY INSTRUMENTS

All the instruments, equipment, stakes and other material necessary to perform all work
shall be provided by the Contractor. The survey work shall be carried out by competent
staff consistent with the current practices. The Contractor shall maintain on site surveying
instruments in perfect working conditions to enable the Engineer to check lines and level at
all times.

Survey instruments and equipment shall include but not limit to the following:

- Electronic Total Station

- GPS
- Electronic Data Recorder
- Disto Laser Meter
- Precision Level Invert Staff
- Automatic Levels
- Power level
- Compass, steel tape, ranging poles

37 MONTHLY PROGRESS REPORT AND PHOTOGRAPHS

Construction of Bridge at Korangi Causeway 0100-14 General Requirements

 37.1 During the continuance of the Contract, the Contractor shall submit monthly
progress reports on forms as approved by the Engineer. Such monthly reports shall
show the actual progress completed as of date of the report plotted against the
schedule as given by the Contractor at the start of work and shall be broken down
so as to indicate status of all activities associated with mobilization, design, material
procurement, manufacture, surveys works, tests with regard to the agreed
Contract programme.

37.2 The Employer and the Engineer reserve the right to coordinate the schedules of
this Contractor and other contractors working at the Site, and to adjust and/or
change any and all such schedules as required during the course of construction in
order to achieve a coordinated project in harmony with the completion date.

37.3 Commencing after the first month of construction, and continuing every month until
completion, the Contractor shall take and submit photographs to the Engineer's
Representative, to show progress of his work and completion of each structure or
major feature.

38 CONTRACTOR TO NOTIFY DELAYS ETC.

Any delay which will affect the completion of Works shall be detailed by the Contractor who
shall state the action he is taking for effective completion of the Contract programme.

The Contractor shall submit a report in respect of the various sections of the Works, the
equipment in use or held in readiness, a return of labour and supervisory staff, and details
of any matters arising which may generally affect the progress of the work.

The Contractor shall give a summary of the detailed progress report giving the position with
regard to the agreed Contract programme.

The progress reports shall be set out in a format to the approval of the Engineer, and
forwarded promptly so that on receipt the information contained therein is not more than 21
days out of date.

If during execution of the Contract, the Employer considers the progress position of any
section of the work to be unsatisfactory, or for any other reason relating to the Contract, he
will be at liberty to convene a meeting and the Contractor’s Representatives are to attend
such meeting.

The Contractor's Site Office shall prepare and submit 6 copies of a monthly progress report
along with the photographs to the Employer and Engineer's Site Office. This report shall
summarize site activities and record and details where difficulties in maintaining the agreed
programme are being experienced or are likely to cause subsequent delay.

The Contractor's Site Office shall also prepare and submit to the Engineer's Site Office 2
copies of Daily Activity Report summarizing the main activities to be undertaken each day,
noting special activities such a tests, alignment checks, etc. The Contractor shall be
responsible for submitting daily, manpower & equipment details deployed at site. The
contractor shall also be responsible for expediting the delivery of all material and equipment
to be provided by himself and his subcontractors if any.

39 PHOTOGRAPHS

As soon as work commences on Site, the Contractor shall provide photographs of the
works from positions to be selected by the Engineer. Each photographic / digital print shall
not be less than 150mm x 100mm and shall bear a printed description, a serial number and
the date when taken.

The negatives/soft copies of all photographs shall be held at the Contractor’s Site Office,
numbered and handed over to the Employer at the completion of the Contract.

Construction of Bridge at Korangi Causeway 0100-15 General Requirements

40. FACTORY INSPECTION TEST

All major equipment to be supplied under this Contract shall be subject to inspection and
testing by two (02) representatives of the Employer / Engineer at its point of original
manufacture or final shop assembly before its dispatch to site. The Contractor shall make
necessary arrangements and provide all the facilities required for the representatives of
Employer and Engineer for conducting such inspection at Contractor’s cost. The cost of
travel including overseas travel, arranging of Visas, boarding and lodging of Employer’s and
Engineer’s representatives shall be the responsibility of the Contractor.

In addition, for foreign travel, the Contractor shall provide (for Two persons) TA/DA in US$
for out-of-pocket expenses, at US$200 per day per person. The number of days shall be
actual days spent in travel calculated from the dates of travel from and to the hometown of
the concerned representative nominated for inspection. The TA/DA amount shall be
provided before start of travel from hometown.

The equipment which shall be inspected and tested at the manufacturer’s works includes
but not limited to: Expansion Joint, Bearing Pads, Strand Wire and LED Lights.

The Contractor shall give atleast 3 (three) weeks’ notice to the Employer / Engineer for
attending such inspections / tests.

Prior to the tests, the Contractor shall submit detailed test procedure to be adopted by the
manufacturer and forms to record the results of the tests, for Engineer’s approval.

41. FACILITIES FOR THE EMPLOYER

41.1 Site Office / Equipments

The Contractor shall construct and maintain Employer’s Site Office (RCC Structure) at
designated places having about 150 square meter covered area including janitorial
staff and peons, for both sites as per the specifications for the full Construction and
Defects Liability Period. A preliminary layout of the site office shall be provided by the
Employer. After receiving letter of acceptance the Contractor will submit to the
Employer / Engineer detailed shop drawings for review and approval. Specifications
for construction of site office shall be the same as provided in Volume-IIB of the
bidding documents.

The Employer’s site office shall be furnished and equipped with brand new furniture,
equipment, air-conditioners, electrical fittings etc., at least as per the list given below
and additionally as per requirement of site or as directed by the Employer:

1. Executive Wooden office table with drawers and side racks

(standard size) 01 (One) No.

2. Executive Officer’s revolving Chairs 01 (One) No.

3. Wooden office table with drawers and side racks

(standard size) 01 (One) No.

4. Officer’s revolving Chairs 01 (One) No.

5. Wooden sitting visitors chairs with arms (standard size) 08 (Eight) Nos.

6. Computer Table 02 (Two) Nos.

7. Steel filing cabinet (standard size) 01 (One) No.

8. Gree DC Inverter Unit (1-1/2 tonne) with stabilizer &

Construction of Bridge at Korangi Causeway 0100-16 General Requirements

 or approved equivalent 01 (One) Nos.

9. Water Dispenser with all accessories including

daily supply of mineral water and routine maintenance 01 (One) No.

10. Electric Kettle & Microwave oven 01 (One) No. Each

11. Medium size refrigerator 8 cft with stabilizer 01 (One) No.

12. Peon / Janitor 02 (Two) No. each

13. HP laptop Core i7 (12th Generation) or equivalent,

8 GB RAM, 1 TB hard disk, along with DVD Writer,
in built Speakers etc. (As per the instructions of
the Engineer) . 2 (Two) Nos.

14. PTCL Charji wireless Internet Connection of LTE with

unlimited downloads or approved equivalent 01 (One) No.

15. Laser Jet Color Printer with Scanner (A4 Size) 01 (One) No.

If any equipment, furniture and installations become unserviceable for any reason
whatsoever the Contractor shall promptly replace the same as and when directed by
the Employer’s Staff. The Employer’s Site office with fittings, fixtures and all other
equipment/accessories shall be maintained and operated for the entire duration of
construction period as well as for the duration of subsequent Defects Liability Period.

The Site Office including fittings, fixtures, furniture, furnishing and all other
equipment/accessories shall become the property of the Employer on completion of
the Contract.

41.2 Transport Facility

The Contractor shall provide, operate and maintain following brand new vehicles for
exclusive use of the Employer:

1. One (01) Toyota Corolla 1.6L Automatic (500 liters / month of fuel for each vehicle)

2. Two (02) Suzuki Cultus Automatic or approved equivalent

(300 liters / month of fuel for each vehicle)

3. One (01) Suzuki Bolan (300 liters / month of fuel)

Except mentioned above the Vehicle shall be Automatic, latest model along with AC
Fitted to meet Employer’s transportation needs for the entire duration of actual
construction period as well as for the duration of subsequent Defects Liability Period.
The use of such transport facility shall be under the control of the Employer. The
Contractor shall be wholly responsible for providing at all times satisfactory operating
services for the Employer. The Contractor shall furnish, supply and provide, as may be
necessary without specific direction of the Employer, all fuels (petrol for each vehicle),
lubricants, tires and other supplies, all maintenance, repairs and running costs and
suitably qualified drivers (for actual Construction and Defect Liability Period) at all
times.

Prior to Ordering the Vehicle, the Contractor shall furnish to the Employer for approval,
detailed specification, name of manufacturer and model no. of the vehicle to be
supplied. These data shall be presented within one week from the date of Engineer's
Order to proceed with the works and the vehicle shall be furnished to the Employer
upon approval within two weeks from the date of Engineer's Order to supply the
Vehicle.

Construction of Bridge at Korangi Causeway 0100-17 General Requirements

 The vehicle shall be right hand drive, and shall be brand new, properly serviced and
ready for use. The Contractor shall provide vehicle to replace any such motor vehicle
that is temporarily or permanently rendered unserviceable for any reason or declared
to be beyond repair by the Engineer, at no additional cost to the Employer. The vehicle
shall be registered in the name of the Employer on purchasing and shall become the
property of the Employer on completion of the Contract.

In case of non-supply of vehicles within the stipulated time, monthly amount of

Rs 800,000/- against each vehicle and POL as per actual shall be deducted from
the Contractor’s Interim Payment Certificates against the vehicles.

42. FACILITIES FOR THE ENGINEER

42.1 Site Office / Equipments

The Contractor shall construct, provide and maintain Engineer's Site Office with
shaded car porch of six vehicles having about 150 square meter covered area as per
the specifications for the full Construction and Defects Liability Period. A preliminary
layout of the site office shall be provided by the Engineer. After receiving letter of
acceptance the Contractor will submit to the Engineer detailed shop drawings for
review and approval. Specifications for construction of site office shall be the same as
provided in Volume-IIB of the bidding documents.

The Engineer's site office shall be furnished and equipped with brand new furniture,
equipment, air-conditioners, electrical fittings etc., at least as per the list given below
and additionally as per requirement of site or as directed by Engineer :

1. Executive Wooden office table with drawers and side racks

(standard size) 01 (One) No.

2. Executive Officer’s revolving Chairs 01 (One) No.

3. Wooden office table with drawers and side racks

(standard size) 10 (Ten) Nos.

4. Officer’s revolving Chairs 10 (Ten) Nos.

5. Wooden sitting visitors chairs with arms (standard size) 16 (Sixteen) Nos.

6. Computer Table 04 (Four) Nos.

7. Steel filing cabinet (standard size) 05 (Five) Nos.

8. Gree DC Inverter Unit (1-1/2 tonne) with stabilizer &

or approved equivalent 02 (Two) Nos.

9. Water Dispenser with all accessories including

daily supply of mineral water and routine maintenance 02 (Two) Nos.

10. PTCL Charji wireless Internet Connection of LTE with

unlimited downloads or approved equivalent 02 (Two) Nos.

11. Electric Kettle & Microwave oven 01 (One) Nos. Each

12. Peon / Janitor 02 (Two) Nos. / 01

(One) No.

13. HP laptop Core i7 (12th Generation) or equivalent,

8 GB RAM, 1 TB hard disk, along with DVD Writer,

Construction of Bridge at Korangi Causeway 0100-18 General Requirements

 in built Speakers etc. (As per the instructions of
the Engineer) 02 (Two) Nos.

14. HP Desktop Core i7 (12th Generation) or equivalent,

16 GB RAM, 1 TB hard disk, along with DVD Writer,
Speakers etc. and 24” HP LED or approved
equivalent (As per the instructions of the Engineer) 04 (Four) Nos.

15. Medium size Refrigerator 8 cft with Stabilizer. 01 (One) Nos.

16. New Photocopier Machine (Capable of handling

A3 & A4 Size pages) of approved brand 01 (One) Nos.

17. Laser Jet Color Printer with Scanner (A4 Size) of

Approved brand. 02 (Two) Nos.

18. Digital Camera Cannon / Sony (or approved

equivalent) with 20 mega pixel, 4x optical zoom,
4 GB flash memory card, built-in flash including
all accessories, battery charger,
data transfer cable, etc. 01 (One) Nos.

19. Multimedia Projector (Viewsonic PA503 x

3600Lumins x GA) or approved equivalent, 01 (one) No.

20. Set of Meeting Table with Comfortable wooden

Chairs with arms of 12 person capacity 01 (one) No.

21. Office supplies and stationeries as per site Each month

Requirements or as required by the site staff

If any equipment, furniture and installations become unserviceable for any reason
whatsoever the Contractor shall promptly replace the same as and when directed by
the Engineer. The Engineer’s Site office with fittings, fixtures and all other
equipment/accessories shall be maintained and operated for the entire duration of
construction period as well as for the duration of subsequent Defects Liability Period.

The Site Office including fittings, fixtures, furniture, furnishing and all other
equipment/accessories shall become the property of the Employer on completion of
the Contract.

In case of non-supply of any of the above mentioned facilities within the

stipulated time, the cost of above mentioned items will be calculated by the
Engineer on the current market rate and the said cost will be deducted from the
Contractor’s Interim Payment Certificate.

42.2 Transport Facility

The Contractor shall provide, operate and maintain brand new fully insured following
vehicles for the use of Engineer’s staff:

1. Two (02) Toyota Corolla 1.6L Automatic or approved equivalent

(550 liters per month of fuel for each vehicle)

Except mentioned above the Vehicle shall be automatic, latest model along with AC
Fitted to meet the transportation needs of the Engineer’s site supervision team for the
entire duration of actual construction period as well as for the duration of subsequent
Defects Liability Period. The use of such transport facility shall be under the control of
the Engineer. The Contractor shall be wholly responsible for providing at all times

Construction of Bridge at Korangi Causeway 0100-19 General Requirements

 satisfactory operating services for the Engineer. The Contractor shall furnish, supply
and provide, as may be necessary without specific direction of the Engineer, all fuels
(petrol for each vehicle), lubricants, tires and other supplies, all maintenance (monthly
or as required in routine), repairs and running costs and suitably qualified drivers (for
actual Construction and Defect Liability Period) at all times.

Prior to Ordering the Vehicle, the Contractor shall furnish to the Engineer for approval,
detailed specification, name of manufacturer and model no. of the vehicle to be
supplied. These data shall be presented within one week from the date of Engineer's
Order to proceed with the works and the vehicle shall be furnished to the Engineer
upon approval within two weeks from the date of Engineer's Order to supply the
Vehicle.

The vehicle shall be right hand drive, and shall be brand new, properly serviced and
ready for use. The Contractor shall provide vehicle to replace any such motor vehicle
that is temporarily or permanently rendered unserviceable for any reason or declared
to be beyond repair by the Engineer, at no additional cost to the Employer. The vehicle
shall be registered in the name of the Employer on purchasing and shall become the
property of the Employer on completion of the Contract.

In case of non-supply of vehicles within the stipulated time, monthly amount of

Rs 800,000/- against each vehicle and POL as per actual shall be deducted from
the Contractor’s Interim Payment Certificates against the vehicles.

43. MEASUREMENT AND PAYMENT

No payment shall be made for the works involved within the scope of this section of
specifications unless otherwise specifically stated in the Bill of Quantities or herein.

The cost thereof shall be deemed to have been included in the quoted unit rate of other
items of the Bill of Quantities.

*** End of Section 0100 ***

Construction of Bridge at Korangi Causeway 0100-20 General Requirements

 SECTION - 0120

CONTRACTOR'S CAMP

1. SCOPE

The work to be done under this item consists of construction, erection, installation and
maintenance of the Contractor's Project Site Offices or main camp and the Contractor's
sub-camps or temporary camps, if any, and shall include all offices, shops, warehouses,
and other operational buildings; all housing and related facilities including accommodations
for the Contractor's personnel.

2. GENERAL

The location of the Contractor's camps, including all buildings, utilities and facilities therefor,
and of the camps or establishments of all persons/parties in the vicinity operating or
associated with the Contractor shall be subject to approval of the Engineer.

The work to be done under this item will terminate upon the actual Completion Date.
However, if directed by the Engineer or the Employer, the Contractor shall continue such
work to the extent required by the Contractor's personnel during the Defects Liability Period.
No compensation shall be paid for the continued operation and maintenance of the
Contractor's Camps during the Defects Liability Period.

Upon completion of the Works, or at such time within the Defects Liability Period as directed
by the Engineer, the Contractor shall remove all buildings, utilities and other facilities from
the Site and restore all camp areas to a neat and clean condition. The Employer may opt to
retain any or all of the above mentioned facilities for his use after the completion of the
works, in which case the Contractor shall have no claim on these facilities.

Contractor shall protect the environmental interests and HSE (Health, safety &
Environmental) regulations at camp and works sites during execution of the contractual
work.

3. CODES AND STANDARD

The construction, operation and maintenance of all camps of the Contractor shall comply
with all applicable provisions of current Pakistan Labour Camp Rules.

4. MAINTENANCE

The Contractor shall furnish, make arrangements for, and carry out proper and adequate
maintenance of the Contractor’s Camp areas at such camp to provide a neat, well-kept
camp in all respects with pleasant and healthy surroundings and conditions for all occupants
of their camp. The Contactor’s camp shall be kept clean, well-graded, free from under
growth and bush and adequately drained. Roads and streets shall be kept in good
condition. All utilities shall be adequately and properly operated and maintain to provide
services and conditions meeting the requirements of these specifications in all respects.

Adequately equipped and properly staffed portable first aid stations or dispensaries shall be
provided by the Contractor at camps and other strategic locations to administer first aid
treatment at any time required and free of charge to all persons on the Site, including
employees of the Engineer and the Employer.

Construction of Bridge at Korangi Causeway 0120-1 Contractor’s Camp

5. MEASUREMENT AND PAYMENT

No payment shall be made for the works involved within the scope of this section of
specifications unless otherwise specifically stated in the Bill of Quantities or herein.

The cost thereof shall be deemed to have been included in the quoted unit rate of other
items of the Bill of Quantities.

*** End of Section 0120 ***

Construction of Bridge at Korangi Causeway 0120-2 Contractor’s Camp

 SECTION - 0130

STAKE-OUT SURVEY

1. SCOPE

The work to be done under this item the Contractor shall make the stakeout survey for
construction purposes with competently qualified men, consistent with the current practices.
The work shall proceed immediately upon the award of the Contract and shall be
expeditiously progressed to completion in a manner and at a rate satisfactory to the
Engineer. The Contractor shall keep the Engineer fully informed as to the progress of the
stakeout survey. The scope of this section of specifications is covered by detailed
specifications as laid down herein.

2. MATERIAL AND EQUIPMENT

All instruments, equipment, stakes and other material necessary to perform all work shall be
provided by the Contractor. These instruments and equipment shall be available to
Engineer at all times for the purpose of checking the work of the Contract.

All stakes used shall be of a type approved by the Engineer, clearly and permanently
marked so as to be legible at all times. It shall be the Contractor's responsibility to maintain
these stakes in their proper position and location at all times. Any existing stakes or markers
defining property lines and survey monuments which may be disturbed during construction
shall be properly tied into fixed reference point before being disturbed and accurately reset
in their proper position upon completion of the work.

3. CONSTRUCTION

The Contractor shall trim trees, bushes and other interfering objects, not consistent with the
plan, from survey lines in advance of all survey work to permit accurate and unimpeded
work by his stake-out survey crews and the Engineer's survey crews. The exact position of
all work shall be established from control points, which are shown on the plans or modified
by the Engineer. Any error, apparent discrepancy in or absence of data shown or required
for accurately accomplishing the stakeout survey shall be referred to the Engineer for
interpretation or furnishing when such is observed or required.

The Contractor shall be responsible for the accuracy of his work and shall maintain all
reference points, stakes, etc. throughout the life of the Contract. Damaged, destroyed or
inaccessible reference points, bench marks or stakes shall be replaced by the Contractor.
Existing or new control points that will be or are destroyed during construction shall be re-
established and all reference ties recorded thereon shall be furnished to the Engineer. All
stakeout survey work shall be referenced to the centerlines shown on the Plans. All
computations necessary to establish the exact position of the work from control points shall
be made and preserved by the Contractor. All computations, survey notes and other
records necessary to accomplish the work shall be kept neatly and made available to the
Engineer upon request and furnished to the Employer upon Contract completion.

The Engineer may check all or any portion of the stakeout survey work or notes made by
the Contractor and any necessary correction to the work shall be immediately made. Such
checking by the Engineer shall not relieve the Contractor of any of his responsibilities for the
accuracy or completeness of his work.

Reference points, base lines, stakes and benchmarks for borrow pits shall be established by
the Contractor.

All required right-of-way and easement limits shall be established, staked and referenced by
the Contractor concurrent with the construction stakeout survey.

Construction of Bridge at Korangi Causeway 0130-1 Stake-out Survey

 The Contractor shall place at least two offset stakes or references at each centre lines
station and at such intermediate stations as the Engineer may direct. From computations
and measurements made by the Contractor, these stakes shall be clearly marked with the
correct centre line, station number, offset and cut or fill so as to permit the establishment of
the true centre line location during construction. He shall locate and place all cut, fill, slope,
line grade or other stakes and points as the Engineer may direct to be necessary for the
proper progress of the work.

4. MEASUREMENT AND PAYMENT

No payment shall be made for the works involved within the scope of this section of
specifications unless otherwise specifically stated in the Bill of Quantities or herein. The cost
thereof shall be deemed to have been included in the quoted unit rate of other items of the
Bill of Quantities.

*** End of Section 0130 ***

Construction of Bridge at Korangi Causeway 0130-2 Stake-out Survey

 SECTION – 0200

DEMOLISHING & DISMANTLING WORKS

1. SCOPE

The work covered by this Section of the Specifications consists of furnishing all plant, labour,
equipment, appliances and performing all operations in connection with demolition/ dismantling
and removal of existing sheds, jetty structures, asphalt road, pavement, kerbs, medians,
foundations, stone pitching, approaches/plate forms, buildings, trees, plants, removal of
services with accessories and rail tracks, sleeper, embankments, stone ballast, plain &
reinforced concrete and concrete/ block masonry structures including disposal of demolished/
dismantled and removed material to designated places. Whole work shall be done in
accordance with these specifications and as directed by the Project Manager.

2. GENERAL REQUIREMENTS

2.1 The work includes demolition, salvage of identified items and materials, and removal of
resulting rubbish and debris. Rubbish and debris shall be removed , unless otherwise
directed . Materials that cannot be removed daily shall be stored in areas specified by
the Project Manager. In the interest of conservation, salvage shall be pursued to the
maximum extent possible. The usable / salvaged material shall become the property of
the Employer.

2.2 All existing structures and utilities obstructing the construction shall be demolished. For
further details and extent of demolition work refer todrawings.

3. SUBMITTALS

The procedures proposed for the accomplishment of the work.

The procedures shall provide for safe conduct of the work, including procedures and methods
to provide necessary supports, lateral bracing and shoring when required, careful removal and
disposition of materials specified to be salvaged, protection of property which is to remain
undisturbed, coordination with other work in progress, and timely disconnection of utility
services. The procedures shall include a detailed description of the methods and equipment to
be used for each operation, and the sequence of operations.

4. DUSTCONTROL

The amount of dust resulting from demolition shall be controlled to prevent the spread of dust
to occupied portions of the construction site and to avoid creation of a nuisance in the
surrounding area. Use of water will not be permitted when it could result in, or create,
hazardous or objectionable conditions such as ice, flooding and pollution.

5. PROTECTION

5.1 Protection of Personnel

5.1.1 During the demolition work the Contractor shall continuously evaluate the
condition of the structure being demolished and take immediate action to
protect all personnel working in and around the demolition site. No area,
section, or component of floors, roofs, walls, columns, pilasters, or other
structural element will be allowed to be left standing without sufficient bracing,
shoring, or lateral support to prevent collapse or failure while workmen remove
debris or perform other work in the immediate area.

5.1.2 Floors, roofs, walls, columns, pilasters, and other structural components that
are designed and constructed to stand without lateral support or shoring, and

Construction of Bridge at Korangi Causeway 0200-1 Demolishing & Dismantling Work

 are determined to be in stable condition, may be allowed to remain standing
without additional bracing, shoring, of lateral support until demolished. The
Contractor shall ensure that no elements determined to be unstable are left
unsupported and shall be responsible for placing and securing bracing,
shoring, or lateral supports as may be required as a result of any cutting,
removal, or demolition work performed under this contract

5.2 Protection of Existing Property

Before beginning any demolition work, the Contractor shall survey the site and
examine the drawings and specifications to determine the extent of the work. The
Contractor shall take necessary precautions to avoid damage to existing items to
remain in place, to be reused, or to remain the property of the User; any damaged
items shall be repaired or replaced as approved by the Project Manager. The
Contractor shall coordinate the work of this section with all other work and shall
construct and maintain shoring, bracing, and supports as required. The Contractor
shall ensure that structural elements are not overloaded and shall be responsible for
increasing structural supports or adding new supports as may be required as a result
of any cutting, removal, or demolition work performed under this contract.

5.3 Protection From the Weather

The usable and salvageable materials shall be protected from the weather at all times
handing over to the Employer.

5.4 Protection of Trees

Trees within the project site which might be damaged during demolition and which are
indicated to be left in place shall be protected by a 1.83 m high fence. The fence shall
be securely erected a minimum of 1.5 m from the trunk of individual trees or follow the
outer perimeter of branches or clumps of trees. Any tree designated to remain that is
damaged during the work under this contract shall be replaced in kind or as approved
by the Project Manager.

6. BURNING

The use of burning at the project site for the disposal of refuse and debris shall not be permitted.

7. USE OFEXPLOSIVE

Use of explosives shall not be permitted.

8. PROCEDURES

8.1 The Project Manager will define the limits where demolition/ dismantling and removal
activity is to be done and shall approve the procedures/ methods to be adopted by the
Contractor. The Contractor shall layout the boundaries/ limits for Project Manager’s
checking and approval before commencing dismantling work.

8.2 Whole work shall be performed in an orderly manner and the Contractor shall take all
necessary precautions and expedients to prevent damages to the adjacent structures,
installed equipment/ machinery, pipes, conduits, any other installation etc. Any
damage caused to the structures and installations due to negligence of the Contractor
during demolition/ dismantled and removal operations shall be repaired/ replaced by
the Contractor at his cost and to the satisfaction of the Project Manager.

9. DEMOLITION OF SHEDS, STRUCTURES, ROAD, PAVEMENTS AND RAILWAY TRACKS,

MASONRY WORKS, BUILDINGS AND PLAIN/ REINFORCEDCONCRETE

The Contractor shall demolish sheds, structures, road pavements , railway tracks, masonry /

Construction of Bridge at Korangi Causeway 0200-2 Demolishing & Dismantling Work

 flooring works, stone pitching, buildings and plain/ reinforced concrete works to the line and
depth as shown on the Drawings or as directed by the Project Manager. Explosives shall not
be used to remove the plain and reinforced cement concrete or any other material whatsoever.
Mechanically operated breakers, concrete saws, chipping hammers or other approved
methods shall be employed for cutting. Care shall be taken that existing services and
structures are not damaged. It shall be the responsibility of the Contractor to replace at his cost
any services and structures damaged by the Contractor due to his negligence during cutting
operations or thereafter until the whole of cut parts/ areas are restored to original condition to
the satisfaction of the Project Manager.

10. CLEARANCE OF GREENAREA

The bushes/ plants in existing green area shall be cleared off up to the roots and the surface
shall smoothen and cleared from all debris and any organic material before receiving new
layer.

11. REMOVAL OF EXISTING SERVICES/UTILITIES

The Contractor shall mark all the services/ utilities falling within the ROW. After getting
approval from the Project Manager, the Contractor shall remove all such services/ utilities as
per the requirement/ specifications of the relative department whose utilities/ services are
being removed/ shifted.

12. DISPOSAL OF MATERIAL

12.1 All debris, materials resulting from demolition/dismantling works shall be disposed off
within 25 Km places designated by the Project Manager in the manner of disposition
required and directed by the Project Manager.

13. UNSALVAGEABLEMATERIAL

Concrete, masonry, and other noncombustible material, shall be disposed off the site.

13.2 All salvaged/ useable materials resulting from demolition and removal shall remain the
property of the Employer and shall be stacked at designated places.

13.3 The Contractor shall segregate the useable materials as directed by the Project
Manager and stack at designated places.

14. CLEANUP

Debris and rubbish shall be removed from site. Debris shall be removed and transported in a
manner that prevents spillage on streets or adjacent areas. Local regulations regarding hauling
and disposal shall apply.

All debris materials resulting from demolition / dismantling works shall be disposed off to
places designated by the Project Manager in the manner of disposition required and directed
by the Project Manager.

15. USE OF DISMANTLEDMATERIAL

The non-reusable material like concrete, concrete blocks etc will be broken up to 3” down size
and used as fill material for deep fill as directed by the Project Manager and disposal of non fill
able debris/ demolished/ removed materials at designated location including loading, unloading
and transportation complete in all respect up to any leads as directed by the Project Manager
and up to the satisfaction of the Project Manager. The non fill able debris will be disposed. All
useable materials like reinforcement, steel gates etc will be the property of the contractor.

Construction of Bridge at Korangi Causeway 0200-3 Demolishing & Dismantling Work

16. MEASUREMENT ANDPAYMENT

16.1 General
Except otherwise specified herein or elsewhere in the Contract
Documents no measurement and payment will be made for the under
mentioned items related to this section. The cost thereof shall be
deemed to have been included in the quoted unit rate of the items of the
Bill of Quantities under this section.

16.1.1 Safety measures for adjacent infra structure and facilities.

16.1.2 Temporary diversion and safety measures, demarcation / layouts etc.
16.1.3 Loading, unloading, transportation, disposal and stacking of all demolished/
dismantled/ removed material within free haulage limit of 25Km measured
along the most direct route from the boundary of the project or to the place
as designated by the Project Manager.
16.1.4 Loading, unloading, transportation and stacking of all usable material to the
place as designated by the Project Manager.
16.1.5 Permissions/ approvals, if required, from the relative department and
information to the stack holders.
16.1.6 Earthwork
16.1.7 hessian cloth, plaster of paris etc
16.1.8 Repair / finishing of adjacent component of dismantled structure.

16.2 Removing of Existing Street Light

Measurement

Measurement for acceptably Removal of existing street lighting poles including

brackets, foundation and stacking to designated places complete in all respect will be
made on the basis of each of the existing light as shown in drawing and as directed
by the Engineer.

Payment

Payment will be made for acceptable measured quantity of Removing of street light
on the basis of each quoted in the Bill of Quantities and shall constitute full
compensation for all the works related to the item

Construction of Bridge at Korangi Causeway 0200-4 Demolishing & Dismantling Work

 SECTION – 0400

GEOTECHNICAL INVESTIGATIONS

1. GENERAL

The work covered by this section of the specifications consists of furnishing all plant, labour,
equipment, appliances, materials and performing all operations in connection with the drilling,
collection of disturbed and undisturbed samples, in-situ and laboratory testing for geotechnical
investigations to determine the type, true nature, arrangement, thickness and texture of the various
soil strata and the extent and the conditions of different materials as they exist to the depth and
locations specified, complete in strict accordance with this section of the specifications and the
applicable drawings, and subject to the terms and conditions of the Contract.

2. METHODS & PROCEDURES FOR INVESTIGATIONS

2.1 The Contractor will mobilize and demobilize his equipment, plant & tools etc. including shifting
of rigs etc. from one borehole location to another. A proper tent with furniture shall be
provided onshore by the Contractor for the Client and Consultant’s Supervisor during the
investigation period. No separate payment shall be made for mobilization & demobilization of
rig, platform, equipment etc. and the cost of these items shall be deemed to be included in
other items of work.

2.2 The location of boreholes and testpits shall be established in the field by the Contractor as
directed by the Engineer’s Representative. Locating the boreholes accurately in the field and
determining their ground elevations shall be the sole responsibility of the Contractor.

All the boreholes shall be located by field survey to an accuracy of 0.5m in plan and 0.05m in
ground surface elevation given with respect to layout specified by the Engineer’s
Representative. All survey procedures and calculations shall be in a form such that locations
may be verified.

2.3 Drilling of boreholes in overburden shall be accomplished by rotary-cum-wash boring method.

When hard clay / rock is encountered then continuous core drilling (minimum NX or NW size)
with double tube core barrel shall be carried out. Depending on the hardness of rock,
tungsten carbide bit and diamond core bits shall be used for maximum core recovery.

2.4 The standard penetration tests (SPTs) shall be performed as per ASTM D-1586-84 (1992).

2.5 The undisturbed soil samples extracted by Shelby tube shall be as per ASTM D1587-83.

2.6 The representative / selected hard clay and rock samples shall be waxed, labeled and safely
transported to an approved laboratory. The remaining core samples shall be preserved in
wooden core boxes properly marked and placed in sequence. The preservation and
transportation of rock core samples shall be carried out as per ASTM D5079-90.

2.7 Ground water shall be recorded in all the boreholes. The ground water level shall be
measured each day before starting work and also 48 hours after completing the borehole. All
unusual water conditions and elevations at which such conditions are encountered shall be
carefully observed by the Contractor. The ground water elevation, casing tip elevation and
time of measurement shall be recorded.

Also the ground water depth in boreholes shall be determined by the following methods as
directed by the Engineer.

- After completion of drilling of a borehole to the required depth, the borehole shall be
emptied to a certain depth lower than the expected ground water level as directed by the
Engineer, through bailing out. The depth of ground water shall be determined after 24

Construction of Bridge at Korangi Causeway 0400-1 Geotechnical Investigation

 hours of bailing out of ground water. The level thus determined shall be recorded as the
ground water level.

- Clean water shall be added in the borehole so as to raise the water level in the borehole
to a certain level as directed by the Engineer. The depth of water level shall be
determined after 24 hours of adding water. The level thus determined shall be recorded
as the ground water level. No separate payment shall be made for monitoring and
keeping the record of ground water levels of the boreholes as specified. The cost shall be
deemed to have been included in the item rate for various items of work.

2.8 All the laboratory testing shall be performed as per relevant ASTM standards. In case relevant
ASTM standard is not available then equivalent BS standard will be applicable.

3. REPORTS

The Geotechnical Investigation Report to be prepared and submitted by the Contractor shall include
the following:

- A general description of the site, including a site plan showing the principal topographic
features, existing and adjacent structures and location of borings.

- Narrative and graphical description of the subsurface conditions encountered at site,

identifying the local geologic formations and area seismicity. The logs of soil borings and
penetration tests shall be shown graphically. Core recovery and rock quality designation shall
be mentioned. The sub-soil shall be classified as per Unified Soil classification system. Both
narrative and soil symbols shall be mentioned on the bore logs and laboratory soil samples
tested.

- Complete description of rock including colour, weathering, bedding, fracture, hardness,

texture etc. should be included in the report and mentioned on each bore log.

- Liquefaction Potential of the site should be analyzed in detail and recommendations with
regard to this phenomenon should be included in the report.

- A description of the analyses and correlations used in evaluating the test data to arrive at
engineering appraisals and design recommendations.

- Recommendations for type of foundation, their allowable bearing pressures and pile
capacities. Required depths of shallow foundations and deep foundations for the multi storey /
ancillary buildings and tanks etc. Co-efficient of lateral earth pressure and modulus of sub-
grade reaction (horizontal & vertical) based on soil type and insitu compactness.

- Recommendations for pavement design

- Aggressivity of subsoils and groundwater on buried R.C. works and any special measures
required for their protection

- Type of cement and preventive measures against environmental affects.

4. MEASUREMENT AND PAYMENT

4.1 General

Except otherwise specified herein or elsewhere in the Contract Documents, no measurement

and payment shall be made for the under mentioned specified works related to the relevant
items of the Bill of Quantities. The cost thereof shall be deemed to have been included in the
quoted rates of respective items of the Bill of Quantities:

Construction of Bridge at Korangi Causeway 0400-2 Geotechnical Investigation

 4.1.1 Disposal of sub-surface material obtained from boring / drilling to designated area as
directed by the Engineer.

4.2 Mobilization and demobilization

Measurement

Measurement will be made of the work under this item and payment shall be based on the
completion of work as specified herein.

Payment

The payment shall constitute full compensation for all costs for mobilization and
demobilization. The contract rates shall be deemed to include all costs for providing,
transporting, operating and maintaining all the equipment and plant necessary for site
investigation work along with providing water, power, providing all insurance covers, providing
any other expense not covered in the item rates of the BOQ and shifting and setting up at
each borehole location.

4.3 Execution of bore hole

Measurement

The actual quantity shall consist of the full depth of acceptable vertical drill hole as measured
along the line of the hole.

Payment

All the necessary operations done to accomplish drilling as specified shall be deemed to be
part of this item. The casing of the drill holes or boreholes, taking and recording of water
levels in holes, supply of daily field record and drill / borehole logs and all associated costs
shall be deemed to be included in the contract rate. No separate payment shall be made for
backfilling of holes and drilling of angle holes.

4.4 Carrying out standard penetration tests (SPT) in drill / boreholes

Measurement

The measurement for standard penetration tests shall be made as number of standard
penetration tests actually performed on the instructions of the Engineer in a drill hole or a bore
hole.

Payment

Payment shall be made as a unit for each test. The contract rate shall be deemed to include
all labour and equipment required to perform the tests including standing time of labour and
plant while the test is being set up and dismantled or in progress and the preparation and
supply to the Engineer of any preliminary copies of test data and results as well as all the
costs for providing jars, labeling, preservation and transportation of samples to the laboratory.

Construction of Bridge at Korangi Causeway 0400-3 Geotechnical Investigation

4.5 Collection of undisturbed Soil samples from boreholes using Shelby/Pitcher/Denison
sampler etc.

Measurement

Measurement shall be made as number of acceptable undisturbed open drive tube samples
Pitcher/Denison samples separately and actually recovered on the instructions of the
Engineer.

Payment

Payment shall be made as a unit for each undisturbed sample successfully recovered. The
contract rate for these items shall be deemed to include the cost of any incidental delay of
standing time of labour and plant, for the cost of taking, sealing, labeling, transporting
samples and the cost of supply of all approved tubes, containers, crates and boxes which
shall become the property of the Engineer after delivery to the approved laboratory.

4.6 Collection and preservation of groundwater samples from boreholes/Test pits

Measurement

Measurement shall be made as number of water samples actually taken on the instructions of
the Engineer.

Payment

Payment shall be made as a unit for each water sample. All costs incurred for providing
equipment, material, labour and bailing out of the hole, if necessary and taking sealing,
labeling, transporting the water samples as well as the cost of the containers shall be deemed
to be included in the contract rate for water sampling.

4.7 Engineering Lab

Measurement

Measurement under the item “Engineering Lab” shall be made as per actual number of
laboratory tests performed according to ASTM, AASHTO or the equivalent British Standards,
or as directed by the Engineer.

Payment

Payment shall be made for number of laboratory test actually performed in the laboratories
approved by the Engineer according to the price bid by the Contractor in the Bill of Quantities
as a lump sum for each test. The lump sum shall be deemed to include complete laboratory
testing for the specified test according to ASTM, AASHTO or British Standards and
presentation of reports in standard form as directed by the Engineer.

*** End of Section Specifications***

Construction of Bridge at Korangi Causeway 0400-4 Geotechnical Investigation

 SECTION – 1100

EARTHWORKS

1.0 SCOPE

The work under this section of the specifications consists of furnishing all plant,
labour, equipment, appliances and materials and in performing all operations in
connection with excavation, backfilling/filling for all type foundations, trenches and
embankments including stock piling of suitable excavated material, disposal of
unsuitable and surplus excavated material in accordance with this section of
specifications, the applicable drawings and subject to terms and conditions of the
Contract.

2.0 APPLICABLE STANDARDS

Materials, construction and testing shall comply with the following codes and standards:

ASTM C 136 Sieve or screen analysis of fine and coarse aggregate

ASTM D 422 Testing for Liquid and Plastic Limit of Soils

ASTM D 596 Water Analyses

ASTM D 1556 Density of soil in place by the sand cone method

ASTM D 1557 Moisture-Density relation of soils.

ASTM D 2167 Density of soil in place by the Rubber-Balloon method

ASTM D 2216 Moisture content of soil

ASTM D 4253 Test method for maximum Index Density and unit weight of soils

ASTM D 4254 Test method for minimum Index Density and unit weight of soils

ASTM D 1883 CBR-California Bearing Ratio test

3.0 GENERAL

3.1 The Contractor shall acquaint himself with the nature of the ground, existing
structures and subsurface materials (soil / rock) which will be encountered during
excavation or earthworks. The Employer does not guarantee or warrant in any way
that the materials to be found in the excavation will be similar in nature to that of
any samples which may have been exhibited or indicated in the Geo-Technical
Investigation Report, Drawings or any other Contract Documents or to material
obtained from boring or trial holes. The Contractor shall be deemed to have made
local and independent inquiries as to, and shall take whole risk of the nature of the
subsurface materials (soil / rock) to be excavated or penetrated and the Contractor
shall not be entitled to receive an extra or additional payment nor to be relieved
from any of his obligations by reasons of the nature of such ground and subsurface
material.

3.2 The Contractor shall submit a detailed list of plant and equipment which he shall
undertake to bring to the site and to carry out the work. The list shall satisfy the
Engineer as to type, size and quantity. The Contractor shall place on the site of
the work all of the equipment listed and all subsequent equipment required for
approval of the detailed program of work and such equipment which may be
directed by the Engineer. All equipment which is proposed to be used on the

Construction of Bridge at Korangi Causeway 1100-1 Earthworks

 work shall be of sufficient size and in such mechanical condition as to meet
requirement of work and produce a satisfactory quality of work. In no case shall
the Contractor remove from the site, the plant and equipment without the written
approval of the Engineer. The Contractor shall supply all plant and equipment
necessary for the construction of each phase of the work and it must be on site,
inspected and approved by the Engineer. If after use of the equipment the
Engineer determines that the work carried out does not meet the Contract
requirement, the equipment shall be changed and the deficient work shall be
removed and corrected as direct by the Engineer.

3.3 All suitable materials from stripping of top soil and excavation shall be used
unless otherwise declared unsuitable by the Engineer. The suitable material
shall comply with the requirements as specified in the respective clauses for
various items.

3.4 The Contractor shall jointly survey the area marked for service lines, buildings or
other structures or any area designated by the Engineer and prepare the survey
drawings showing natural ground profile and cross-section and submit to the
Engineer for approval prior to start of any earthwork operation.

All suitable material from excavations shall be transported to and placed in fill
areas or stockpiled at locations designated by the Engineer. Materials from
excavation and stripping shall be stockpiled separately.

Existing utilities which are to remain in service or to be relocated and to remain

in service until relocation are to be determined by the Contractor. They shall be
safeguarded and protected from damage.

If any existing service lines, utilities and utility structures which are to remain in
service are uncovered or encountered during the operations, shall be safe
guarded, protected from damage and supported as directed by the Engineer.

3.5 All excavations, cut and fills shall be constructed to the lines, levels and gradients
specified with any necessary allowance for consolidation, settlement and drainage
so that at the end of Defects Liability Period the ground shall be at the required
lines, levels and gradients. During the course of the Contract and during Defects
Liability Period any damage or defects in cuts and fills, in structures and other
works, caused by slips, falls of wash-ins or any other ground movement due to the
Contractor's negligence shall be made good by the Contractor at his own cost.

4.0 SITE PREPARATION

4.1 The Contractor shall set out the works and shall be responsible for true and perfect
setting out of the same and for correctness of the positions, levels, dimensions and
alignments of all parts thereof. If at any time any error in this respect shall appear
during the progress of the works, the Contractor shall at his own expense rectify
such error, to the satisfaction of the Engineer.

4.2 The Contractor shall construct and maintain accurate bench marks so that the
Lines and Levels can be easily checked by the Engineer.

4.3 The Contractor shall construct and maintain such temporary drains in addition to
those shown on the plans, as will adequately drain areas during construction.

4.4 The Contractor shall perform a joint survey with the Engineer's Representative, of
the area where earth work is required, plot the existing ground levels on the
drawings and obtain approval from the Engineer before starting the earth work and
shall supply a copy to the Employer duly checked, signed and authenticated by the
Engineer before start of work.

Construction of Bridge at Korangi Causeway 1100-2 Earthworks

5.0 CLASSIFICATION OF EXCAVATION

No classification shall be made of any material excavated / cut as to its class, nature, origin
or condition. The excavation will be unclassified as being carried out in all kinds of
subsurface material including soil and rock.

Blasting will be permitted only when proper precautions are taken for the safety of all
persons, the work, and the property. All damage done to the work or property shall be
repaired at the Contractor’s expense. All operations of the Contractor in connection with the
transportation, storage, and use of explosives shall conform to all state and local regulations
and explosive manufacturers’ instructions, with applicable approved permits reviewed by the
Engineer. Any approval given, however, will not relieve the Contractor of his / her
responsibility in blasting operations.

In each distinct blasting area, where pertinent factors affecting blast vibrations and their
effects in the area remain the same, the Contractor shall submit a blasting plan of the initial
blasts to the Engineer for approval. This plan must consist of holes size, depth, spacing,
burden, type of explosive, type of delay sequence, maximum amount of explosive on any
one delay period, depth of rock and depth of overburden if any. The maximum explosive
charge weights per delay included in the plan shall not be increased without the approval of
the Engineer.

The Contractor shall keep a record of each blast fired , its date, time and location; the
amount of explosives used, maximum explosive charge weight per delay period, and, where
necessary, seismograph records identified by instrument number and location.

The excavation wherever required will be carried out below ground water level by
dewatering the area.

The Contractor shall build, maintain and operate all berms, channels, flumes, sumps and
other temporary diversion and protective works needed to divert the surface water through
or around the required excavation. All excavation shall be dewatered and kept free of
standing water, water seeping from the sides and bottom of excavation above, the free
level. The Contractor shall furnish, install, operate and maintain all drains, sumps, pumps
and other equipment needed to dewater the excavation areas. Dewatering methods that
cause a loss of fines from the bottom and slopes of the excavation will not be permitted.

Prior to commencement of dewatering of the required excavation , the Contractor shall

furnish the Engineer for review and comments with complete plans and sketches for
diverting surface water if any.

Submission for review and comments of the required plans and sketches and any approval
from the Engineer shall not relieve the Contractor of any of his duties and obligations under
the Contract.

6. FOUNDATIONS / TRENCHES

6.1 Excavations

6.1.1 Excavation shall include the removal of all material of every name and
nature. Excavations shall be carried out in accordance with
excavation plans and sections shown on the Drawings.

6.1.2 The major portion of excavations shall be carried out by mechanical

excavators and excavated materials disposed off to stock on spoil as per
Drawings or as directed by the Engineer. The excavation, which cannot
be done by mechanical means, shall be done by manual tools. Unless
otherwise specified by the Engineer, leveling, trimming and finishing to the
required levels and dimensions shall be done manually. The material

Construction of Bridge at Korangi Causeway 1100-3 Earthworks

 suitable for fill and backfill if approved by the Engineer shall be stockpiled
within the free haulage limit from the project boundary of the works.

6.1.3 The Contractor shall give reasonable notice that he intends to commence
any excavation and he shall submit to the Engineer full details of his
proposals. The Engineer may require modifications to be made if he
considers the Contractor's proposals to be unsatisfactory and the
Contractor shall give effect to such modifications but shall not be relieved
of his responsibility with respect to such work.

6.1.4 For major excavations, the Contractor shall submit for the prior approval of
the Engineer full details and drawings showing the proposed method or
procedure, supporting and strutting, etc. The design, provision,
construction, maintenance and removal of such temporary works shall be
the responsibility of the Contractor and all cost in these respects shall be
included in the quoted unit rate for the permanent work.

6.1.5 The Contractor's attention is drawn particularly to his obligations under the
Conditions of Contract in respect of those works, which are in close
proximity to existing buildings.

6.1.6 The Contractor shall preserve the completed excavation from damage due
to slips and earth movements, ingress of water from any source
whatsoever and deterioration by exposure to the sun and the effects of the
weather.

6.1.7 All excavation of every description, in whatever material encountered shall

be performed to the elevations and dimensions shown on the Drawings in
such a manner as to avoid interruption to work in other parts of the site.
The Contractor shall be responsible for injury to the other works caused
during excavation period.

6.1.8 Excavation shall extend to adequate distance from walls and footings to
allow for placing and removal of forms, installations of services and for
inspection, except where the concrete for walls and footings is authorized
to be deposited directly against excavated surfaces. Undercutting will not
be permitted.

6.1.9 All excavations in foundations shall be taken to 150 mm above the final
excavation elevations shown on the drawings and the last 150 mm shall be
trimmed carefully to a smooth and level surface. Immediately after trimming
to the final elevation, a layer of blinding concrete shall be placed to the
thickness shown on the drawings. All excavations for foundations which
have been trimmed and disturbed shall be compacted and covered by lean
concrete by the end of the day. It is specifically brought to the notice of
the Contractor that any excavation taken down to the trimmed elevation
which is left over-night or for any length of time thereafter, uncovered by
the blinding concrete, shall be required to be trimmed to such lower
elevation as directed by the Engineer and any extra work or any
consequent increase in the quantities caused thereby shall not be paid to
the Contractor.

6.1.10 No excavation shall be covered nor any permanent work commenced

until the foundation has been inspected by the Engineer and his
permission to proceed is given.

6.1.11 If excavation for sub-structures are carried below the required level, as
shown on the Drawings or as directed by the Engineer, the surplus depth
shall be filled in with concrete of same grade as of blinding concrete at the
sole cost of the Contractor.

Construction of Bridge at Korangi Causeway 1100-4 Earthworks

 6.1.12 All excavation shall be performed in the dry. The placing of blinding
concrete, placing of reinforcement and casting of the permanent works in
the excavation shall be carried out in the dry and the Contractor shall have
sufficient dewatering equipment for this purpose. The Contractor shall
design, provide and maintain effective dewatering system during
excavation and construction of foundations up to plinth level so as to keep
the foundation area dry. Adequate precautions shall be taken to prevent
any erosion due to undercutting from underneath the previously
constructed adjoining foundations.

6.1.13 Shoring, where required during excavation, shall be installed to protect

workmen and the bank, adjacent paving, structures and utilities. The term
shoring shall also be deemed to cover whatever methods the Contractor
elects to adopt, with prior approval of Engineer, for upholding the sides of
excavation and also for planking and strutting to excavation against the
side of roadways and adjoining properties in existing hardcore of any
other material. The Contractor will be held responsible for upholding the
sides of all excavations and no claim for additional excavation, concrete or
other material will be considered in this respect.

6.1.14 Existing utility lines that are shown on the drawings or the locations of
which are made known to the Contractor prior to excavation and that are to
be retained, as well as utility lines constructed during excavation and
backfilling, and if damaged, shall be repaired by the Contractor at his own
expense. Any existing utility lines which are not known to the Contractor in
sufficient time to avoid damage, if inadvertently damaged during
excavation, shall be repaired by the Contractor and adjustment in payment
will be made as approved by the Engineer. When utility lines which are to
be removed, are encountered within the area of operations the Contractor
shall notify the Engineer in ample time for the necessary measures to be
taken to prevent interruption of the service.

6.1.15 Excavated material suitable for use as fill and backfill shall be stockpiled
within free haulage limit from the project boundary as directed by the
Engineer. This stockpiled material shall be transported back to places
requiring fill or backfill.

6.1.16 Excavated material unsuitable for use as fill and backfill shall be disposed
off by the Contractor at locations approved by the Engineer within specified
free haulage limit.

6.1.17 Where applicable the excavation work shall include the excavation in
above water table and excavation below water table. The Contractor shall
submit the proposal for dewatering from the areas of excavation for the
approval of the Engineer and shall provide all plant, equipment, pumps,
sheeting, well points as required to keep the water table 1.0 metre below
the deepest foundation as shown on the drawings till the completion of
foundation works.

6.1.18 The Contractor shall make independent enquiries and perform and make
independent observations to ascertain the water table in the areas of
excavations during the period when the construction works are in progress.
The Contractor shall take whole risk of any nature for fluctuation of the
water table from his own findings. The Employer/Engineer does not bind
himself in any way and shall not be responsible for any information given
by him or any information, observations or values obtained from his
reports, Drawings, and Documents or anywhere in this Document.

Construction of Bridge at Korangi Causeway 1100-5 Earthworks

 6.2 EMBANKMENT CONSTRUCTION

6.2.1 General

It shall consist of construction of select embankment for paved areas and

common embankment for unpaved, areas. Only approved material shall be
used in the construction of embankments.

All embankment construction shall be made to the lines, levels, profiles and
grades as shown on the drawings or established by the Engineer. During
progress of the work it may be found necessary or desirable by the
Engineer to vary the levels, elevations and grades from those shown on
the drawings. The Contractor shall perform the embankment construction
to the revised levels, elevation as established by the Engineer.

Where embankments are to be placed in water logged areas and which

are inaccessible to heavy construction equipment, a working platform shall
be first established, consisting of a blanket of fill material placed on the
water logged area. The thickness of the working platform shall be about 0.5
metre unless directed otherwise by the Engineer and the width shall be that
of the embankment. The placement and compaction of the working
platform shall be performed by use of light equipment as directed by the
Engineer. No density requirements are specified for the working platform,
however, subsequent layers above shall be compacted to densities
specified in the relevant items.

Benching of sufficient width for slope stability and movement of equipment

and machinery shall be carried out for embankment formation in areas of
steep slopes.

6.2.2 Select Embankment

The select embankment shall be constructed under all paved areas. The
area shall be prepared (after stripping of top soil) by scarifying the surface
to a minimum depth of 150 mm and compacting it to required densities.

6.2.2.1 Material

The suitable subsurface material obtained from excavation (except

stripping of top soil) shall be used in the construction of select
embankment. The material shall be A-4 or superior as per
AASHTO soil classification. The soaked CBR of the material shall
be equal to or greater than 6. In the top 30 cm the material shall be
A-4 or superior and the PI ≤ 8. When excavated material consists
predominately of rock fragments of such size that the material can
not be placed in layers of the prescribed thickness without
crushing, pulverizing or further breaking down the pieces, such
material may be placed in layers not exceeding 60 cm in
thickness. Each layer shall be leveled and smoothed with suitable
leveling equipment and by distribution of spalls and finer fragments
of rock. These type lifts shall not be constructed above an
elevation (150 cm) below the finished sub-grade.

6.2.2.2 Formation of Embankment

Embankment shall be formed in successive horizontal layers of

not more than (200 mm) in loose depth for the full width of the
cross-section, unless otherwise approved by the Engineer.

Construction of Bridge at Korangi Causeway 1100-6 Earthworks

 The material placed in layers and the sub-grade scarified shall be
compacted to the density specified below:

Depth (cm) Percent of Max. dry Density as per ASTM

Below Subgrade Level D1557
Cohesive Soil Non-Cohesive Soil Cohesive Soil Non-Cohesive Soil
0 to 30 0 to 60 95% 100%
30 to 75 60 to 100 93% 95%
Over 75 Over 100 90% 90%

Sub-grade level is the surface on which the pavement structure

will be placed.

The maximum density of sand (granular) material (if used) shall

also be determined as per ASTM D4253. The higher of the two
values obtained from ASTM D1557 and ASTM D4253 shall be
used to check the relative compaction of the in place material.

The moisture content of the material should be controlled to within

+2% of the optimum moisture content. In order to achieve a
uniform moisture content throughout, the wetting and drying of the
material, and manipulation shall be required when deemed
necessary. Also, the California Bearing Ratio test (ASTM D1883)
may be conducted on soil if instructed by the Engineer.

The embankment formed by rock fragments of such size that the

material can not be placed in layers of thickness prescribed
without crushing, pulverizing or further breaking down the pieces,
such material may be placed in layers not exceeding 60 cm of
loose measurement and compacted by vibratory roller with mass
as specified hereunder:

Mass per metre width of Depth of fill layer Number of passes of the
Vibratory roll (kg/m) cm roller on each layer
2300 – 2900 40 5
2900 – 3600 50 5
3600 - 4300 60 5

The material shall be carefully placed in layer so that all larger

stones will be well distributed and voids completely filled with
smaller stones, small spall and soil to form a solid mass. After
placing the rock material, surface shall be covered with fine
material having thickness less than 20 cm.

Material for each layer should be consolidated with heavy weight

vibratory roller until settlement as checked between two
consecutive passes of roller is less than 1% of the layer thickness.
When rock to be incorporated in fill is composed largely of weak or
friable material, the rock shall be reduced to a maximum size not
exceeding 50% of the thickness of the layer being placed.

6.2.3 Common Embankment

6.2.3.1 Material

The area requiring common embankment, i.e. graded strip, and

other unpaved areas shall be constructed from the excavated soil

Construction of Bridge at Korangi Causeway 1100-7 Earthworks

 and rock. The top soil obtained from stripping may be used at
deeper level with the approval of the Engineer.

6.2.3.2 Formation of Embankment

Before placing and compacting the fill material the ground shall be
scarified to a depth of 15 cm and compacted to a dry density of
90% as per laboratory compaction test method ASTM D1557. The
moisture content of soil during compaction of scarified layer and
successive layers shall be within +2% of optimum moisture
content before rolling to obtain the desired density results. The
successive horizontal layers shall be formed in loose depth
(200mm) for the full width of the cross section unless otherwise
approved by the Engineer. Each layer will be compacted to dry
density of 90% as per laboratory compaction test method
ASTM D 1557.

The layer thicknesses and compaction requirements shall be the

same as specified under ‘Select Embankment’ for embankment
formed by rock fragments.

No rock larger than 8 cm in any dimension shall be placed in top

thirty (30 cm) of embankment unless allowed by the Engineer.

6.2.3.3 Tolerances

Select Embankment

The grade surface of each layer excluding final layer, shall be smooth
and even and tolerance from required grade shall not be more than 20
mm.

Common Embankment
The grade surface of each layer including the final layer, shall be smooth
and even and tolerance from required grade shall not be more than 20
mm.

6.3 Fill and Backfill

6.3.1 After completion of foundations, walls, trenches and other construction

below the elevation of the final grades and prior to start of back filling,
forms shall be removed and the excavation shall be cleaned of trash and
debris.

6.3.2 The backfilling shall include filling under the floors, around the foundation
and in trenches.

6.3.3 The backfilling shall include loading, unloading, transporting, placing,

stacking, spreading of earth, watering, rolling, ramming and compacting,
etc., complete as specified herein.

6.3.4 Filling under floor/trenches shall be done with approved selected material
obtained from required excavation or outside sources. It shall be
predominantly granular material and free from slurry mud, organic or other
unsuitable matter and capable of compaction by ordinary means.

6.3.5 The Contractor shall provide the approved quality of backfill and fill material
required to complete the fill and backfill from the places designated by the
Engineer.

Construction of Bridge at Korangi Causeway 1100-8 Earthworks

 6.3.6 Filling in foundations/trenches shall be placed in 200 mm layers and
compacted at optimum moisture content by mechanical means or other
means as approved by the Engineer.

6.3.7 Material for backfilling shall be as approved by the Engineer and shall be
placed in layers not exceeding 200 mm measured as compacted material
and saturated with sufficient water and compacted to produce in-situ
density not less than 95% of the maximum dry density at optimum moisture
content, achieved.

6.3.8 All fill areas shall be left neat, smooth and well compacted, the top surface
consisting of the normal site surface soil, unless otherwise directed.

6.3.9 Depending on the capacity of the compacting equipment the Engineer may
instruct increased thickness of successive layers to be placed.

6.3.10 Fill shall not be placed against foundation walls prior to approval by the
Engineer. Fill shall be brought up evenly on each side of the walls as far as
practicable. Heavy equipment for spreading and compacting the fill shall
not be operated closer to the wall than a distance equal to the height of the
fill above the top of footing.

6.3.11 In case the Contractor has to arrange the fill material from outside source
the quality of the fill material will be subject to the approval of the Engineer.
The Engineer shall require the Contractor to carry out various tests of the
fill material. All such tests shall be made at an approved laboratory at the
cost of the Contractor.

6.3.12 Backfilling of foundations / trenches shall be carried out only after the
structural works within the excavations have been inspected, tested and
approved by the Engineer.

6.3.13 Layers upto an elevation of 300 mm above the top of the bedding shall not
be more than 150 mm in loose thickness and the remainder of the layers
above that elevation shall not be more than 150 mm of compacted
thickness.

6.3.14 If it is found necessary to alter the moisture content of the fill material in any
way, then, very strict control shall be exercised over the wetting and/or the
drying process and frequent moisture content tests shall be carried out.

6.3.15 The stabilization of compacted fill/backfill surfaces shall be smooth and

even and shall not vary more than 10mm in 3 meters from true profile and
shall not be more than 12.5mm from true elevation.

6.4 Engineered Fill

The material for engineered fill shall be the earth obtained from required excavation
which will be free from organic matter, roots and other deleterious materials or the
sandy soil obtained from outside borrow areas or the blend of the two soils.

The soil for engineered fill shall in general should be A-4 or better soil group with
PI≤8 and the soaked CBR value of the material to be equal or greater than 10.

Engineered fill material shall meet the following requirements or as approved by

the Engineer.

Construction of Bridge at Korangi Causeway 1100-9 Earthworks

 a) Grading Requirement

mm Inch. A B

25 V1 100 100
19 3 / 4” 60-100 75-100
4.75 No.4 50-85 55-100
2.0 No.10 40-70 40-100
0.425 NO.40 25-45 20-50
0.075 No.200 0-15 5-15

b) Material satisfying the requirements of coarse sand falling under. soil

classification A-3 (AASHTO). In case, coarse sand is utilised for granular fill it
shall be ensured that the same is confined properly with approved material.

c) The material shall have a Plasticity Index of not more than size (6) as
determined by AASHTO T-89 and T-90.

7.0 QUALITY CONTROL

A testing program shall be submitted by the Contractor. Tests shall be performed by the
Contractor to ensure compliance with the specifications as required. A copy of all test
reports shall be submitted to the Engineer for approval. The test shall be performed in
accordance with the following test procedures and frequency of testing.

Prior to construction of embankment, classification and compaction tests shall be carried out
on stock-piled material obtained from stripping of top soil and excavated subsurface
material (soil & rock). The tests shall be carried out as per ASTM 422, ASTM 424 and
ASTM D 1557. A family of laboratory compaction curves as per ASTM D 1557 representing
typical material shall be developed for the fill / backfill material.

The frequency of classification tests shall be for every 1000 cu.m of fill material. The
Engineer may alter the frequency of testing depending on the type of material and variation
encountered at site.

The field density tests shall be performed as per ASTM D 1556 or ASTM D 2167. The
frequency of testing shall be as under:

Select Embankment
2
Area requiring 90% to 93% compaction – one test in every 500 m area in each layer
2
Area requiring 95% & 100% compaction – one test in every 300 m area in each layer

Common Embankment
2
Area requiring 90% compaction – one test in every 1000 m area

The average of four tests are required to be greater than the required compaction and not
more than one test be 1.8% less than required percentage of compaction. This is for 100%
compaction. For 95% to 90% compaction the following is required.

%age Compaction One test not less than

95% 93.5%
90% 89.5%

Construction of Bridge at Korangi Causeway 1100-10 Earthworks

8.0 DISPOSAL OF SURPLUS EXCAVATED MATERIAL

8.1 The rejected unsuitable material and surplus excavated material shall be disposed
of within the haulage limit of 10 km from project site NGIA in line with municipality
laws as directed by the Engineer.

8.2 The disposal of surplus/unsuitable excavated material shall include loading,

unloading, transporting, stacking, spreading and leveling as directed by the
Engineer.

9.0 SAND BEDDING/CRUSH AGGREGATE BEDDING

9.1 The sources of supply of all fine and coarse aggregates shall be subject to the
approval of the Engineer.

9.2 All fine and coarse aggregates shall be clean and free from clay, loam, silt and
other deleterious matter. If required, the Engineer reserves the right to have
them washed by the Contractor at no additional expense. Coarse and fine
aggregates shall be delivered and stored separately at site. Aggregates shall not
be stored on muddy ground or where they are likely to become dirty or
contaminated.

9.3 Sulphate content of aggregates shall not exceed 0.40 percent by weight for each
individual source of coarse and fine aggregate. Chloride content of aggregates
shall not exceed 0.05 percent by weight for each source of coarse and fine
aggregate..

9.4 Fine aggregate shall be hard coarse sand, crushed stone or gravel screenings
and shall conform to requirements of PS 243 and/or BS 882 and/or ASTM C-33.

9.5 Coarse aggregate shall be gravel or crush stone of hard, durable material free
from laminated structure and conforming to PS 243 and/or BS 882 and/or ASTM
C-33.

10. MEASUREMENT AND PAYMENT

10.1 General

Except otherwise specified herein or elsewhere in the Contract Documents no

measurement and payment will be made for the under mentioned items related
to this section. The cost thereof shall be deemed to have been included in the
quoted unit rate of the items of the Bill of Quantities under this section.

10.1.1 De-watering where required to keep the foundations and services line
trenches dry during construction of Works.
10.1.2 Timber shoring, planking, strutting and providing slope for upholding the
sides of excavations.
10.1.3 Any fill with approved material necessitated by over excavation due to
fault or convenience of the Contractor.
10.1.4 Stockpiling the excavated material at approved location within free
haulage limit from the Project Boundary and transporting back suitable
material to places requiring fill or backfill.
10.1.5 Foundation bed preparation for service line trenches and building.
10.1.6 Extra excavation involved in providing adequate working space around
sides of foundation and service line trenches.

Construction of Bridge at Korangi Causeway 1100-11 Earthworks

 10.1.7 Scarifying, rolling, leveling, watering and compacting the fill and backfill
to required density.
10.1.8 All laboratory and field tests stipulated in these specifications.
10.1.9 Disposal of rejected surplus and unsuitable excavated material.

10.2 Earthworks

10.2.1 Measurement

Measurement of acceptably completed Works of excavation in all kinds

of sub-surface material up to specified depth including dewatering and
disposal of surplus / rejected excavated material with loading, unloading
& transportation to designated places up to any lead etc as directed by
the Engineer complete in all respect.

10.2.2 Payment

Payment will be made for acceptable measured quantity of excavation

on the basis of unit rate per cubic meter quoted in the Bill of Quantities
and shall constitute full compensation for all the works related to the
item.

10.2 Excavation for Foundations/Trenches

10.2.1 Measurement

The quantities set out for excavation and its subsequent disposal shall
be deemed to be the bulk quantity before excavating and no allowance
shall be made for any subsequent variations in bulk or for any extra
excavation.

Unless otherwise shown on the Drawings quantities of excavation shall

be measured of acceptably completed works on the basis of vertical
excavation lines required for the nominal concrete dimensions of the
structural members of foundations.

Measurement of acceptably completed works of excavation will be made

on the basis of number of cubic meter of material excavated for
foundation, pipeline trenches as shown on the drawing. It shall be
calculated/ measured from pre-work levels and the levels shown on the
drawing.

10.2.2 Payment

Payment will be made for acceptable measured quantity of excavation

on the basis of unit rate per cubic meter quoted in the Bill of Quantities
and shall constitute full compensation for all the works related to the
item.

*** End of Section 1100 ***

Construction of Bridge at Korangi Causeway 1100-12 Earthworks

 SECTION - 1520

PILING WORK
1. SCOPE

The work under this section of specification shall consists of furnishing all plant, labour,
equipment, appliances and material and performing all operations necessary for the
execution of the works as contained in this section in accordance with the specifications,
FHWA guidelines (FHWA-NHI 18-024), relevant ACI, ASTM, API and AWS standards, and
as per drawings and/or as directed by the Engineer, including but not limited to the
following for a complete job:

1.1 Drilling of boreholes in offshore and onshore conditions i.e., on ground and below sea
bed level of the diameter and lengths as shown on the drawings or as directed by the
Engineer.

1.2 Supply, fabrication and placement of reinforcing steel bar cage for piles as shown on
the drawings in offshore and onshore conditions.

1.3 Supply and placement of concrete by tremie for construction of piles, in accordance
with section 2300 in offshore and onshore conditions.

1.4 Supply and installation of complete Pile Load Test arrangement, conducting the test as
per latest ASTM standard and submission of test report.

1.5 Preparation of piles’ head for low strain sonic integrity test, conducting the test as per
latest ASTM standard and submission of test report.

1.6 Supply, driving and installation of permanent steel liner (casing) of required diameter
and thickness.

2. SUBMITTALS

2.1 Refer to Section 0100 "General Requirements".

2.2 Submit details, method of statement and drawings for the following activities:

- Drilling of boreholes in offshore and onshore conditions.

- Installation of permanent steel liner.
- Methodology & procedure of placing reinforcement and concrete for
constructing the piles.
- Sonic integrity testing on working and test piles
- Pile Load Testing on working and test piles.

3. SUPERVISORY STAFF

The Contractor shall have at site at all times, only qualified, experienced, orderly and
thoroughly competent persons, who shall conduct and supervise all work related to
construction of piles. Since the construction of piles requires special knowledge and utmost
care, the Contractor shall have at least one qualified and experienced Engineer specialized
in this fieldwork that shall be present full time during execution.

4. LOCATION OF PILES

The location of piles shall be established by the Contractor as shown on the drawing or as
directed by the Engineer from the reference points provided by the Engineer. Establishing
the pile locations accurately in the field shall be the sole responsibility of the Contractor.

Construction of Bridge at Korangi Causeway 1520-1 Piling Works

 The Contractor shall carry out levelling survey and provide ground/sea bed elevations and
tip/top elevations of each pile. The elevations shall be given with respect to a reference
bench mark provided by the Engineer.

5. NUMBER, DIAMETER AND LENGTH OF PILES

The piles shall be constructed true to line, level and profiles as shown on the drawings or
as directed by the Engineer.

The piles shall have specified diameter and length as shown on the drawings or as
directed by the Engineer.

The Engineer may direct the positions, the number, diameter and length of piles/casing to
be changed at his discretion and according to design requirements during the progress of
work.

6. MOBILISATIONS AND DEMOBILISATION

Mobilization shall consist of the delivery at the site of all plant, equipment and materials
supplies in satisfactory working order. Adequate plant and equipment shall be employed at
site. Mobilization shall also include the shifting of necessary plant, equipment including
drilling rig and necessary materials/supplies from one pile location to other within the site
and setting up of such equipment in satisfactory manner at each location.

For offshore drilling, lowering of steel reinforcement cage, pouring of concrete and other
related works in the sea, pontoons, barges and fixed platform shall also be mobilized. The
plant and equipment shall be stable under sea conditions and boring for piles shall be
accomplished without excessive movement or tilting.

Demobilization shall consist of the removal from site of all plant, equipment and materials
after completion of the work and leaving the site clear, clean and tidy.

7. DRILLING OF BOREHOLES IN SOIL/ROCK

7.1 Boring

The Contractor shall use percussion or any other method as approved by the
Engineer for drilling of boreholes in soil/rock. The Contractor shall mobilize at site
adequate and suitable drilling equipment for smooth, continuous and timely
execution of work. All materials, tools, plants and equipment shall be provided by
the Contractor to the satisfaction of the Engineer. The cost of which shall be
deemed to have been included in the rate of boring for RCC bored cast-in-situ
piles.

At locations where, there is a possibility of encountering underground services

during drilling of boreholes for piles it would be necessary to excavate a pit (2.5m
deep) at each borehole location prior to commencement of drilling operation. In
spite of this precaution, the drilling in the top 5m shall be advanced carefully. The
responsibility of avoiding hitting / damaging any underground services rest with the
Contractor. In case of accidentally hitting / damaging underground services occurs,
the same shall be repaired / restored by the Contractor.

The Contractor shall not perform casing installation or drilling operations within a
clear distance of three diameters of a newly poured pile within twenty (24) hours of
the placement of concrete.

7.2 Permanent Steel Casing including Driving

Construction of Bridge at Korangi Causeway 1520-2 Piling Works

 The Contractor shall provide and drive permanent mild steel casing/liner of required
length, thickness and diameter. It will however be responsibility of the Contractor to
drive the casing without distortion, buckling etc. The casing shall be driven to the
required level as directed by the Engineer.

Steel for permanent casing shall conform to the requirement of ASTM A 36

2
standard with a minimum yield stress of 250N/mm (36000 psi). All welding shall
be in conformance with AWS specifications using electrodes E 60 XX or equal.
The minimum length of each shell of casing shall be 2.5
metres the top end shell which may be of lesser length.

Only welders tested and certified as per AWS D 1.1 or equivalent standard for the
type of welding to be executed shall be employed for this work. Relevant
certificates are to be handed over to the Engineer.

Prior to commencement for fabrication of liner, the Contractor shall submit to the
Engineer for his approval Welder Performance Qualification(WPQ),Welding
Procedure Qualification Record(WPQR) and Welding Procedure Specification
(WPS) providing at least the following information :

- Material type & thickness

- Welding Process
- Type of Welding Consumables
- Welding Position
- Welding Heat Input
- Type of Welding Joint
- Surface preparation prior to welding
- Filler material and flux
- Welding sequence
- No of Passes and Penetration of each Pass
- Procedure for non-destructive testing

All welds shall be made to ensure 100% penetration. The welding seam quality
factor shall be u=1.0. Full penetration pre-qualified welds, as per AWS specification
shall be used.

Defective welds shall be repaired in accordance with AWS D1.1 or replaced and re-
tested by the same method and acceptance standard used to examine the original
weld. Whenever, defective welds are found, cause of the defects shall be
determined and corrective action shall be instituted immediately.

All testing repair replacement of welds shall be at the Contractor’s expense.

All welds shall be free of slag, inclusions and porosity,100% visual inspection shall
be carried out for all welds. In addition to visual inspection, welds shall be tested
by (not less than 20% of Welding joints).Dye Penetration Inspection(DPI) Test as
per ASTM E1417/E1417M-11e1or/Magnetic Particle Inspection(MPI)Test as per
ASTM E-709-08/ASTM E-1444 methods as and where so directed. The Contractor
shall submit schedule details and results of tests to the Engineer.

The steel lining sections shall preferably be ready welded together to complete
length at the manufacturer’s plant with ends cut straight. If the casing is to be
transported in parts to the site proper marking of the ends at the joint to be welded
at site is to be provided for to ensure accurate fitting. Any butt welds to be
executed at the working yard shall have the same standard for quality and
acceptance as that for the welds executed at manufacturer’s plant.
Refer General Notes of “ Structures” for the application of paint and coating
system on steel pile casing.

Construction of Bridge at Korangi Causeway 1520-3 Piling Works

 All the liners shall be stored and stocked carefully in such a manner as not to inflict
any damage. The liners shall not be stocked more that 3 tiers high.

The liner shall be transported to be set-up and pitched with accuracy. The position
of driving the liner shall be determined by the Contractor with the help of high
precision surveying instruments by using permanent and verified base
points/bench marks.

The Contractor shall make him thoroughly familiar with the site conditions and job
requirements and propose the most suitable liner driving method for approval. The
approval however, will not relieve the Contractor from his total responsibility for the
job. If the liner is damaged during driving in a manner which prevent the proper
formation of pile, such casing shall be withdrawn from bore before concrete is
placed and shall be replaced without any financial implication to the Employer and
with the approval of the Engineer.

During the driving of liner the alignment shall be monitored and controlled by
appropriate measures throughout the process. The liner shall be driven accurately
both laterally and longitudinally and true to the vertical as indicated on the
drawings.

The drilling in the hole shall not be permitted in advance of liner tip. It may also be
noted that back hammering of liner will not be allowed.

7.3 Stabilizing the Holes

The Contractor shall ensure at all times that the hole does not collapse during and
after boring. The permanent steel liner can be omitted where it can be shown to
the satisfaction of the Engineer that lowering of reinforcement cage and concreting
operation will not entrain soil from the sides of the hole by caving. The Contractor
may use bentonite or cement slurry or any other drilling method with written
approval from the Engineer.

Bentonite slurry (if used) should be hydrated for at least 24 hours prior to its use in
pile construction. Bentonite slurry should be used under controlled condition, i.e. its
properties shall -conform to the limits specified in FHWA manual (FHWA-NHI 18-
024). Slurry sampling and testing should be carried out as per recommendations of
FHWA manual or as directed by the engineer to ensure that slurry properties
remain with the specified limits.

7.4. Clean-Out at the Bottom of Piles

After the bore has reached its final penetration as stipulated on the drawings and
as may be additionally ordered by the Engineer on the basis of data obtained in
the field, it shall be thoroughly cleaned of all loose material and made ready to
receive the reinforcement cage and concrete, to the satisfaction of the Engineer.

Adequate tools for cleaning the base of the pile holes, including cleanout buckets
and hydraulic pumps shall be available at the site.

7.5 Collection and Preservation of Samples from Boreholes

The Contractor shall keep a complete bore hole log with visual classification of
each borehole supported by an adequate number of samples preserved, sealed
and labelled in plastic jars. In this context, an adequate number of samples shall
mean not less than one sample for every 3 metres of boreholes and in addition not
less than one sample at every significant change in soil strata.

Construction of Bridge at Korangi Causeway 1520-4 Piling Works

 No payment shall be made for obtaining and preserving the soil/rock samples from
boreholes.

8. TOLERANCES

Tolerance in plan position, verticality and lateral deviation and deviation in the level of the
pile shall be as follows:

- Plan position at pile top ± 75 mm

- Pile head level ± 25 mm
- Verticality 1:150

9. DISPOSAL OF DRILLING MATERIAL

The sub-surface material obtained from drilling shall be disposed off within free haulage
limit of 10 Kilometers from the Project boundary.

10. REINFORCEMENT IN PILES

Steel reinforcement shall be provided in piles in accordance with drawings. Circular

concrete spacers shall be provided at appropriate spacing to ensure cover for concrete.

The Contractor must ensure that the spacers are of same strength as that of concrete used
in the piles and they move freely around the reinforcing bars.

11. CONCRETE IN PILES

Concrete of specified class as mentioned on the drawing shall be provided and filled in
bore holes by tremie in one go. The concrete for piles shall be in accordance with the
relevant technical specifications given in Section 2300 and as shown on the drawing of
General Notes (Structures). The slump of concrete shall be 175 to 225 mm, Admixture
shall be used in manufacturing concrete to obtain required slump, improve workability and
avoid segregation.

A bottom-capped or pig-plugged tremie should be used to minimize contamination of

concrete during initial charging process. The tremie pipe shall have a minimum inside
diameter of 250 mm. It is recommended that throughout the concrete placement, the
bottom end of the tremie shall remain embedded a minimum of 3 m into the fresh concrete
to maintain a seal throughout concrete placement to prevent reentry of slurry suspension
into the pipe.

Proper overflow of concrete at the top shall be ensured by complete removal of

subsurface material mixed with concrete.

Concrete should be placed as promptly as possible, preferably within four hours after
completion of the borehole to avoid excessive filter cake thickness (if bentonite is used).
Failing to meet this requirement, contractor shall take necessary measures as per
recommendations of FHWA manual (FHWA-NHI 18-024) or as directed by the engineer.

As a pile is completed, the projected length shall be immediately and carefully protected
from any condition that will damage or adversely affect the hardening of concrete.

The Contractor shall not perform casing installation or drilling operations within a clear
distance of three diameters of a newly poured pile within twenty (24) hours of the
placement of concrete.

During the course of construction, the Contractor will always ensure that no part of the
structure is loaded beyond its design capacity.

Construction of Bridge at Korangi Causeway 1520-5 Piling Works

12. RECORD AND REPORTS

12.1 Records

The Contractor shall keep accurate records of all the works accomplished under
this section of the specifications. All such records shall be preserved in good
condition and order by the Contractor until they are delivered and accepted by the
Engineer. The Engineer shall have the right to examine such records at any time
prior to their delivery to him.

The following information shall be included in the records for each pile :

- Pile number and elevation of top and bottom of piles.

- Elevation of existing ground level and sea bed level at each pile location.

- Type of drilling operations.

- Date and time by depths when drilling operations were performed and piles
constructed. Time consumed in concreting each pile.

- Type of soil/rock encountered in the hole including borelog.

- Total depth of each bore hole.

- Bentonite slurry details, including test results should be mentioned in the pile
construction report.

- Theoretical volume of concrete required and the volume of concrete actually

consumed in each pile.

- Quantity of constituents for each batch of mix, water cement ratio and the
results of all quality control tests.

- Details of reinforcement.

- Remarks concerning any unusual occurrence during drilling and concreting.

The presence of Engineer's Representative or the keeping of separate records by

his representative shall not relieve the Contractor of the responsibility for the work
specified in this clause.

12.2 Reports

Reports of construction of each pile shall be communicated to the Engineer as

follows:

- Reports as the work proceeds.

- The records as specified above in duplicate not later than 24 hours after the
completion of each borehole and concreting of piles.

- 6 copies of the final report of the works within one month of the completion of
the last pile.
The final report shall include:

- Layout showing the "As-built" arrangement of piles.

Construction of Bridge at Korangi Causeway 1520-6 Piling Works

 - Observations and results of laboratory tests regarding quality control of
concrete.

- Contractor's evaluation of test results.

13. CUTTING OF PILE HEADS

The pile heads shall be cut to the bottom of pile caps or as shown on the drawings. The cut
shall be smooth and horizontal. Due care shall be taken for protecting the edges and
reinforcement.

14. DUMMY CLASS "E" CONCRETE

If due to unavoidable circumstances there is a delay in construction of pile caps/deck slab

then the exposed steel reinforcing bars of piles shall be covered with Class "E" concrete
using appropriate formwork, as approved by the Engineer.

15. PILE INTEGRITY TESTING OF WORKING AND TEST PILES

Piles' head shall be prepared as per latest ASTM D-5882 for performance of sonic integrity
testing. Piles' heads should be clean of loose concrete, soil, standing water or any other
foreign materials. Small areas of about 6 inch diameter (three axi-symmetric points
equidistant from the center of pile and one at center) should be prepared by a hand grinder
to provide a smooth horizontal surface for sensor attachment and hammer impact.

The Contractor shall submit method statement for the performance of sonic integrity testing
for approval of the Engineer. Sonic integrity testing shall be carried out as per latest ASTM
D-5882.

16. STATIC AND HIGH STRAIN DYNAMIC LOAD TESTING OF SELECTED WORKING
AND TEST PILES

16.1 General

a) The Contractor shall submit his method and plans for performing load test
on piles.

b) Pile load test shall be conducted up to the maximum specified load.

c) The Contractor shall be responsible for bringing all equipment labour and
other supplies to the site for a complete job and for satisfactory execution
of the test according to latest ASTM D 1143 for static pile load test and
latest ASTM D 4945 for high strain dynamic test, and as directed by the
Engineer.

d) The Contractor shall submit to the Engineer up to date calibration

certificates of all the equipment as specified in ASTM D 1143/ASTM D
4945 from a laboratory approved by the Engineer.

e) The Contractor shall submit details of his method of pile load test prior to
start of test for approval of the Engineer, which will include drawing and
back-up calculations to ensure stability and adequacy of the arrangement.

f) Care shall be taken to ensure the center of gravity of the loading

arrangement is on the axis of the pile.

Construction of Bridge at Korangi Causeway 1520-7 Piling Works

 g) The record of pile load test shall be kept on an approved format. For each
such load test, two copies of the relevant field data shall be supplied to the
Engineer within 48 hours of the completion of that test.

The Contractor shall keep accurate record and report of load testing of
piles in accordance with subsection Record & Reports.

The presence of Engineer or the keeping of separate records by his

representative for the work specified in this clause.

16.2 Report

Report of pile load test shall be communicated to the Engineer as follows:

- Oral report as the work proceeds.

- Three copies of the final report within one week of completion of the pile load
tests.

- The final report shall include all the information as mentioned in the ASTM D
1143/ASTM D 4945.

17. MEASUREMENT AND PAYMENT

17.1 General

Except otherwise specified herein or elsewhere in the Contract documents, no

measurement and payment shall be made for the under mentioned specified works
related to the relevant items of the Bill of Quantities. The cost thereof shall be
deemed to have been included in the quoted unit rate of respective items of the Bill
of Quantities.

17.1.1 Mobilization and demobilisation of all plant, equipment, materials at site

including shifting of necessary plant, equipment, supplies materials etc.
from one pile location to another.

17.1.2 Clean out at bottom of piles.

17.1.3 Bentonite or cement slurry used during boring operation.

17.1.4 Excavation of test pits prior to commencement of boring to avoid hitting

underground services.

17.1.5 Disposal of subsurface material obtained from boring/drilling , within free

haulage limit of 10 km from the Project boundary.

17.1.6 Carrying out survey and levelling work for determining locations, alignment
and ground elevations for each pile.

17.1.7 Wastage of concrete in construction including the concrete consumed

outside the theoretical lines shown on the drawings and required for
proper overflow of concrete at the top to ensure complete removal of
subsurface material mixed with concrete.

17.1.8 Admixtures i.e. air entraining admixture, plasticizer, retarders and Integral
water proofing admixture (Betocrete C16 or approved equivalent) in
concrete.

Construction of Bridge at Korangi Causeway 1520-8 Piling Works

 17.1.9 Providing and installing, supports, hooks, spacers, binding wire and laps
not shown on drawings including wastage and rolling margin.

17.1.10 Cutting of pile heads to the specified level.

17.1.11 Dismantling/ cutting of dummy concrete class “E”

17.1.12 Cut-off & Splicing because of Contractors fault and/or defective work.

17.1.13 Protection, curing and repair of defects.

16.1.14 Providing, fixing, striking etc. of formwork, where required.

17.1.15 Maintenance and submission of record and reports of work as specified in

this section.

17.1.16 Protective coating for steel liner.

17.1.17 Preparation of Piles' head for the performance of low strain integrity test,
static load test and high strain dynamic test as per requirement of the
relevant ASTM standards.
17.1.18 all type of admixtures.

17.2 Static Pile Load test on Test Pile / on Selected Working Pile

17.2.1 Measurement

Measurement of acceptably conducted of Static Pile Load test on test pile

& on Selected Working Pile will be made in Each.

17.2.2 Payment

Payment shall be made for the acceptable measured quantity of pile for
Static Pile Load test on test pile & on Selected Working Pile on the basis
of unit rate per each quoted in the Bill of Quantities and shall constitute full
compensation for all the works related to the item.

17.3 Pile Integrity Test / Static Pile Load test

17.6.1 Measurement

Measurement of acceptably conducted of pile integrity test will be made in

each.

17.6.2 Payment

Payment shall be made for the acceptable measured quantity of pile

integrity test on the basis of unit rate per each quoted in the Bill of
Quantities and shall constitute full compensation for all the works related
to the item.

*** End of Section 1520 ***

Construction of Bridge at Korangi Causeway 1520-9 Piling Works

 SECTION - 2100

FORMWORK

1.0 SCOPE

The work under this section of the Specifications consists of furnishing all plant, labour,
equipment, appliances and materials and in performing all operations in connection with
the supply and installation of formwork for the purpose of containing concrete during
placement and consolidation in the required shape and form.

2.0 GENERAL

It shall be the responsibility of the Contractor to perform the work by engaging well
trained and experienced staff.

APPLICABLE CODES AND STANDARDS

The latest edition of following ACI, ASTM, Pakistan & British Standard are relevant to
these specifications wherever applicable:

2.1 ACI (American Concrete Institute)

ACI 301 Specifications for Structural Concrete .

- ACI 318 Building Code Requirements for Structural Concrete

- ACI 347 Guide to Formwork to Concrete(ANSI A145.1)

2.2 APA (Engineered Wood Association)

- EWA High Density Overlay Concrete Form, Class 1

- EWA Structural 1, Exterior Quality, Class 1

- EWA Plastic Overlay Plywood Forms

2.3 ANSI (American National Standard Institute)

- NBS PSI Voluntary Product Standard, Structural Plywood (ANSI-A199.1)

Latest editions of the codes/standards shall be used in all cases.

3.0 MATERIALS

The Contractor shall use the following materials for different purposes as stated below:

3.1 Timber: Form framing, sheathing and shoring.

3.2 Plywood: Form sheathing and panels.

3.3 Steel

- Heavy forms and false work

- Column and joint forms
- Permanent forms
- Welding of permanent forms

Construction of Bridge at Korangi Causeway 2100-1 Formwork

3.4 Form Ties, Anchors and Hangers: For securing formwork against placing loads and `
pressures.

3.5 Coatings: Facilitate form removal.

3.6 Steel Joints: For formwork support.

3.7 Steel frame shoring: For formwork support.

4.0 DELIVERY AND STORAGE

4.1 Delivery

The delivery of formwork components shall be made in a manner so as not to cause

damage.

4.2 Storage

Form work should be stored, after cleaning and preparing for re-use, if used before in
such a manner that access to all different component is available.

Form work component which can be affected by weathering shall be stored in

appropriate building or under covers and shade.

5.0 WORKMANSHIP

5.1 Forms shall have sufficient strength to withstand the pressure resulting from placement
and vibration of the concrete and shall have sufficient rigidity to maintain specified
tolerances.

Where required details and locations of special forms to be used are set out on the
drawings. The Engineer may reject any formwork in any part of the work which has been
constructed with a non- approved formwork. Approval of form work by the Engineer shall
be one of these conditions to be fulfilled before concreting. The Engineer may reject any
concreting where it does not conform to the approved model.

5.2 Earth cuts shall not be used as forms for vertical surfaces of reinforced concrete work
unless required as such or permitted by the Engineer.

5.3 Formwork shall be of timber, steel, plywood, proprietary building boards and such special
materials, as may be approved by the Engineer, which give the required finish and shape
to the surface of concrete. Wooden formwork shall be free from loose knots and shall be
well seasoned.

5.4 The formwork shall conform to the shape, lines and dimensions as shown on the plans,
and be so constructed as to remain sufficiently rigid during the placing and compacting of
the concrete, and shall be sufficiently tight to prevent loss of liquid from the concrete.

The design and engineering of the formwork, as well as its construction, shall be the
responsibility of the Contractor. Where necessary, to maintain the specified tolerances,
the formwork shall be cambered to compensate for anticipated deflections in the
formwork due to the weight and pressure of the fresh concrete and due to construction
loads.

The Contractor shall establish and maintain, in an undisturbed condition and until final
completion and acceptance of the project, sufficient control points and bench marks to
be used as references for checking upon tolerances.

5.5 Requirements for `facing materials' are given in Clause 7, Section 2300 relevant to
`Finishing of Formed Surfaces.'

Construction of Bridge at Korangi Causeway 2100-2 Formwork

5.6 Where natural plywood-form-finish, grout-cleaned-finish, smooth-rubbed-finish,
scrubbed-finish, or sand-floated-finish is required, forms shall be smooth (faced with
plywood, liner sheets, or prefabricated panels) and true to line, in order that the surfaces
produced will require little dressing to arrive at true surfaces. Where any as-cast finish is
required, no dressing shall be permitted in the finishing operation.

5.7 Where as-cast surfaces, including natural plywood- form-finish are specified, the panels
of material against which concrete is cast shall be orderly in arrangement, with joints
between panels planned in approved relation to openings, building corners, and other
architectural features.

5.8 Where panels for as-cast surfaces are separated by recessed or otherwise emphasized
joints, the structural design of the forms shall provide for locating form ties, where
possible, within the joints so that patches of tie holes will not fall within the panel areas.

5.9 Forms shall not be re-used if there is any evidence of surface wear and tear or defect
which would impair the quality of the surface finish. Forms shall be thoroughly cleaned
and properly coated before re-use.

5.10 Forms shall be sufficiently tight to prevent loss of mortar from the concrete. Unless
otherwise specified in the Contract documents chamfer strips shall be placed in the
corners of forms to produce beveled edges on permanently exposed surfaces. Interior
corners on such surfaces and the edges of formed joints will not require beveling unless
required by the Contract documents.

5.11 Positive means such as wedges or jacks for accurate adjustment and for proper removal
of shores and struts shall be provided and all settlement shall be monitored during
concrete placing operation. Forms shall be securely braced against lateral deflections.

5.12 Where concreting of thin members is required to be carried out within formwork of
considerable depth, temporary openings in the sides of the formwork shall be provided
where necessary to facilitate the placing and consolidation of concrete. Small temporary
openings shall also be provided at the bottom of the formwork for columns, walls and
deep beams to permit the cleaning out of debris and observation immediately before
concrete is deposited.

5.13 Form ties shall be constructed so that the ends or end fasteners can be removed without
causing appreciable spalling at the faces of the concrete. After the ends or end
fasteners of form ties have been removed, the embedded portion of the ties shall
terminate not less than twice the diameter or twice the minimum dimension of the tie
from the formed faces of concrete to be permanently exposed to view and in no case
shall this distance be less than 20mm. When the formed face of the concrete is not to be
permanently exposed to view form ties may be cut off flush with the formed surfaces.

Through bolts may be permitted provided that they are greased to allow for easy
withdrawal and the holes subsequently made good. Through bolts are not to be used on
water-retaining structures.

5.14 At construction joints contact surface of the form sheathing for flush surfaces exposed to
view shall overlap the hardened concrete in the previous placement by no less than
25mm. The forms shall be held against the hardened concrete to prevent offsets or loss
of mortar at the construction joint so as to maintain a true surface.

5.15 Wood forms for wall opening shall be constructed to facilitate loosening, if necessary, to
counteract swelling of the forms.

5.16 Wedges used for final adjustment of the forms prior to concrete placement shall be
fastened in position after the final check.

Construction of Bridge at Korangi Causeway 2100-3 Formwork

5.17 Formwork shall be so anchored to shores or to other supporting surfaces or members
that upward or lateral movement of any part of the formwork system during concrete
placement will not occur.

5.18 Runways or planks for moving labour and equipment shall be provided with struts or legs
and shall be supported directly on the formwork or upon the structural member without
resting on the reinforcing steel.

5.19 All surfaces of forms and embedded materials shall be cleaned of any accumulated
mortar or grout from previous concreting and of all other foreign material before placing
fresh concrete.

5.20 Forms shall be sufficiently tight to prevent leakage of grout or cement paste. Board
forms having joints opened by shrinkage of the wood shall be removed and replaced.
Plywood and other wood surfaces not subject to shrinkage shall be sealed against
absorption of moisture from the concrete by either (1) a field applied, approved form oil
or sealer, or (2) a factory applied non-absorptive liner. When forms are coated to prevent
bond with concrete, it shall be done prior to placing of the reinforcing steel. Excess
coating material shall not be allowed to stand in puddles in the forms nor allowed to
come in contact with the concrete against which fresh concrete will be placed. Care
shall be taken that such approved composition is kept out of contact with the
reinforcement. Where as-cast finishes are required, materials, which will impart a stain to
the concrete, shall not be applied to the form surfaces. Where the finished surface is
required to be painted, the material applied to form surfaces shall be compatible with the
type of paint to be used.

5.21 For reinforced concrete, under no circumstances shall forms be struck until the concrete
attains strength of at least twice the stress to which the concrete may be exposed at the
time of striking.

The strength referred to shall be that of concrete using the same cement and
aggregates, with the same proportions, and cured under conditions of temperature and
moisture similar to those obtaining in the work. Where possible, the formwork should be
left for longer time as it would assist the curing.
O
In normal circumstances (generally where temperature are above 20 C and where
ordinary cement is used) forms may be struck after expiry of the following periods:

- Walls, Columns & Vertical Sides 48 Hours or as may be decided

of Beams & slab by the Engineer

- Beams Soffits 10 Days (shores or props left

under)
- Removal of shores or props to 14 Days (Spanning up to 4
Slabs meters)

16 Days (Spanning up to 5
meters)

18 Days (Spanning up to 6
meters)

For rapid hardening cement 3/7 of the above period will be sufficient in all cases except
vertical sides of slabs, beams and columns which should be retained for a minimum of
24 hours.

The number of shores or props, their sizes and disposition shall be such as to be able to
safely carry the full dead load of the slab and beams, as the case may be.

Construction of Bridge at Korangi Causeway 2100-4 Formwork

 Proper allowance shall be made for the decrease in rate of hardening of concrete in cold
weather and the above minimum duration must be increased when the mean daily
O
temperature is below 20 C.

5.22 When repair of surface defects or finishing is required at an early age, forms shall be
removed as soon as the concrete has hardened sufficiently to resist damage from
removal operations.

5.23 Top forms on sloping surfaces of concrete shall be removed as soon as the concrete has
attained sufficient stiffness to prevent sagging. Any needed repairs or treatment required
on such slopping surfaces shall be performed at once and be followed by the specified
curing.

5.24 Wood forms for wall openings shall be loosened as soon as this can be accomplished
without damage to the concrete.

5.25 All formwork shall be removed without such shock or vibration as would damage the
reinforced concrete. Before the top plank and struts are removed, the concrete surface
shall be exposed where necessary in order to ascertain that the concrete has sufficiently
hardened. Proper precautions shall be taken to allow for the decrease in the rate of
hardening that occurs with all cement in the cold weather.

5.26 When reshoring or repropping is permitted or required, the operations shall be planned in
advance and shall be subject to approval. While reshoring is underway no live loads
shall be permitted on the new construction.

In no case during reshoring shall concrete in beams, slab, columns or any other
structural member be subjected to combined dead and construction loads in excess of
the load permitted by the Engineer for the developed concrete strength at the time of
reshoring.

Reshores shall be placed as soon as practicable after stripping operations are complete
but in no case later than the end of working day on which stripping occurs.

Reshores shall be tightened to carry their required loads without overstressing the
construction. Reshores shall remain in place at least until tests representative of the
concrete being supported have reached the specified strength.

5.27 Floors supporting props or shores under newly placed concrete shall have their original
supporting props or shores left in place or shall be reshored. The reshoring system shall
have a capacity sufficient to resist the anticipated loads and in all cases shall have a
capacity equal to at least one half the capacity of the shoring system above. The
reshores shall be located directly under a shore position above unless other locations
are permitted.

The reshoring or re-propping shall extend over a sufficient number of storeys to distribute
the weight of newly placed concrete, forms and live loads in such a manner that the
design superimposed loads of the floors supporting shores or props are not exceeded.

5.28 It is generally desirable to give forms for reinforced concrete an upward camber to
ensure that the beams or slabs (specially cantilever slabs) do not have a sag when they
have taken up their deflection, but this should not be done unless permitted by the
Engineer.

5.29 No loads, other than man and light plant required in connection with the actual work in
hand, shall be allowed on suspended floors until 28 days after concreting where ordinary
Portland Cement is used and 14 days when rapid hardening Portland Cement is used.

Construction of Bridge at Korangi Causeway 2100-5 Formwork

5.30 Prior to placing concrete, all forms shall be inspected and all debris and extraneous
matter removed. The form oil or release agent shall not react with concrete to affect the
strength nor shall it give any colour. It shall be applied in such a manner as not to
contaminate the reinforcement and other fixtures to be embedded in concrete.

6.0 MEASUREMENT AND PAYMENT

Except otherwise specified in the Bill of Quantities no payment will be made for the
works involved within the scope of this section of the specifications.

The cost thereof shall be deemed to have been included in the quoted unit rate of
relevant concrete items of the Bills of Quantities.

*** End of Section 2100 ***

Construction of Bridge at Korangi Causeway 2100-6 Formwork

 SECTION - 2300

PLAIN AND REINFORCED CONCRETE

1.0 SCOPE

The work under this section of the specification consists of furnishing all plant, labour,
equipment, appliances and materials and in performing all operations in connection with
the supply, manufacture, transporting, placing, consolidating, finishing and curing of plain
and reinforced concrete for pavements and other structures as shown in the drawings,
as specified herein and as required by the site conditions or as directed by the Engineer,
for a complete job. Reinforcement does not form part of this section.

2.0 GENERAL

APPLICABLE CODES AND STANDARDS

The latest edition of following ACI, ASTM, Pakistan & British Standard are relevant to
these specifications wherever applicable:

2.1 ACI (American Concrete Institute)

- 117 Standard Specification for Tolerances for Concrete Construction and Materials.

- 201.2 Guide to Durable Concrete

- 211.1 Standard Practice for Selecting Proportions for Normal, Heavy Weight and Mass
Concrete.

- 214 Evaluation of Strength Test Results of Concrete.

- 301 Specifications for Structural Concrete .

- 303.1 Standard Specification for Cast -In-Place, Architectural Concrete

- 304R Guide for Measuring, Mixing, Transporting, and Placing Concrete

- 305 Hot Weather Concreting

- 308 Standard Specification for Curing Concrete

- 308R Guide to Curing Concrete

- 309 Guide for Consolidation of Concrete

- 315 Details and Detailing of Concrete Reinforcement .

- 351.1R Grouting between Foundation and Bases for Support of Equipment &
Machinery.

- 318 Building Code Requirements for Structural Concrete

- 347 Guide to Formwork for Concrete.

- 350R Code Requirment for Environmental Engineering Concrete Structures and

Commentary.

- 544.1R State-of-the-Art Report on Fiber Reinforced Concrete

Construction of Bridge at Korangi Causeway 2300-1 Plain & Reinforced Concrete

 - 544.2R Measurement of Properties of Fiber Reinforced Concrete

- SP-2 ACI Manual of Concrete Inspection (ACI 311.1R)

- SP-142 Fiber Reinforced Concrete Developments and Innovation

- SP-155 Testing of Fiber Reinforced Concrete
- SP-182 Structural Applications of Fiber Reinforced Concrete

2.2 ASTM (American Society for Testing and Materials)

- C 31 Standard Practice for Making and Curing Concrete Test Specimens in the Field

- C 33 Standard Practice for Concrete Aggregates

- C 39 Standard Practice for Compressive Strength of Cylindrical Concrete Specimens

- C 40 Standard Practice for Organic impurities in Fine Aggregate for concrete.

- C 42 Standard Practice for Obtaining and Testing Drilled Cores and Sawed Beams of
Concrete

- C 78 Standard Practice for Flexural Strength of Concrete (Using Simple Beam

with Third Point Loading)

- C 87 Standard Practice for Effect of Organic Impurities in Fine Aggregates on

Strength of Mortar.

- C 88 Standard Practice for Soundness of Aggregates by use of sodium sulphate and

magnesium sulphate

- C 94 Standard Practice for Ready-Mixed Concrete

- C 109 Standard Practice for Compressive Strength of Hydraulic Cement Mortars

(using 2 in or (50mm) cube specimen.

- C 117 Standard Practice for Materials Finer than No.200 Sieve in Mineral Aggregates
by Washing.

- C 123 Standard Practice for Light weight particles in aggregates

- C 125 Standard Terminology Relating to Concrete and Concrete Aggregates

- C 127 Standard Terminology Relating to Test Method for Specific Gravity and
Absorption of Coarse Aggregate

- C 128 Standard Terminology Relating to Test Method for Specific Gravity and
Absorption of Fine Aggregate

- C 131 Standard Terminology Relating to Resistance to Degradation of Small Size

Aggregate by Abrasion of Small Size Coarse Aggregate by Use of the Los Angeles
Machine

- C 136 Standard Terminology Relating to Sieve Analysis of Fine and Coarse

Aggregates

- C 138 Standard Terminology Relating to Unit Weight, Yield, and Air Content
(Gravimetric) of Concrete

Construction of Bridge at Korangi Causeway 2300-2 Plain & Reinforced Concrete

 - C 142 Standard Terminology Relating to Clay Lumps and Friable Particles in
Aggregates

- C 143 Standard Terminology Relating to Slump of Hydraulic Cement Concrete

- C 144 Standard Specification for Aggregate for Masonry Mortar

- C 150 Standard Specification for Portland Cement

- C 156 Standard Specification for Test Method for Water Loss (From a Mortar
Speciment) through Liquid Membrance – Forming Curing compound for concrete.

- C 157 Standard Specification for Length Change of Hardened Hydraulic Cement

Mortar and Concrete

- C 171 Standard Specification for Sheet Materials for Curing Concrete

- C 172 Standard Specification for Sampling Fresh Mixed Concrete

- C 173 Standard Test Method for Air Content of Freshly Mixed Concrete by the
Volumetric Method

- C 185 Standard Test Method for Air Content of Hydraulic Cement Mortar

- C 186 Standard Test Method for Heat of Hydration of Hydraulic Cement

- C 188 Standard Test Method for Density of Hydraulic Cement

- C 191 Standard Test Method for Time of Setting of Hydraulic Cement by Vicat Needle

- C 217 Standard Test Method for Weather resistance of Natural Slate

- C 227 Standard Test Method for Potential Alkali Reactivity of Cement - Aggregate
Combination.

- C 231 Standard Test Method for Air Content of Freshly Mixed Concrete by the
Pressure Method

- C 260 Standard Test Method for Air-Entraining Admixtures for Concrete

- C 289 Standard Test Method for Potential alkali-silica reactivity of Aggregates

- C 293 Standard test method for Flexural Strength of Concrete (using simple beam with
center Point Loading)

- C 309 Standard Specification for Liquid Membrane-Forming Compounds for Curing

Concrete

- C 321 Standard Test method for Bond Strength of Chemical Resistant Mortars.

- C 330 Standard Specification for Light Aggregates for Structural Concrete

- C 332 Standard Specification for Light weight Aggregates for Insulating Concrete.

- C 348Standard Test method for Flexural strength of Hydraulic Cement Mortars

- C 494 Standard Specification for Chemical Admixtures for Concrete

Construction of Bridge at Korangi Causeway 2300-3 Plain & Reinforced Concrete

 - C 535 Standard Specification to Degradationof Large Size Coarse Aggregates by
Abrasion and Impact in Los Angeles Machine.

- C 595 Standard Specification for Blended Hydraulic Cements

- C 596 Standard Test method for Drying, shrinkage of Mortar Containing

Hydraulic Cement

- C 685 Standard Specification for Concrete Made by Volumetric Batching and

Continuous Mixing

- C 881 Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

- C 989 Standard Specification for Ground Granulated Blast – Furnace Slag for use in
Concrete and Mortars.

- C1602 Standard Mixing Water Used in the Production of Hydraulic Cement Concrete

- C 1399 Test Method for Obtaining Average Residual-Strength of Fiber-Reinforced

Concrete

- D 75 Standard Practice for Sampling Aggregates

- D 512 Standard Practice for Chloride Ion in Water and Waste Water

- D 516 Standard Practice for Sulphate Ion in Water and Waste Water

- D 596 Standard Practice for Reporting Results of Analysis of Water

-D 6690 Standard Specifications for Joint and Crack Sealant, Hot applied for Concrete
and Asphalt Pavements.

- D 1411 Standard Test Method for Water-Soluble Chlorides Present as Admixes in

Graded Aggregate Road Mixes

- D 1751 Standard Specifications for Preformed Expansion Joint Fillers for Concrete
Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

- D 1752 Standard Specifications for Preformed sponge Rubber and Cork Expansion
Joint Fillers for Concrete Paving and Structural Concrete

-- E 11 Standard Specifications for Woven Wire-Cloth Sieves for Test sieve

- E 96 Standard Test Method for Water Vapour Transmission of Materials

- E 154 Standard Test Method for Water Vapors Retarders used in Contract with Earth
under concrete Slab on walls or As Ground Covers.

- E 337 Standard Test Method for measuring Humidity with Phychrometer (Measurement
of wet and Dry Bulb Temperature)

- CALIF 217 Method of Test for Sand Equivalent

- CALIF 227 Method of Test for Evaluating Cleanness of Coarse Aggregate

2.3 CRD US Army Corps of Engineers

- COE CRD C 119 Method of Test for Flat and Elongated Particles in Coarse Aggregate

-COE CRD C400 Requirements for Water for Use in Mixing and Curing Concrete

Construction of Bridge at Korangi Causeway 2300-4 Plain & Reinforced Concrete

 - COE CRD C 513 Handbook for Concrete and Cement Corps of Engineers
Specifications for Rubber Waterstops

- COE CRD C 572 Handbook for Concrete and Cement Corps of Engineers
Specifications for Polyvinyl Chloride Waterstops

2.4 B.S (British Standard)

- BS EN 197-1 Cement composition, Specification and Conformity criteria for Common

Cement.

-BS EN 932-6 Tst for General Properties of Aggregates Definition of Repeatability and
Reproducibility

-BS ISO 3310-2 Test sieved Technical Requirement and Testing. Test Sieves of
Perforated Metal Plate.

-BS EN 1008 Mixing water for Concrete. Specifications for sampling , Testing, and
Assessing the suitability of water, including water recovered from processes in
Concrete industry as mixing water for concrete

-BS EN 1992-1 Design of Concrete Structures . General Rules and Rules for Buildings.

In addition, the latest editions of other Pakistan Standard, ACI, ASTM & British Standard
and other Standards as may be specified by the Engineer for Special Materials and
construction are also relevant.

3.0 SUBMITTALS

All submittals shall be in accordance with the schedule of submittals prepared by the
Contractor and approved by the Engineer.

3.1 Proposed Mix Designs

Submit proposed designs for trial design batches for each grade of concrete along with
samples of proposed material.

Submit proposed final mix designs for each grade of concrete at least 7 calendar days
before the date planned for the start of concrete placement, along with samples of
proposed materials which differ from those submitted previously, and reports of
successful 3, 7 and 28 calendar day strength tests, for Engineer's approval.

3.2 Construction Procedure

Submit to the Engineer procedures for the following:

a) Both hot and cold weather concreting procedures shall be submitted to the
Engineer by Contractor regardless of the need for the immediate implementation
of such not less than two weeks before beginning the work. Procedures shall
include requirements for insulation, enclosures and the like. Finishing
procedures and timing and duration of curing shall be described.

b) Contractor's construction procedures shall be computer word processed

procedure and shall include charts and diagrams as applicable and necessary,
to fully explain the subject procedures, methods and equipment operation in
order to allow effective review by the Engineer, assist the Testing Agency's
evaluation of the work, and to allow Contractor's personnel to perform work in full
conformance to the Tender & Contract Document.

Construction of Bridge at Korangi Causeway 2300-5 Plain & Reinforced Concrete

 c) Protection of concrete against injury due to mechanical contact and construction
operation.

d) Protection of work by other trades.

3.3 Placement Schedule

Submit a placement schedule for approval prior to start of concrete placement

operations. Daily concrete pour schedules shall be submitted 24 hours in advance of
planned pours.

3.4 Formwork

Submit for approval copies of manufacturer's data and installation instructions for
proprietary materials including form coatings, manufactured form systems, ties and
accessories.

3.5 Certificates of Compliance

Submit certificates of compliance covering cement types, reinforcement, grout materials,

additives, epoxy-resin materials etc. The certificates of compliance shall include the
material or product manufacturer's statements that supplied items conform to
Specifications.

3.6 Testing Programme

Submit test programme for all specified requirements along with the testing schedule for
approval of the Engineer.

3.7 Test Reports

Submit test reports showing the result of required tests and compliance with specified
standards and codes, for approval. Test reports shall be certified by the Contractor and
the Testing Agency.

3.8 Samples

Submit to the Engineer for acceptance prior to purchase, fabrication or delivery, samples
of materials for his approval.

Substitute products or materials proposed by the Contractor shall be submitted as

samples for approval. The samples shall be accompanied by detailed information about
materials.

3.9 Shop Drawings

Shop drawings shall be submitted to the Engineer for approval in accordance with the
requirements of the Contract Documents and as specified herein under:

a) Shop drawings furnished for this section shall conform to the best standards of
the construction industry. Shop drawings shall be prepared under the
supervision of competent engineering personnel. Prior to submittal, the
Contractor shall check each shop drawing for compliance with the requirements
of the Contract Documents. As evidence of conformance with this requirement,
each shop drawing shall bear the seal and the self-written signature of
Contractor's registered Professional Engineer.

b) Shop drawings shall include plans, elevations, sections and complete details to
describe clearly, at an ample scale for all works to be provided. Drawings shall
be accurately dimensioned, where applicable, and shall be noted clearly.

Construction of Bridge at Korangi Causeway 2300-6 Plain & Reinforced Concrete

 c) Work of Other Trades: Show in the shop drawings, and dimension thereon,
holes required for passage of work of other sections through Cast-In-Place
Concrete Work. Prepare and submit to the Engineer field work drawings for
holes not shown in shop drawings.

d) Submit shop drawings for curved and radial concrete formwork and identify the
formwork materials proposed for use.

e) Construction Joint, Expansion Joint and contraction Joint Drawings: Show all
joints given in the drawings, specified herein, and required by Contractor to
provide for the sequence of pourings. Submit in sufficient time to allow the
orderly detailing of reinforcing steel. Reinforcement shop drawings shall be
prepared in conformance with the accepted Construction Joint, Expansion Joint
and contraction Joint Drawings. Measures to control cracks e.g. shrinkage strips,
admixture as per relevant ACI codes shall be shown on the drawings.

f) Reinforcing Steel, including welded wire fabric (WWF), shall be detailed in strict
accordance with the methods and procedures provided in "ACI Detailing
Manual". Reinforcing steel drawings shall be submitted simultaneously with
related shop drawings.

Prepare shop drawings which provide for reinforcement, including dowels,

properly positioned in all concrete work, so that material can be properly cut,
bent and placed. Form not be removed for at least twelve (12) hours after the
concrete has been placed. Forms shall be carefully given in shop drawings.
Reinforcing steel drawings shall show, to scale, all concrete work including pits,
kerbs, trenches, pads, equipment bases, steps, slopes, curves, openings, holes,
blockouts and the like. Provide schedules and details showing placing
sequences, bending, lengths and locations of all reinforcement.

h) Detailing: All reinforcing steel shall be detailed in strict compliance with ACI 318
and ACI 315.

3.10 Coordination Drawings

Submit coordinated drawings of the following:

All sleeve locations, whether round or of other shape, penetrating exterior and interior
walls, pits, slabs, beams, other structural systems and pavements.

The position of all embedded items required to receive the work of other trade, including
details needed to assure correct placement of both the embedded items and the
reinforcing steel.

The Contractor shall coordinate and crosscheck for accuracy, completeness and correct
relationship to the work of other sections, each shop drawing prepared for the work of
this section, including each shop drawing prepared by nominated subcontractors.
Contractor's check shall include a verification of strict compliance with the Contract
Documents and shall be performed prior to submission of each shop drawing for review
by the Engineer. The Contractor shall certify the co-ordination, accuracy, and Contract
compliance of each shop drawing by a written statement placed in each drawing and
attested by the responsible person in charge of the work for Contractor. The personally
inscribed initials of the person(s) preparing each drawing as well as the detailing
agency's supervisor and chief checker shall be included in the title block or similar
prominent location.

Construction of Bridge at Korangi Causeway 2300-7 Plain & Reinforced Concrete

3.11 Mill Test

Furnish the Engineer with certified mill test report for cement and for steel reinforcement,
including bars, welded wire fabric, dowels, anchors and splices for approval.

3.12 Name of Manufacturers/Suppliers

Submit for acceptance by the Engineer:

- Aggregates
- Ready mix concrete
- Reinforcing bars
- Welded steel wire fabric
- Concrete accessories
- Cement
- Admixture
- Joint filler
- Joint sealants
- Water stops
- Membrane curing, sealing, hardening compound
- Bonding compound
- Form oil
- Anchors

4.0 MATERIALS

4.1 Cement

4.1.1 The cement shall be fresh and of approved origin and manufacturer. It shall be one
of the following as may be specified by the Engineer or type of cement as shown in
the drawings and / or BOQ.

- Modified Ordinary Portland Cement meeting the following compound content

limits shall be used
C 3 A SHALL NOT BE LESS THAN 5% NOR MORE THAN 8%
C 4 AF + 2C 3 A SHALL BE LESS THAN OR EQUAL TO 25%
Al 2 O 3 SHALL BE LESS THAN OR EQUAL TO 6%

- Sulphate Resistant Portland Cement (low alkali) complying with the

requirements of ASTM C-150 Type V.

- Ordinary Portland Cement Type II (low alkali) complying with the requirements of
ASTM C-150.

- Ordinary Portland Cement Type III High Early Strength Cement (Rapid
Handening Cement) complying with the requirements of ASTM C150.

- Portland Blast–Furnace Slag Cement shall conform to BS-EN 197-1 or to ASTM

C-595. Slag shall consist of finely ground granulated iron blast–furnace slag and
shall conform to ASTM C-989 Grade 80, 100, or 120.

- The proportioning of OPC and Portland Blast Furnace Slag material shall be in the
ratio of 60 OPC to 40 Slag or as approved by the Engineer.

4.1.2 Unless otherwise specified, ordinary Portland Cement complying with the
requirements of ASTM C150 Type 1 shall be used.

4.1.3 The Contractor shall supply to the Engineer at fortnightly intervals, reports of
tests for conformance with the relevant specified standard in respect of the

Construction of Bridge at Korangi Causeway 2300-8 Plain & Reinforced Concrete

 samples of cement from the work-site. These tests shall be carried out in a
laboratory approved by the Engineer.

4.1.4 Only one brand of each type of cement shall be used for concrete in any
individual member of the structure. Cement shall be used in the sequence of
receipt of shipment, unless otherwise directed.

4.1.5 There shall be sufficient cement at site to ensure that each section of work is
completed without interruption.

4.1.6 Cement reclaimed from cleaning of bags or from leaky containers shall not be
used.

4.1.7 The Contractor shall provide and erect (at his cost) in a suitable plain, dry, well
ventilated, weather-proof and water proof shed of sufficient capacity to store the
cement.

4.1.8 The cement shall be used as soon as possible after delivery and cement which
the Engineer consider has become stale or unsuitable through absorption of
moisture from the atmosphere or otherwise shall be rejected and removed
immediately from the site at the Contractor's expense. Any cement in containers
damaged so as to allow the contents to spill or permitting access of the
atmosphere prior to opening of the container at the time of concrete mixing shall
be rejected and removed immediately from the site at the Contractor's expense.

4.1.9 Mixing together of different types of cement shall not be permitted.

4.2 Aggregates

4.2.1 The sources of supply of all fine and coarse aggregates shall be subject to the
approval of the Engineer.

Aggregates shall conform to ASTM C33 (including applicable ASTM Documents

referenced therein) and as specified. Coarse aggregates shall be well graded
from fine to coarse within the prescribed limits of this specification. Fine
aggregate shall consist of natural sand, manufactured sand or combination of
the two and shall be composed of clean, hard, and durable spherical or cubical
particles. Coarse aggregate shall consist of crushed or uncrushed gravel,
crushed stone, or a combination thereof and shall be clean, hard, uncoated
particles of maximum nominal size as specified for each grade of concrete.

All fine and coarse aggregates shall be clean and free from clay, loam, silt and
other deleterious matter. If required, the Engineer reserves the right to have
them washed by the Contractor at no additional expense. Coarse and fine
aggregates shall be delivered and stored separately at site. Aggregates shall not
be stored on muddy ground or where they are likely to become dirty or
contaminated. The materials shall be stock piled for a period before use for at
least a day so as to drain nearly to constant moisture content. The grading of the
coarse and fine aggregates shall be tested at least once for every 100tonnes
supplied, to ensure that grading is uniform and same as that of the samples
used in preliminary tests.

The sulphate content of aggregates shall not exceed 0.40 percent by weight for
each individual source of coarse and fine aggregate. The chloride content of
aggregates shall not exceed 0.05 percent by weight for each source of coarse
and fine aggregate. The total sulphate content of concrete shall not exceed 4.0
percent by weight of the cement. The total chloride content of concrete shall not
exceed 0.40 percent by weight of the cement.

Construction of Bridge at Korangi Causeway 2300-9 Plain & Reinforced Concrete

 Aggregates, when tested in accordance with CRD C119 shall contain not more
than 8 percent by weight of thin, flat and elongated particles.

Petrographic analysis of aggregate shall be carried out initially for each source and
periodically whenever directed by the Engineer.

The specific gravities and absorption of aggregates shall be identified in

accordance with ASTM C 127 and ASTM C 128.

Aggregates shall be tested for deleterious reactivity with alkalis in the cement,
which may cause excessive expansion of concrete. Test of coarse and fine
aggregate shall be made in accordance with ASTM C1260. If the expansion of
the coarse and / or fine aggregates test specimen, tested in accordance with
ASTM C1260 does not exceed 0.1% at 16 days from casting, then the coarse
and fine aggregates shall be accepted.

Prior to the initial use of each source of aggregates, certified tests shall be
performed on aggregates to verify compliance with these specifications and
submitted for Engineer's review and approval.

Gradation of coarse aggregates for concrete shall conform to the gradations

given in Table-I.

The gradation of combined coarse and fine aggregates shall be within the
grading limit specified in Table-II.

The Fineness Modulus of fine aggregate (sand) shall be not less than 2.6 nor
more than 3.1. In at least four out of five successive test samples, the modulus
shall vary by not more than 0.20 from the moving average for the last five tests.
The gradation of the coarse aggregate will be suitable if the results of four out of
the last five consecutive tests comply with the gradation requirements.

Furnish certified test reports for aggregate tests listed in Table-III, Quality Tests.

4.3 Water

Only potable water from the sources approved by the Engineer shall be used. The
Contractor shall supply sufficient water for all purposes, including mixing the concrete,
curing and cleaning plant and tools. Performance requirements for mixing water shall
conform to ASTM C1602. Testing of water shall be carried out in accordance with ASTM
D596 or BS 3148.

In case of doubt, the Engineer will require that concrete mixed with water proposed to be
used should be tested to have a compressive strength not less than 90% of the strength
of concrete mixed with distilled water.

4.4 Concrete Patching Compound

Use an approved epoxy-resin compound applied according to manufacturer's

instructions. Compound shall be paintable material which produces no evidence of
bleeding and which, after final set, shall not be affected by high humidity and moisture.
Epoxy-resin compound shall comply with FSMM-G-650, Type 1, Grade C or Approved
Equivalent.

4.5 Fiber Reinforced Concrete

Duracrete Polypropylene Fiber or approved equivalent concrete reinforcing: Concrete

shall be treated with Duracrete polypropylene synthetic reinforcing fibers or approved
equivalent when indicated on the drawings or as otherwise specified by the Engineer in
accordance with the fiber manufacturer’s recommendations.

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 a. Synthetic reinforcing fibers shall be manufactured from virgin polypropylene.
b. The dosage rate shall be1.8 kg/cu.m (3.0 Lb/ Cu yd) of concrete.
c. Fiber supplier shall provide technical assistance, if required.
d. All fibers must meet or exceed the standards and specifications set forth in ACI
544, Fiber Reinforced Concrete.
e. Listed below are the minimum properties of the polypropylene fibers for use. All
fibers must meet or exceed the characteristics described in ACI-544, IR, Table
1.1, Fiber Reinforced Concrete.

1. Tensile Strength: 4.4 grams/denier

2. Elongation at break: 12%
3. Fiber: 100% Fibrillated / Monofilament Polypropylene (as per site
requirement)
4. Lengths: 19 mm
5. Absorption: Nil
6. Specific gravity: 0.9
7. Ignition point: 593 °C
8. Melting point: 160-170 °C
9. Heat & UV stabilization: Long term
10. Thermal conductivity: Low
11. Electrical conductivity: Low
12. Salt resistance: High
13. Acid resistance: High
14. Alkali resistance: 100% (alkali proof)

4.6 Additives

All additives shall be from a manufacturer approved by the Engineer.

Air Entraining Admixtures shall conform to ASTM C 260. Other admixtures shall conform
to ASTM C 494.

Crystalline water proofing admixture (Betocrete-C16 by Schomburg Germany or

Approved equivalent) shall be added in the concrete of walls, base slab & columns of
underground tanks as per manufacturer`s specifications and specified in the structural
drawings.

4.7 Vapour Barrier

Polyethylene sheeting conforming to ASTM E154 and 0.2mm thick as a minimum. Other
similar material having a vapour permeance rating not exceeding 0.5per meter as
determined by ASTME96, will be considered unless noted otherwise.

4.8 Grout

a) Damp Pack Bedding Grout: Mix of one part Portland cement and 2 parts of fine
aggregate proportioned by weight and not more than 4 gal. (17 liters) of water
per bag of cement.

b) Pre-mixed, Non-Shrink, Non-Metallic Grout: "Masterflow 713" manufactured by

Master Builders, "Euco-N.S." manufactured by the Euclid Chemical Company or
other approved equal.

Construction of Bridge at Korangi Causeway 2300-11 Plain & Reinforced

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 c) Pre-mixed, Non-Shrink, Metallic Grout: "Embeco636" manufactured by Master
Builders, "Firmix" manufactured by the Euclid Chemical Co., or other equivalent
approved product.

d) Expansive Grout: C0E CRD-C588, Type A or M, as required.

4.9 Cover Material for Curing

Curing material shall conform to the following:

a) Impervious Sheeting: ASTM C171, type optional, except that polyethylene

sheeting shall be 0.1mm minimum thickness, white opaque. Where the work is
exposed to high winds the impervious sheeting shall not be used.

b) Burlap: Cloth made of jute or kenaf shall conform with AASHTO M182 and shall
2
weigh a minimum 0.3kg/m .

c) Standard Specification for Liquid Membrane Forming Compound: ASTM C309,

Type 2.

4.10 Joint Fillers

ASTM D 1751, preformed, Non- Extruding and resilient bituminous type or ASTM D1752,
preformed sponge rubber cork.

4.11 Joint Sealants

ASTM D 7116.

4.12 Water stops

Water stops shall be one of the following types as specified in the drawings.

Provide flat, dumbbell type or center bulb type water stops at construction joints where
shown. Web thickness not less than 5mm for units up to 125mm wide, and not less than
10mm for widths over 125mm. Provide polyvinyl chloride (PVC) water stops complying
with US corps of Engineers specification or ASTM D-412 or ASTM D-638 or approved
manufacturer.

Re-swellable thermo-plastic water stop (INDU-FLEX-CJ13 by Schomburg Germany or

approved equivalent) to be applied as per manufacturer’s recommendation

4.13 Epoxy Resin

ASTM C 881, type, Grade 3, Class C.

4.14 Formwork

a) Formwork for Concrete Pavement

Forms shall be made of steel of an approved section, with a base width of at least two
hundred (200) millimeters and the depth shall be equal to the thickness of the pavement
at the edge as shown on the plans. The forms shall be staked with steel stakes, and
stakes shall be of a length approved by the Engineer. Each section of forms shall have a
stake pocket at each end and at intervals of not more than one and one-half (1.5) metres
between ends. The stake pockets shall have approved devices for locking the form to the
steel stakes. Each section of forms shall be straight and free from bends and warps at all
times. No section shall show a variation greater than three (3) millimeter in three (3)
metres from a true plane surface on the top of the form, and the inside face shall not vary
more than six (6) millimeters from a plane surface.

Construction of Bridge at Korangi Causeway 2300-12 Plain & Reinforced

Concrete
 Before placing forms, the underlying base shall be to the required grade, and shall be
firm and compact. The forms shall have full bearing upon the foundation throughout their
length and shall be placed with exactness to the required grade and alignment of the
edge of the finished pavement. They shall be so supported during the entire operation of
placing, tamping and finishing the pavement that they will not deviate vertically at any
time more than three (3) millimeters from the proper elevation.

Forms shall not be removed for at least twelve (12) hours after the concrete has been
placed. Forms shall be carefully removed in a manner to avoid damage to the pavement.
Under no circumstances will the use of pry bars between the forms and the pavement be
permitted. Pavement, which in the opinion of the Engineer, is damaged due to the
careless removal of forms shall be repaired by the Contractor, as directed by the
Engineer, at the Contractor's own expense.

Forms shall be thoroughly cleaned and oiled each time they are used.

When pavement is placed adjoining existing concrete pavement upon which the finishing
machine will travel, any irregularities in the old pavement shall be ground down to a true,
uniform surface, of sufficient width to accommodate the wheels of the finishing
equipment, if necessary to obtain proper smoothness of the pavement.

b) Formwork for Structures

Material, workmanship etc. of formwork for structures, refer specification Section2100.

5.0 MATERIAL TESTING

A. Samples and Testing

Samples from stock on the site or suppliers materials shall be taken by the Contractor in
presence of the Engineer. Furnish tests and certificates as specified.

B. Cement

Sampled cement shall be tested by a testing laboratory. Certified copies of laboratory

test reports shall be furnished for each lot of cement and shall include all test data,
results and certification that the sampling and testing procedures are in conformance
with the Specifications for approval. No cement shall be used until test results are
satisfactory. Cement that has been stored for more than four months after being tested
shall be re-tested before use. Cement found unsatisfactory under test shall be
immediately removed from the construction site or supplier stock.

C. Aggregates

Aggregate sampling shall conform to ASTM D 75. Aggregates shall be sampled and
tested by a testing laboratory. No aggregate shall be used until test results are
satisfactory to the Engineer.

D. Water

Water analysis shall be performed in accordance with ASTM D 596, and the report shall
be submitted for Engineer's approval.

E. Admixtures

Sampling and testing of all admixtures used in concrete mix shall be in accordance with
the standard procedure recommended by an approved testing laboratory. No admixture
shall be used until test results are satisfactory and approved.

Construction of Bridge at Korangi Causeway 2300-13 Plain & Reinforced

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F. Concrete

a) Compressive Strength: The Contractor shall provide and test three sets of specimens
taken under the supervision of the Engineer from each 125 cubic metres or not less than
once a day from each grade of concrete placed. Samples shall be secured in
accordance with ASTM C 172. Test specimens shall be made and cured in accordance
with ASTM C-31. Specimens shall be tested in accordance with ASTMC39 or ACI-214.
Test specimens shall be evaluated for each grade of concrete specified in conformance
with ACI318, chapter "Concrete Quality". The standard age of concrete for tests shall be
3, 7 and 28 calendar days.

b) Slump and Entrained Air: Slump test and entrained air tests shall be performed in the
field under the supervision of the Engineer. Slump test shall conform to ASTM C 143 and
entrained air content shall be determined in accordance with ASTM C 231 or C 173 as
applicable.

c) Concrete removed for the Structure: When the results of the strength test of the
specimen indicate deficiency in specified requirements or where there is other evidence
that the quality of concrete is below specified requirements, core boring tests shall be
made in conformance with ASTM C-42. If a deficiency is discovered, the Contractor may
be allowed to make load test, at his expense, and results shall be evaluated in
conformance with ACI 318, Chapter 20.

5.1 Frequency of Testing

a) The following tests shall be performed initially for approval and as per required frequency
thereafter:

- Aggregates ASTM C 33 -----------

- Soundness ASTM C 88 bi-weekly
- Specific Gravity ASTM C 127 weekly
- Absorption ASTM C 128 weekly
- Abrasion ASTM C 131 weekly
- Gradation ASTM C 136 daily
- Sand Equivalent ASTM C 217 weekly
- Cleanliness ASTM C 227 weekly
- Elongation CRD C 119 bi-weekly
- Chloride Sulphate ASTM D 512 bi-weekly
Content
- Water Analysis ASTM D 596 bi-weekly
- Alkali silica Reactivity ASTM C 1260 -----------
- Total Alkalies ASTM C1260 -----------

b) The following tests shall be performed initially for approval and thereafter as
specified:

- Concrete Compressive Strength: ASTM C39. Three sets of specimens for each
75 cu.m of each grade of concrete placed or at least three sets for each grade
per work shift.

- Flexural Strength: Three sets of specimens for each 100 cu.m of concrete
placed or at least three sets per work shift. The concrete shall be sampled in

Construction of Bridge at Korangi Causeway 2300-14 Plain & Reinforced

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 accordance with ASTM C172. Flexural strength specimens shall be made in
accordance with ASTM C 31 and tested in accordance with ASTM C 78.

- Sulphate (S03) Content, Chloride Content and pH value: One test per month for
each grade of concrete. Broken laboratory specimens from strength tests shall
be used for hardened concrete Sulphate, Chloride content and pH Value tests.

6.0 EXECUTION

6.1 Nominal Concrete Mixes

6.1.1 The cement, fine aggregate and the coarse aggregate shall be weighed
separately. The proportions of cement to fine aggregate and coarse aggregate
shall be adjusted as per ACI 211 & ACI 318 so as to provide the concrete of the
required crushing strength when tested as set out in Table III.

6.1.2 The Contractor shall regulate and arrange mixing of the ingredients for the
designed mix of the concrete by weight-batching.

6.1.3 Water/Cement Ratio

The quantity of water used shall be just sufficient to produce a dense concrete of
the specified strength. For all exterior exposed work and foundations the
water/cement ratio shall not exceed 0.45, allowance being made for any water in
the fine and coarse aggregates.

6.1.4 Workability

Admixtures may be used where necessary to achieve required workability, with

the Engineer's approval. For concrete pavements, the mix determined shall be
workable concrete having a slump between 13mm and 50mm, as determined by
ASTMC143. For other structures the concrete shall be proportioned and
produced to have a slump of 75mm or less if consolidation is to be by vibration,
and 125mm or less if consolidation is to be by methods other than vibration.

6.2 Strength and Durability Requirements for Concrete

Strength and Durability Requirements for Concrete are given below:

Class of Concrete Specified Cylinder Compressive Strength at 28 days (MPa)

A1 35.0
A 28.0
B 21.0
C 17.0
D 8.0
E 5.0

The flexural strength of concrete for pavement shall be 4.5 MPa at 28 days as per ASTM
C 78 with minimum cement content of 340Kg of cement per cubic metre of concrete. The
flexural strength requirement is the governing factor, excess cement if any used to
achieve the required flexural strength shall not be payable.

6.2.1 The Contractor shall adopt all necessary measures as per ACI201.2, like proper
grading of aggregates, control of water cement ratio and cement content, proper
compaction and curing, to achieve dense and durable concrete.

6.2.2 The Contractor shall submit mix design by weight for each grade of concrete at
least 45 calendar days before any placement of concrete, along with samples of
the proposed materials. Manufacture 12nos. test cylinders
12" (305mm) x 6" (152mm) in accordance with ASTMC-31, and in accordance

Construction of Bridge at Korangi Causeway 2300-15 Plain & Reinforced

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 with the mix design batching by weight and test 3 cylinders each at 3, and
28 days in the presence of Engineer's Representative, in accordance with
ASTMC-39 and submit all relevant data and results of tests for approval of the
Engineer. The Contractor shall obtain approval from the Engineer in writing for
each mix design before producing the actual concrete for the works.

6.3 Batching

6.3.1 All cement, including cement supplied in bulk, shall be batched by weight. A bag
of cement may be taken as 50 kg.

6.3.2 Aggregates shall be batched by weight, due allowance being made for water
content. Aggregates may be batched by volume only with the prior permission of
the Engineer. The apparatus for weight batching may be as integral part of the
mixer or a separate unit of a type approved by the Engineer. It shall be accurate
within 2% and shall be checked for accuracy at least once a week.

6.3.3 The quantity of additives shall be as prescribed by the manufacturer or as

directed by the Engineer.

6.4 Mixing

6.4.1 The concrete shall be mixed in an approved batch mixer. It shall be fitted with
the manufacturer’s plate stating the rates, capacity and the recommended
number of revolutions per minute and shall be operated in accordance therewith.
It shall be equipped with a suitable charging mechanism and an accurate water
measuring device.

6.4.2 Mixing shall continue for the period recommended by the mixer manufacturer or
until there is apparently a uniform distribution of the materials and the mass is
uniform in colour, whichever period is longer. However, minimum mixing time
shall not be less than 1-1/2 minutes.

If it is desired to use a mixing period of less than 1-1/2 minutes, the Engineer’s
approval shall be obtained in writing.

6.4.3 Controls shall be provided to ensure that the batch cannot be discharged until
the required mixing time has elapsed. At least three quarters of the required
mixing time shall take place after the last of the mixing water has been added.

6.4.4 The interior of the mixer shall be free of accumulations that will interfere with
mixing action. Mixing blades shall be replaced when they have lost 10 percent of
their original height.

6.4.5 Concrete shall be mixed only in quantities for immediate use. Concrete which
has set shall not be re-tempered, but shall be discarded.

6.5 Transporting

6.5.1 The concrete shall be transported from the place of mixing to the place of final
deposit as rapidly as practicable by means which will prevent segregation or loss
of or addition to ingredients. It shall be deposited as nearly as practicable in its
final position so as to avoid re-handling or flowing. All skips vehicles, or
containers used for transporting the concrete shall be thoroughly clean.

6.5.2 During hot or cold weather, concrete shall be transported in deep containers, on
account of their ratios of surface area to mass, which reduces the rate of loss of
water by evaporation during hot weather and loss of heat during cold weather.

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 a) Batching: The Contractor shall submit to the Engineer for review the
plans and capacity of the concrete batching plant and delivery
equipment, which shall comply with ASTM C-94.

The Contractor shall furnish test certificates for the scales and metering
devices before producing concrete and at least every six weeks
thereafter.

b) Accuracy of Plant Batching: Cement measured by weight in individual

batchers shall be within +1.0 percent of the desired intermediate and
final weights in cumulative batchers. The minimum batching accuracy
shall be +0.3 percent of scale capacity for small loads below 30 percent
of scale capacity.

Aggregate measured by weight in individual batchers shall be within

+2.0 percent of the desired weight, or within +1.0 percent of the desired
intermediate and final weights in cumulative batchers; but in either case,
the minimum batching accuracy shall be +0.3 percent of scale capacity
for small loads below 15 percent and 30 percent of scale capacity,
respectively.

Water measured by volume or by weight shall be within +1.0 percent of

the desired amount.

Liquid admixtures measured by volume or by weight shall be within +1.0

percent of the desired amount.

Compensation for changes of moisture content in fine and coarse

aggregate shall be made by devices which shall correct the batch water
and the weight of the affected aggregate simultaneously without
changing the batch setting.

c) Mixing and Delivery: Concrete shall be mixed completely in the batching

plant. Records shall be kept of water added in normal batching.

Concrete shall be transported to the point of discharge in agitator-mixer

trucks, or by other approved means.

Trip tickets shall be provided for each delivery. The tickets shall show
the designation of the materials in each batch, measured weight or
volume of materials, methods of cooling concrete, class of concrete,
batch number, mixer number, batch volume, date and time water was
added to the mix, time of discharge from the mixer, and delivery truck
number.

When it is necessary to add water to the agitator-mixer, it shall be done

in accordance with ASTM C 94 and recorded.

6.6 Concrete for Pavement

6.6.1 The base upon which the concrete pavement is laid shall have been constructed
or prepared under other relevant section of the specifications and shall be
smooth, compacted and true to the grade and cross-section shown on the
drawing and shall be maintained throughout the period of placing concrete
pavement.

To prevent flow of cement slurry from concrete and de-bonding of cement

treated base course from concrete pavement, polyethylene sheet 0.2mm thick
as vapour barrier, as per drawings and relevant section of specifications shall be
placed on cement treated base coarse, prior to placing of concrete.

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 Air entraining admixture shall be added in such a manner that will ensure
uniform distribution of the agent throughout the batch. The air content of freshly
mixed air –entrained concrete shall be based upon trial mixes with the materials
to be used in the work adjusted to produce concrete of the required plasticity and
workability. The percentage of air in the mix shall be 4.5%. Air content shall be
determined by testing in accordance with ASTM C 231.

6.6.2 Slip-Form Construction

The concrete shall be distributed uniformly into final position by a self propelled
slip-form paver without delay. The alignment and elevation of the paver shall be
regulated from outside reference lines established for this purpose. The paver
shall vibrate the concrete for the full width and depth of the strip of pavement
being placed and the vibration shall be adequate to provide a consistency of
concrete that will stand normal to the surface with sharp well defined edges.
The sliding forms shall be rigidly held together laterally to prevent spreading of
the forms.

The plastic concrete shall be effectively consolidated by internal vibration with

transverse vibrating units for the full width of the pavement and/or a series of
equally placed longitudinal vibrating units. The space from the outer edge of the
pavement to longitudinal unit shall not exceed 225 mm. The spacing of internal
units shall be uniform and shall not exceed 450 mm.

The term internal vibration means vibrating units located within the specified
thickness of pavement section.

The rate of vibration of each vibrating unit shall be within 8000 to 12000 cycles
per minute and the amplitude of vibration shall be sufficient to be perceptible on
the surface of the concrete along the entire length of the vibrating unit and for a
distance of at least 300 mm. The frequency of vibration or amplitude shall vary
proportionately with the rate of travel to result in a uniform density and air
content. The paving machine shall be equipped with a tachometer or other
suitable device for measuring and indicating the actual frequency of vibrations.

The concrete shall be held at a uniform consistency. The slip-form paver shall
be operated with as nearly a continuous forward movement as possible. And all
operations of mixing, delivering, and spreading concrete shall be coordinated to
provide uniform progress with stopping and starting of the paver held to a
minimum. If for any reason, it is necessary to stop the forward movement of the
paver, the vibratory and tamping elements shall also be stopped immediately.
No tractive force shall be applied to the machine, except that which is controlled
from the machine.

When concrete is being placed adjacent to an existing pavement, that part of the
equipment which is supported on the existing pavement shall be equipped with
protective pads on crawler tracks or rubber-tired wheels on which the bearing
surface is offset to run a sufficient distance from the edge of the pavement to
avoid breaking the pavement edge.

6.6.3 Formwork

Before placing forms, the underlying base shall be to the required grade, and
shall be firm and compact. The forms shall have full bearing upon the foundation
throughout their length and shall be placed with exactness to the required grade
and alignment of the edge of the finished pavement. They shall be so supported
during the entire operation of placing, tamping and finishing the pavement that

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 they will not deviate vertically at any time more than three (3) millimeters from
the proper elevation.

Forms shall not be removed for at least twelve (12) hours after the concrete has
been placed. Forms shall be carefully removed in a manner to avoid damage to
the pavement. Under no circumstances will the use of pry bars between the
forms and the pavement be permitted. Pavement, which in the opinion of the
Engineer, is damaged due to the careless removal of forms shall be repaired by
the Contractor, as directed by the Engineer, at the Contractor's own expense.

Forms shall be thoroughly cleaned and oiled each time they are used.

When pavement is placed adjoining existing concrete pavement upon which the
finishing machine will travel, any irregularities in the old pavement shall be
ground down to a true, uniform surface, of sufficient width to accommodate the
wheels of the finishing equipment, if necessary to obtain proper smoothness of
the pavement.

6.6.4 Placing Reinforcement

All pavement reinforcement shall be placed as shown on the plans. All

reinforcement required by the works shall be held in proper position by sufficient
number of metal bar supports or chairs as approved by the Engineer. The
dowels may be installed mechanically by means of equipment and methods
approved by the Engineer. The satisfactory placement of the dowels shall
depend upon the ability of the mechanical device to place the dowels in their true
position. The Engineer may require, when satisfactory placement is not obtained
by mechanical means, that the dowels be installed ahead of placing the concrete
and that they be securely staked and tied if necessary to hold them in their exact
position. The use of removable devices, supporting the bars from the forms, will
not be permitted.

6.6.5 Placing Concrete

a) General

The concrete shall be deposited on the base course in successive batches for
the full width between forms or in front of the slip form paver and in a manner
which will require as little re-handling as possible. Spreading shall be done by an
approved mechanical spreader in a manner that will prevent segregation and
separation of the materials. Necessary hand spreading shall be done with
shovels, not rakes. Workmen shall not be allowed to walk in the freshly mixed
concrete with boots or shoes coated with earth or foreign substances. The
amount of material deposited shall be sufficiently in excess of that required to
form the pavement to the required cross section after consolidation in order to
provide a roll of concrete ahead of the front screed of the finisher or finishing
machine for the full length of the screed.

When concrete is placed adjoining a previously constructed lane of pavement

and when mechanical equipment will be operated upon the existing lane of
pavement, the concrete shall be at least 7 days old and at a flexural strength
approved by the Engineer. If only finishing equipment is carried on the existing
lane, paving in adjoining lanes may be permitted after 3 days, if approved by the
Engineer.

Concrete shall be thoroughly consolidated against and along the full length and
on both sides of all expansion joint assemblies, by means of vibrators inserted in
the concrete. Vibrators shall not be permitted to come in contact with a joint
assembly, the grade, or a side form. In no case shall the vibrator be operated
longer than fifteen (15) seconds in any one location.

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 Concrete shall be deposited as near to expansion and contraction joints as
possible without disturbing them, but shall not be dumped from the discharge
bucket or hopper onto a joint assembly unless the hopper is well centered on the
joint assembly. Damage to joint assemblies caused by dumped concrete shall be
repaired immediately, as directed by the Engineer, at the Contractor's expense.

Should any concrete materials fall on or be worked into the surface of a

completed slab, they shall be removed immediately by methods approved by the
Engineer.

Placement of concrete ahead of the initial spreader strike- off shall not be more
than fifteen (15) minutes ahead of final spreader strike-off. If concrete is placed
in one (1) layer only, the placement of concrete shall not be more than twenty
(20) minutes ahead of the spreader strike-off.

b) Works in extreme weather

Unless authorized in writing by the Engineer, mixing and concreting operations

shall be discontinued when a descending air temperature in the shade and away
o
from artificial heat reaches 4 C and shall not be resumed until an ascending air
o
temperature in the shade and away from artificial heat reaches 2 C. When
concreting is authorized during cold weather, the Engineer may require the
aggregates to be heated by either steam or dry heat prior to being placed in the
mixer. The apparatus used shall heat the mass uniformly and shall be arranged
to preclude the possible occurrence of overheated areas which might be
detrimental to the materials. Unless otherwise authorized, the temperature of
o
the mixed concrete shall not be less than 10 C at the time of placement in the
forms.
o
If the air temperature is 2 C or less at the time of placing concrete, the Engineer
o
may require the water and/or the aggregate to be heated to not less than 21 C
o
nor more than 66 C. Concrete shall not be placed on frozen sub-grade nor shall
frozen aggregates be used in the concrete.

During periods of warm weather when the maximum daily air temperature
o
exceeds 30 C, the forms and/or the underlying material shall be sprinkled with
water immediately before placing the concrete, the concrete shall be placed at
the coolest temperature practicable, and in no case shall the temperature of the
o
concrete when placed exceed 32 C. The aggregates and/or mixing water shall
be cooled as necessary to maintain the concrete temperature at or not more
than the specified maximum.

6.6.6 Joints

a) General

Joints shall be constructed exactly in accordance with the details shown on the
plans and the Specifications and with the best of workmanship.

b) Expansion Joints

Expansion joints shall be of the type and dimensions and of the spacing shown
on the plans. Joint filler shall be of premolded compressible material according
to ASTM D1751 or ASTM D1752, and joint sealant material shall be according to
material specified in para 6.6.12a of these specifications.

The entire joint assembly shall be of a type designated on the drawings and shall
be installed in such a position that the centerline of the joint assembly is
perpendicular to the centerline of the pavement slab and the dowels lie parallel

Construction of Bridge at Korangi Causeway 2300-20 Plain & Reinforced

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 to the centerline of the slab. Finished joints shall not deviate more than six (6)
millimeters in the horizontal alignment from a straight line. No plugs of concrete
shall be permitted anywhere within the expansion space.

One-half of the length of each dowel bar shall be painted, and then thoroughly
coated with hard grease, or lubricant as approved by the Engineer, to prevent
the concrete from bonding to that portion of the dowel.

An expansion cap of the dimensions shown on the plans shall be placed on the
greased end of each dowel. The greased ends shall be free to slide in the dowel
holder and shall extend in the direction as indicated on the plans. Any excess
grease on the dowel holder shall be removed.

The joint shall be securely staked or fastened in place prior to placing the
concrete and in a manner to ensure that the joint and the dowel bars will remain
in their proper position after the concreting and finishing operations are
completed.

The finishing machine shall be operated in a manner that will prevent

displacement of the joint. If for any reason it is necessary to straighten a joint,
any depressions caused by this operation shall immediately be filled with fresh
concrete, re-spaded and brought to the original crown in advance of the
longitudinal finishers. Any fluid laitance or mortar caused by this operation shall
be removed and replaced with fresh concrete.

For concrete poured within the forms, when the finishing machine approaches
the joint on the first trip, the excess concrete shall be shoveled ahead and the
tamper and each screed, in turn, shall be lifted over the joint. On the second trip
of the finishing machine, the screed may be operated over the joint.

c) Contraction Joints

Contraction joints shall be of the type and dimensions and at the spacing shown
on the plans.

Sawed contraction joints shall be cut by means of an approved concrete saw.

The joints shall not be sawed until the concrete has hardened to the extent that
tearing and raveling is precluded.

All joints shall be sawed during the initial curing period and the sawing shall
begin before the pavement starts shrinking and before uncontrolled cracking
takes place.

Any procedure which results in premature and uncontrolled cracking shall be

revised immediately by adjusting the sequence of cutting the joints or the time
interval involved between the placing of the concrete or the removal of the curing
media and the cutting of the joints. In no case shall the pavement be left
overnight without having the joints sawed.

The joints shall be sawed at the depth, spacing, and lines shown on the plans.
Guidelines or devices approved by the Engineer shall be provided to ensure
cutting the joint in a straight line and perpendicular to the centerline of the
pavement.

The dust resulting from sawing shall be completely removed from the joint and
adjacent areas by means of an air jet or a combination of air and water applied
under pressure immediately after the joint has been cut, and before filling with
joint sealant.

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 When the plans specify that dowels be installed through contraction joints, the
base course at the contraction joints shall be accurately trimmed to the required
cross section and to the proper depth of the pavement.

A string line shall be stretched between the pavement forms along the centerline
of the joint.

Each dowel shall be painted and thoroughly coated with hard grease, or
lubricant, in accordance with the directions shown on the plans or as approved
by the Engineer, to prevent the concrete from bonding to that portion of the
dowel.

The entire joint assembly shall be an approved type and shall be installed in
such a position that the centerline of the joint assembly is perpendicular to the
centerline of the pavement and the dowels lie parallel to the pavement surface
parallel to the centerline of the pavement.

The greased ends of the dowels shall be placed in the direction as indicated on
the plans and shall be free to slide in the dowel holder. Any excess hard grease
on the dowel holder shall be removed.

d) Construction Joints

A butt construction joint shall be made perpendicular to the centerline of the

pavement at the close of each day's work and also when the process of
depositing concrete is stopped for a length of time such that, in the opinion of the
Engineer, the concrete will have taken its initial set. This joint shall be formed by
using a clean plank header having a nominal thickness of fifty (50) millimeters, a
width of not less than the thickness of the pavement and a length of not less
than the width of the pavement. The header shall be cut true to the cross-section
of the finished pavement and shall be accurately set and held in place in a plane
at right angles to centerline and perpendicular to the surface of the pavement.

The top surface of the header shall be protected with steel as approved by the
Engineer. On the face along the center of the header there shall be fastened a
trapezoidal piece of metal or wood the full length of the header. Seventy
millimeters wide and at least forty millimeters in depth as per drawing to form a
grooved joint. The header shall have drilled holes to accommodate the dowel or
tie bars hereinafter specified. Upon resumption of work any surplus concrete
remaining upon the base course shall be removed. The header shall then be
carefully removed and fresh concrete deposited against the old in such a
manner as to avoid injury to the edge of the old concrete. The fresh concrete
shall be vibrated into the groove in a manner to ensure an interlocking joint.

Dowel bars or load transfer devices shall be used in all construction joints in
accordance with the details shown on the plans. The edges of the joint shall be
grooved, edged, and sealed with the material used for sealing expansion and
contraction joints.

No construction joint shall be placed within three (3) metres of an expansion,

contraction, or other construction joint.

6.6.6 Consolidating and Finishing for Concrete Pavement

a) Sequence: The sequence of operations shall be the strike-off and consolidation,

floating and removal of laitance, straight edging, and final surface finish. The
addition of superficial water to the surface of the concrete to assist in finishing
operations generally will not be permitted. If the application of water to the
surface is permitted by the Engineer, it shall be applied as a fog spray by means
of approved spray equipment.

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 b) Finishing at Joints: The concrete adjacent to joints shall be compacted or firmly
placed without voids or segregation against the joint material; it shall be firmly
placed without voids or segregation under and around all load-transfer devices,
joint assembly units, and other features designed to extend into the pavement.
Concrete adjacent to joints shall be mechanically vibrated as required in sub-
section 6.4.4. After the concrete has been placed and vibrated adjacent to the
joints, the finishing machine shall be operated in a manner to avoid damage or
misalignment of joints. If uninterrupted operations of the finishing machine, to
over and beyond the joints, cause segregation of concrete, damage to, or
misalignment of the joints, the finishing machine shall be stopped when the
screed is approximately 20cm from the joint. Segregated concrete shall be
removed from the front of and off the joint; the screed shall be lifted and set
directly on top of the joint, and the forward motion of the finishing machine shall
be resumed. Thereafter, the finishing machine may be run over the joint without
lifting the screed, provided there is no segregated concrete immediately between
the joint and the screed or on top of the joint.

c) Machine Finishing: The concrete shall be spread as soon as it is placed, and it

shall be struck off and screeded by an approved finishing machine or a finishing
screed of the slip form paver. The machine shall go over each area as many
times and at such intervals as necessary to give the proper consolidation and to
leave a surface of uniform texture. Excessive operation over a given area shall
be avoided. When side forms are used, the tops of the forms shall be kept clean
by an effective device attached to the machine, and the travel of the machine on
the forms shall be maintained true without lift, wobbling, or other variation
tending to affect the precision finish. During the first pass of the finishing
machine, a uniform ridge of concrete shall be maintained ahead of the front
screed for its entire length. When in operation, the screed shall be moved
forward with a combined longitudinal and transverse shearing motion, always
moving in the direction in which the work is progressing, and so manipulated that
neither end is raised from the side forms during the striking-off process. If
necessary, this shall be repeated until the surface is of uniform texture, true to
grade and cross section, and free from porous areas.

d) Hand Finishing: Hand finishing methods will not be permitted, except under the
following conditions. In the event of breakdown of the mechanical equipment,
hand methods may be used to finish the concrete already deposited on the
grade; in areas of narrow widths or of irregular dimensions where operation of
the mechanical equipment is impractical. Concrete, as soon as placed, shall be
struck off and screeded. An approved portable screed shall be used. A second
screed shall be provided for striking off the bottom layer of concrete when
reinforcement is used.

The screed for the surface shall be at least 0.6m longer than the maximum width
of the pavement to be struck off. It shall be of approved design, sufficiently rigid
to retain its shape, and shall be constructed either of metal or of other suitable
material covered with metal. Consolidation shall be attained by the use of a
suitable vibrator.

e) Floating: After the concrete has been struck off and consolidated, it shall be
further smoothed, trued, and consolidated by means of a longitudinal float, using
one of the following methods:

1. Hand Method: The hand-operated longitudinal float shall not be less

than 3.6 m in length and 15 cm in width, properly stiffened to prevent
flexibility and warping. The longitudinal float, operated from foot bridges
resting on the side forms and spanning but not touching the concrete
shall be worked with a sawing motion, while held in a floating position
parallel to the pavement centerline and passing gradually from one side

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 of the pavement to the other. Forward movement along the centerline of
the pavement shall be in successive advances of not more than one-half
the length of the float. Any excess water or soupy material shall be
wasted over the pavement edge on each pass.

2. Mechanical Method: The Contractor may use a machine composed of a

cutting and smoothing float(s), suspended from an guided by a rigid
frame or part o slip form paver. The frame shall be carried by four or
more visible wheels riding on and constantly in contact with, the side
forms or pavement subgrade. If necessary, long-handled floats having
blades not less than 1.5 m in length and 1.5 cm in width may be used to
smooth and fill in open textured areas in the pavement. Long-handled
floats shall not be used to float the entire surface of the pavement in lieu
of mechanical methods. When strike-off and consolidation are done by
hand and the crown of the pavement will not permit the use of the
longitudinal float, the surface shall be floated transversely by means of a
long-handled float. Care shall be taken not to work the crown out of the
pavement during the operation. After floating any excess water and
laitance shall be removed from the surface of the pavement by a
straightedge 3m or more in length. Success drags shall be lapped one-
half the length of the blade.

f) Straight-edge Testing and Surface Correction: After the pavement has been
struck off and consolidated and while the concrete is still plastic, it shall be
tested for trueness with a 5m straightedge. For this purpose the Contractor shall
furnish and use an accurate 5m straightedge swung from handles 0.9 m longer
than one-half the width of the pavement. The straight edge shall be held in
contact with the surface in successive positions parallel to the centerline of the
pavement and the whole area gone over from one side of the pavement to the
other, as necessary. Advancing shall be in successive stages of not more than
one-half the length of the straight edge. Any excess water and laitance shall be
removed from the surface of the pavement. Any depressions shall be
immediately filled with freshly mixed concrete, struck off, consolidated and
refinished. High areas shall be cut down and refinished. Special attention shall
be given to assure that the surface across joints meets the requirements for
smoothness. Straightedge testing and surface corrections shall continue until the
entire surface is found to be free from observable departures from the straight
edge and until the slab conforms to the required grade and cross section. The
use of long-handled wood floats shall be confined to a minimum; they may be
used only in emergencies and in areas not accessible to finishing equipment.

6.6.7 Surface Texture

The surface of the pavement shall be finished with broom finish for all newly
constructed concrete pavements.

Brush or Broom Finish: If the pavement surface texture is to be a type of brush

or broom finish, it shall be applied when the water sheen has practically
disappeared. The equipment shall operate transversely across the pavement
surface, providing corrugations that are uniform in appearance and
approximately 2mm in depth. It is important that the texturing equipment not tear
or unduly roughen the pavement surface during the operation. Any imperfections
resulting from the texturing operation shall be corrected.

6.6.8 Skid Resistant Surfaces

In addition to broom and brush finish in the plastic concrete pavement skid
resistant surfaces comprising either saw-cut grooves, plastic grooves or wire
combing shall be provided as specified below and as directed by the Engineer.

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 a) Sawcut Grooves: For new concrete pavements that have hardened,
transverse grooves shall be saw-cut in the pavement forming a 6mm by
6mm by 31mm configuration. The grooves shall be continuous for the
entire runway length. They shall be saw-cut transversely in the runway
pavement to within 3m of the runway pavement edge to allow adequate
space for equipment operation. The maximum transverse saw-cut
grooves shall not exceed 40 m. The tolerances for the saw-cut grooves
shall meet the following:

Alignment tolerance.
Plus or minus 38 mm in alignment for 23 m.

Groove tolerance.
Minimum depth 5 mm.
Maximum depth 8 mm.

Center-to-center spacing.
Minimum spacing 31 mm.
Maximum spacing 50 mm.

Saw-cut grooves shall not be closer than 76mm to transverse paving joints.
Grooves may be continued through longitudinal construction joints. Cleanup of
waste material shall be continuous during the grooving operation. Waste
material may be disposed of by either flushing with water, sweeping, or
vacuuming. Waste material must not be allowed to enter the storm or sanitary
sewer system.

b) Plastic grooves: The grooves formed in the plastic concrete shall be 6mm by 6
mm by 31 mm. The grooves shall be continuous for the entire runway length and
width. The tolerances for the grooves formed in plastic concrete shall meet the
following:

Alignment tolerance.
Plus or minus 76 mm in alignment for 23 m.

Groove tolerance.
Minimum depth 3 mm.
Maximum depth 10 mm.
Center-to-center spacing.
Minimum spacing 31 mm.
Maximum spacing 50 mm.

c) Wire Combing: The wire combing technique shall use steel combs or tines of
various dimensions to form groove-like texture in the plastic concrete pavement
and shall provide grooves that are approximately 3 mm by 3 mm spaced 13 mm
center-to-center.

6.6.9 Surface Test

As soon as the concrete has hardened sufficiently, the pavement surface shall
be tested with a 5 m straight edge, rolling straight edge, or other specified device
as approved by the Engnieer or other specified device. Areas in a slab showing
high spots of more than 6 mm but not exceeding 13 mm in 5 m shall be marked
and immediately ground down with an approved grinding machine to an
elevation that will fall within the tolerance of 6 mm or less. Where the departure
from correct cross section exceeds 13 mm, the pavement shall be removed and
replaced at the expense of the Contractor when so directed by the Engineer.

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 Any area or section so removed shall not be less than 3 m in length nor less
than the full width of the lane involved. When it is necessary to remove and
replace a section of pavement, any remaining portion of the slab adjacent to the
joints that is less than 3 m in length shall also be removed and replaced.

6.6.10 Removing Forms

Unless otherwise provided, forms shall not be removed from freshly placed
concrete until it has set for at least twelve (12) hours, except auxiliary forms
used temporarily in widened areas. Forms shall be removed carefully so as to
avoid damage to the pavement. After the forms have been removed, the sides of
the slab shall be cured as specified for the surface. Major honeycombed areas
will be considered as defective work and shall be removed and replaced at the
Contractor's expense, as directed by the Engineer. Any area or section so
removed shall not be less than three (3) metres in length nor less than the full
width of the paving lane involved. When it is necessary to remove and replace a
section of pavement, any remaining portion of the slab adjacent to the joints that
is less than three (3) metres in length, shall also be removed and replaced.

6.6.11 Protecting and Curing of Concrete Pavement

a) Initial Curing

As the surface of the freshly laid pavement is progressively finished, the initial
curing and protection operations shall commence.

Upon completion of the finishing operation and while the surface of concrete is
still moist, but no free water remains, a liquid curing membrane, as specified in
ASTM C309 (Type 2) shall be applied to the exposed surfaces of the pavement
at the rate of not less than one (1) liter per three and two-thirds (3-2/3) square
metres of surface area when mechanical pressure distributors are used. The
curing membrane, except on irregular areas, shall be applied by means of
approved self-propelled mechanical pressure distributors or approved hand
sprays. Satisfactory means shall be provided for thoroughly mixing the curing
membrane compound before and during its use.

The mechanical spraying equipment shall include a full width spray bar equipped
with multiple nozzles or a traversing spray which travels from one edge of the
pavement to the other. In either case the path of adjacent nozzles or passes of
the traversing spray shall overlap minimum of one-half (1/2) the width of the
spray pattern so that all portions of the surface shall receive double applications
from adjacent nozzles or passes. The pumping, pressure, and distribution
arrangement shall be correlated with the forward speed to provide adequate and
uniform coverage of the pavement at not less than the minimum rate required.
Irregular areas to which the mechanical distributor cannot be adapted may be
covered with hand sprays.

When hand sprays are used, the curing membrane shall be applied in two(2)
applications, each at a rate of not less than one (1) liter per five(5) square
metres of surface area so as to provide a total rate of application of one (1) liter
per two and one-half (2-1/2) square metres of surface area. The path of the
spray on the second application shall be at right angles to the path of the spray
on the first application. When hand operated sprays are permitted, the
equipment supplying the pressure to the spray nozzle shall be capable of
supplying constant and uniform pressure to provide uniform and adequate
distribution of the curing membrane compound at the rates required. If from any
cause, such as rainfall soon after its application, the curing membrane is
damaged, the Contractor shall immediately apply another application of curing
membrane to the surface of the pavement. The rate of application for the
replacement membrane shall be the same as for the original membrane.

Construction of Bridge at Korangi Causeway 2300-26 Plain & Reinforced

Concrete
 Unless otherwise directed by the Engineer, immediately following the application
of the curing membrane, an approved shade structure with canvas shall be
placed approximately 300 mm above the pavement surface. The shade
structure with canvas shall be constructed of materials and in a manner
approved by the Engineer. In no case shall any portion of the shade canvas
come in contact with the pavement. The concrete pavement shall not be
exposed to the direct rays of the sun for more than one (1) hour, within the first
twenty-four hours. The initial curing shall be continued for a period of twenty four
(24) hours from the time the curing membrane is applied.

When forms are removed, the edges of the pavement shall receive curing
membrane at the rate of coverage specified for the pavement surface.

The curing membrane may be applied to the vertical edges of the pavement by
means of hand sprays or by nozzles attached to the mechanical distributor, but
the edges of the pavement shall be covered with curing membrane at the rate
specified within thirty (30) minutes after removal of the forms.

When hot-poured joint compound is used, all joints shall be sawed during the
initial curing period. The shade-canvas may be moved at joint locations for short
periods of time to permit the sawing. Before being sealed, the joints shall be
thoroughly cleaned of all loose saw dust, laitance, dirt, other foreign matter, and
free of water. As the method of final curing is different from that of the initial
curing, the cleaning, and sealing of joints shall be performed immediately
following the removal of the shade-canvas at the end of the initial curing period
and prior to the application of the polyethylene sheeting.

In no case shall any portion of the concrete pavement be exposed to the direct
rays of the sun for more than one (1) hour.

b) Final Curing:

Following jointing operations, curing membrane shall be applied to the joint area
at the rate specified for the pavement surface.

Upon completion of the initial curing period and after the shade canvas has been
removed and jointing operation has been completed including application of
curing membrane, the pavement shall be completely covered with white opaque
polyethylene film as specified in ASTM C171 or AASHTO M-171. Adjoining
sheets shall be lapped a minimum of four hundred and fifty (450) millimetres.
The sheeting shall be held in place in a manner approved by the Engineer.

Final curing shall be continued until the concrete reaches an age of fourteen (14)
days. During this period, the curing membrane and polyethylene film shall be
protected from damage from any cause. Any damage from any cause shall be
immediately repaired by the Contractor at his expense. No traffic, including
workmen shall be allowed on the surface of the pavement until the expiration of
the fourteen (14) day curing period, or as directed by the Engineer.
6.6.12 Sealing Joints

a) Materials

Joint sealant shall be hot-poured elastic type compound, fuel-resistant complying

with ASTM D3569 for airfield pavements constructed with pavement quality
concrete and ASTM D3405 or ASTM D0090 for other pavements and at the joint
formed between flexible and rigid pavements.

Construction of Bridge at Korangi Causeway 2300-27 Plain & Reinforced

Concrete
 b) Execution

After the fourteen (14) day curing period for the pavement has elapsed, the jute
or other protective covering shall be removed from the joint and the joint
thoroughly cleaned of all loose scale, saw dust, dirt, laitance or other matter and
before proceeding with cleaning operation all joints shall be inspected for any
damage or absence of 6mm radius bend at the corner of the joint.

Cleaning may be accomplished with a compressed air jet, air and water under
pressure, wire brushes or in extreme cases the joint shall, when directed by the
Engineer, be resawed to ensure a completely clean joint. The joint surfaces and
adjacent areas of the slab shall be thoroughly clean.

The hot-poured joint material shall be heated in a approved heating unit to the
temperature within the range required as shown by tests. The joint shall be filled
from the bottom of the saw cut to the surface of the pavement. Any joint with a
depth greater than twenty-five (25) millimeters shall be filled with a minimum of
two (2) layers, each layer being approximately equal in depth. The material shall
be poured within the required temperature in the workman like manner neatly so
that it should not spread on the sides of the joint and is evenly placed.

6.6.13 Protection of Pavement

The Contractor shall protect the pavement and its appurtenances against both
public traffic and traffic caused by the Contractor's employees and agents. This
shall include watchmen to direct traffic and the erection and maintenance of
warning signs, lights, pavement bridges, or crossovers, etc. The Contractor's
plans or special provisions will indicate the location and type of device or facility
required to protect the work and provide adequately for traffic. Any damage to
the pavement occurring prior to final acceptance shall be repaired or the
pavement replaced at the Contractor's expense. In order that the concrete be
properly protected against the effects of rain before the concrete is sufficiently
hardened, the Contractor will be required to have available at all time materials
for the protection of the edges and surfaces of the unhardened concrete. Such
protective materials shall consist of rolled polyethylene sheeting at least 4 mils
(0.1 mm) thick of sufficient length and width to cover the plastic concrete slab
and any edges. The sheeting may be mounted on either the paver or a separate
movable bridge from which it can be unrolled without dragging over the plastic
concrete surface. When rain appears imminent, all paving operations shall stop
and all available personnel shall begin cover the surface of the unhardened
concrete with the protective covering.

6.6.14 Opening to Traffic

The Engineer shall decide when the pavement shall be opened to traffic. The
pavement will not be opened to traffic until test specimens molded and cured in
accordance with ASTM C31 have attained a flexural strength of 550 pounds per
square inch (3.792 MPa) when tested in accordance with ASTM C78. If such
tests are not conducted, the pavement shall not be opened to traffic until 14 days
after the concrete was placed. Prior to opening to traffic, the pavement shall be
cleaned.

6.6.15 Surface Tolerances

Extreme care must be exercised in all phases of the operation to assure the
pavement will pass the specified tolerances. The following tolerances are
applicable:

a) Lateral deviation from established alignment of the pavement

edge shall not exceed plus or minus 30 mm in any lane.

Construction of Bridge at Korangi Causeway 2300-28 Plain & Reinforced

Concrete
 b) Vertical deviation from established grade shall not exceed plus
or minus 12mm at any point.

c) Surface smoothness deviations shall not exceed 6 mm from a

5m straight edge placed in any direction, including placement
along and spanning any pavement joint or edge. Contractor
shall provide rolling straight edge with / without recording
arrangements, if so required by the Engineer without any extra
financial implication

6.6.16 Tolerance in Pavement Thickness

Areas found deficient in thickness by more than 1.0 inch (25 mm) shall be
evaluated by the Engineer and, if the deficient areas warrant removal, they shall
be removed and replaced with concrete of the thickness shown on the plans.

6.7 Embedded Items

6.7.1 Suitable templates or instructions or both shall be provided for setting out items
not placed in the forms. Embedded items and other materials for electrical,
mechanical or other operations shall have been completed, inspected tested and
approved before concrete is placed.

Joints at intersections and at ends of pieces shall be made in the manner most
appropriate to the material being used. Joints shall develop effective water-
tightness fully equal to that of the continuous waterstop material, shall
permanently develop mechanical strength not less than that of the parent
section, and shall permanently retain their flexibility.

6.7.2 Electric conduits and other pipes which are planned to be embedded shall not,
with their fittings, displace more than four percent of the area of the cross section
of a column on which stress is calculated or which is required for fire protection.
Sleeves, conduits, or other pipes passing through floors, walls, or beams shall
be of such size or in such location as not to impair unduly the strength of the
construction; such sleeves, conduits, or pipes may be considered as replacing
structurally in compression the displaced concrete, provided that they are not
exposed to rusting or other deterioration, are of uncoated or galvanized iron or
steel not thinner than standard steel pipe, have a nominal inside diameter not
over 50mm and are spaced not less than three diameters on centres. Except
when plans of conduits and pipes are approved by the Engineer, embedded
pipes and conduits other than those merely passing through, shall not be larger
in outside diameter than one third the thickness of the slab, wall, or beams in
which they are embedded nor so located as to impair unduly the strength of the
construction. Sleeve pipes, or conduits of any material not harmful to concrete
and within the limitations of this section may be embedded in concrete with the
approval of the Engineer provided they are not considered to replace the
displaced concrete.

6.7.3 All sleeves, inserts, anchors, and embedded items required for adjoining work or
for its support shall be placed prior to concreting.

All Contractors whose work is related to the concrete or must be supported by it

shall be given ample notice and opportunity to introduce and/or furnish
embedded items before the concrete is placed.

6.7.4 Expansion joint material, waterstops and other embedded items shall be
positioned accurately and supported against displacement. Voids in sleeves,
inserts, and anchor slots shall be filled temporarily with approved readily
removable material to prevent the entry of concrete into the voids.

Construction of Bridge at Korangi Causeway 2300-29 Plain & Reinforced

Concrete
 6.7.5 Non Shrink Grout

Grout of placement under base and bearing plates of steel, machinery and
equipment, for grouting anchor bars and dowels and for similar uses shall be as
specified. The grout shall be used in accordance with the following and as per
manufacturer's recommendations, and as directed by the Engineer.

Concrete surfaces to receive non-shrink grout shall be roughened, cleaned and

dampened. Form shall be provided to retain the grout until sufficiently hard to
support itself. Grout shall be poured in place and thoroughly rodded or strapped
to prevent air entrapment and formation of voids. After non-shrink grout has
received its initial set, it shall be kept damp for at least 24 hours.

TABLE I: Gradation of Concrete Aggregates

Percentage by Weight Passing

Coarse Fine

-------------------------------------------------------------------------------------------
Particle Size Square 19 mm 25 mm 37.5 mm 50 m
Openings (Equivalent to to to to (Sand)
U.S. Sieve Designation) 5 mm 5 mm 19 mm 25 mm
---------------------------------------------------------------------------------------------------------------------------------
¾"-No.4 1"-No.4 1½ "-3/4" 2"-1"

63.0 mm (2 1/2 in.) - - - 100 -

50.0 mm (2 in.) - - 100 90 – 100 -

37.5 mm (1 1/2 in.) - 100 90 - 100 35 – 70 -

25.0 mm (1 in.) 100 95 - 100 20 - 55 0 - 15 -

9.0 mm (3/4 in.) 90 –100 - 0 - 15 - -

12.5 mm (1/2 in.) - 25 - 60 - 0-5 -

09.5 mm (3/8 in.) 20 - 55 - 0-5 - 100

05.0 mm (No.4) 0 - 10 0 - 10 - - 95-100

2.36 mm (No. 8) 0-5 0-5 - - 80-100

1.18 mm (No. 16) - - - - 50 - 85
0.60 mm (No. 30) - - - - 25 - 60
0.30 mm (No. 50) - - - - 5 - 30
0.15 mm (No. 100) - - - - 0 - 10
---------------------------------------------------------------------------------------------------------------------------------

Construction of Bridge at Korangi Causeway 2300-30 Plain & Reinforced

Concrete
 TABLE II: Gradation of Combined Course and Fine Aggregates for Concrete

Particle Size Square Percentage by Weight Passing Sieves

Openings (Equivalent Maximum Aggregate Size
U.S. Sieve Designation) 50mm 37.5mm 25mm 19mm 9.5mm
------------------------------------------------------------------------------------------------------------------------------
63.00 mm (2 1/2 in.) 100 - - - -

50.00 mm (2 in.) 90 - 100 100 - - -

37.05 mm (1 1/2 in.) 70 – 90 90-100 100 - -

25.00 mm (1 in.) 50 - 75 50 - 86 90 - 100 100 -

19.00 mm (3/4 in.) 45 - 70 45 - 75 55 - 100 90 -100 -

12.05 mm (1/2 in.) - - - - 100

09.05 mm (3/8 in.) 38 - 55 38 - 55 45 - 75 60 - 80 90 - 100

05.00 mm (No. 4) 30 - 45 30 - 45 35 - 60 40 - 60 50 - 85

02.36 mm (No. 8) 22 - 35 23 - 38 27 - 45 30 - 45 37 - 52

01.18 mm (No. 16) 15 - 27 17 - 33 20 - 35 20 - 35 25 - 40

00.60 mm (No. 30) 10 - 18 10 - 22 12 - 25 13 - 23 15 - 25

00.30 mm (No. 50) 4 - 10 4 - 10 5 - 15 5 – 15 5 - 15

00.15 mm (No. 100) 1-3 1-3 1-5 1- 5 1- 5

0.075 mm (No. 200) 0-2 0-2 0-2 0-2 0-2

------------------------------------------------------------------------------------------------------------------------------

TABLE III : Quality Tests For Aggregates

Material Test Requirement Test Designation

Coarse Abrasion Loss 40% max. ASTM C 131

Coarse Absorption 2.0% max. ASTM C 127

Coarse Clay Lumps 1.0% max. ASTM C 142

Coarse Surface Coating 0.5% max. ASTM C 117

Coarse and Fine Soundness Loss 10% max. ASTM C 88

Coarse and Fine Sieve As specified ASTM C 136

Fine Absorption 4.0% max. ASTM C 128

Coarse Cleanness 75% min. CALIF 227

Fine Sand equivalent 70% min. CALIF 217

Construction of Bridge at Korangi Causeway 2300-31 Plain & Reinforced

Concrete
6.8 Concrete for Structures

6.8.1 Placing

6.8.1.1 Before placing of concrete, formwork shall have been completed; water shall
have been removed; reinforcement shall have been secured in place; expansion
joint material, anchors and other embedded items shall have been kept in
position; and the entire preparation shall have been approved.

No concrete shall be placed into the foundation pits and trenches until the
ground to receive the same has been examined and approved by the Engineer
for this purpose.

6.8.1.2 Concrete shall be deposited continuously, or in layer of such thickness that no

concrete will be deposited on concrete which has hardened sufficiently to cause
the formation of seams or planes of weakness within the section. If a section
cannot be placed continuously, construction joints shall be located as shown in
the Contract Documents or as approved by the Engineer. Placing shall be
carried out at such a rate that the concrete, which is being integrated with fresh
concrete, is still plastic. Concrete, which has partially hardened, shall not be
deposited. Temporary spreaders in forms shall be removed when the concrete
placing has reached an elevation rendering their services unnecessary. They
may remain embedded in the concrete only if made of metal or concrete and if
prior approval has been obtained.

6.8.1.3 The actual sequence of construction proposed by the Contractor shall be subject
to the Engineer's approval before construction starts on any part of the structure,
and this sequence shall not be varied without the Engineer's approval.

6.8.1.4 The concrete shall be placed as soon after it has been mixed as is practicable.
Once the concrete has left in the mixer, no more water shall be added, although
the concrete may be mixed or agitated to help maintain workability. The concrete
shall not be used if, through any cause, the workability of the mix at the time of
placing is too low for it to be compacted fully and to an acceptable finish by
whatever means available.

The time between mixing and placing should be reduced if the mix is richer or
the initial workability of the mix is lower than normal, if a rapid hardening cement
or an accelerator is used, or if the work is carried out at a high temperature or
exposed to a drying atmosphere.

The Contractor shall ensure that the delay between mixing and placing does not
exceed 45 minutes under any circumstances. Any concrete, which does not
satisfy this requirement shall be discarded.

6.8.1.5 Concrete shall be deposited as nearly as possible in its final position to avoid re-
handling. In no circumstances may concrete be railed or made to flow along the
forms by the use of vibrators. Concreting shall be carried on as a continuous
operation using methods, which shall prevent segregation or loss of ingredients.

6.8.1.6 The free fall of concrete shall not be allowed to exceed two metre and where it is
necessary for the concrete to be placed more than this depth, it shall not be
dropped into its final position, but shall be placed through pipes fed by a hopper.
When a pipe is used for placing concrete the lower end shall be kept inside, or
close to the freshly deposited concrete. The diameter of the pipe shall be not
less than 225 mm.

6.8.1.7 Workmen carrying concrete to the site, and all other workmen, shall move only
along runways or planks placed for the purpose and no person shall be allowed
to walk on the reinforcement.

Construction of Bridge at Korangi Causeway 2300-32 Plain & Reinforced

Concrete
 6.8.2 Consolidation

6.8.2.1 All concrete shall be consolidated by vibration, spading, rodding or forking so

that the concrete is thoroughly worked around the reinforcement, around
embedded items, and into corners of forms, eliminating all air or stone pockets
which may cause honeycombing, pitting, or planes of weakness. Only competent
workmen shall operate vibrators. Use of vibrators to transport within forms shall
not be allowed.

Vibrators shall be inserted and withdrawn at points approximately 450 mm apart.

At each insertion, the duration shall be sufficient to consolidate the concrete but
not excessive so as to cause segregation, generally from 5 to 15 sec. A spare
Vibrator shall be kept on the job site during all concrete placing operations.
Where the concrete is to have an as-cast finish, a full surface of mortar shall be
brought against the form by the vibration process, supplemented, if necessary,
by spading to work the coarse aggregate back from the formed surface.

6.8.2.2 If there is any tendency for the mix to segregate during consolidation, particularly
if this produces excessive laitance, the mix proportions shall be modified to
effect an improvement in the quality of the concrete to the satisfaction of the
Engineer and in conformity with the provisions of Clause 5.

6.8.2.3 Vibrator shall not be allowed to contact the formwork for exposed concrete
surfaces.

6.8.2.4 Mechanical vibrators shall be of a type approved by the Engineer to suit

particular conditions.

6.8.2.5 Over-vibration or vibration of very wet mixes shall be avoided.

6.8.3 Curing and Protection

6.8.3.1 Beginning immediately after placement, concrete shall be protected from

premature drying, excessively hot or cold temperatures and mechanical injury,
and shall be maintained with minimum moisture loss at a relative constant
temperature for the period necessary for hydration of the cement and hardening
of the concrete. The materials and methods of curing shall be subject to
approval of the Engineer.

6.8.3.2 For concrete surfaces not in contact with forms, one of the following procedures
shall be applied immediately after completion of placement and finishing, as
approved by the Engineer.

- Ponding or continuous sprinkling.

- Application of absorptive mats or fabric kept continuously wet.

- Application of waterproof sheet materials approved by the Engineer.

- Application of other moisture-retaining covering as approved.

- Application of a curing compound conforming to ASTM C309.

The compound shall be applied in accordance with the recommendations of the

manufacturer. It shall not be used on any surface against which additional
concrete or other material is to be bonded unless it is proved that the curing
compound will not prevent bond, or unless positive measures are taken to
remove it completely from areas to receive bonded applications.

Construction of Bridge at Korangi Causeway 2300-33 Plain & Reinforced

Concrete
 6.8.3.3 Moisture loss from surface placed against wooden forms or metal forms, and
exposed to heating by the sun, shall be minimized by keeping the forms wet until
they can be safely removed. After form removal, the concrete shall be cured
until the end of the time prescribed as follows by one of the methods specified
above.

6.8.3.4 Curing in accordance with sub-clauses above shall be continued for at least
10 days in the case of all concrete except concrete with rapid-hardening
Portland Cement, for which the period shall be at least 3 days. Alternatively, if
tests are made of cubes kept adjacent to the structure and cured by the same
methods and to the same intensity, moisture retention measures may be
terminated when the average compressive strength has reached 70 percent of
the minimum specified works cube strength. If one of the first four curing
procedures specified above is used initially, it may be replaced by one of the
other specified procedures any time after the concrete is one day old provided
the concrete is not permitted to become surface dry during the transition.
o O
6.8.3.5 When the mean daily outdoor temperature is less than 5 C (41 F), temperature
o o O O
of the concrete shall be maintained between 10 C to 20 C (50 F-68 F) for the
required curing period specified above.

When necessary, arrangements for heating, covering insulation or housing the

concrete work shall be made in advance of placement and shall be adequate to
maintain the required temperature with measures to avoid concentration of heat.
Combustion heaters shall not be used during the first 24 hours, unless
precautions are taken to prevent exposure of the concrete to exhaust gasses,
which contain carbon dioxide.

6.8.3.6 When necessary, provision for wind-breaks, shading, spraying, sprinkling,

ponding or wet covering with a light coloured material shall be made in advance
of placement, and such protective measures shall be taken as quickly as
concrete hardening and finishing operation will allow.

6.8.3.7 Changes in temperature of the air immediately adjacent to the concrete during
and immediately following the curing period shall be kept as uniform as possible
o O o O
and shall not exceed 3 C (37.4 F) in any one hour or 10 C (30 F) in any 24
hour period.

6.8.3.8 Concrete shall be protected from damaging mechanical disturbances, such as

load stresses, heavy shock and excessive vibrations, during the curing period.
All finished concrete surfaces shall be protected from damage by construction
equipment, materials or methods by application of curing procedures, and by
rain or running water. Self-supporting structures shall not be loaded in such a
way as to overstress the concrete.

6.8.4 Works in Extreme Weather

6.8.4.1 Unless adequate protection is provided, and approval is obtained, concrete shall
not be placed during rain.

Rain water shall not be allowed to increase the mixing water nor to damage the
surface finish.
O o
6.8.4.2 When the temperature of the surrounding air is expected to be below 5 C (41 F)
during placing or within 24 hours thereafter, the temperature of the plastic
O o
concrete, as placed, shall be no lower than 13 C (55.4 F) for sections less than
O o
300 mm in any dimensions nor 10 C (50 F) for any other sections.

When necessary, concrete material should be heated before mixing and

carefully protected after placing. In general, heating of mixing water alone to

Construction of Bridge at Korangi Causeway 2300-34 Plain & Reinforced

Concrete
 O o
about 60 C (140 F) may be sufficient for this purpose. Calcium chloride up to a
maximum of 1-1/2 percent of the weight of cement may be used to accelerate
the rate of hardening only with prior written permission of the Engineer. Use of
calcium chloride in excess of 1-1/2 percent is harmful. No frozen material or
concrete damaged by frost shall be removed. It is recommended that concrete
exposed to the action of freezing weather should have entrained air and the
water content of the mix should not exceed 25 litres per bag of cement.
O o
If water or aggregate is heated above 38 C (100 F), the water shall be combined
with the aggregate in the mixer before cement is added. Cement shall not be
mixed with water or with mixtures of water and aggregate having a temperature
O o
greater than 38 C (100 F).

6.8.4.3 During hot weather, the temperature of the concrete as placed shall not be so
high as to cause difficulty from loss of slump, flash set, or cold joints and should
O o
not exceed 32 C (90 F). For mass concreting, this temperature should not
O o O
exceed 21 C (70 F). When the temperature of the concrete exceeds 32 C
o
(90 F), precautionary measures approved by the Engineer shall be put into
O o
effect. When the temperature of the steel is greater than 50 C (122 F), steel
forms and reinforcement shall be sprayed with water just prior to placing the
concrete. The ingredients shall be cooled before mixing, or ice flakes,
or well crushed ice may be substituted for all part of the mixing water if, due to
high temperature, low slump, flash set or cold joints are encountered.

Other precautions recommended by ACI Standard 305 shall also be adopted.

6.8.5 Construction Joints

6.8.5.1 Concreting shall be carried out continuously up to construction joints, the

position and arrangement of which shall be approved by the Engineer.

6.8.5.2 Joints not shown on the drawings shall be so made and located as to least
impair the strength of the structures and shall need prior approval of the
Engineer. In general, they shall be located near the middle of the spans of slabs
and beams unless a secondary beam intersects a main beam at this point, in
which case the joint in the main beam shall be offset a distance equal to twice
the width of the secondary beam. Joints in walls and columns shall be at the
underside of floor slabs or beams, and at the top of footings or floor slabs.
Beams, brackets, column capitals, haunches and drop panels shall be placed at
the same time as slabs. Joints shall be placed at the same time as slabs. Joints
shall be perpendicular to the main reinforcement.

6.8.5.3 Reinforcing steel shall continue across the joints. Key and inclined dowels shall
be provided as, and where directed by Engineer. Longitudinal keys at least
40mm (1-1/2”) deep shall be provided in all joints in walls and between walls and
slabs or footings.

6.8.5.4 When the work has to be resumed on a surface which has hardened, such
surface shall be roughened in an approved manner which will expose the
aggregate uniformly and will not leave laitance, loosened particles of aggregate
or damaged concrete at the surface.

6.8.5.5 The hardened concrete of construction joints and of joints between footings and
walls or columns, between walls or columns and beams or floors they support,
joints in un-exposed walls and all others not mentioned herein shall be
dampened (but not saturated) immediately prior to placing of fresh concrete.

6.8.5.6 The hardened concrete of joints in exposed work, joints in the middle of beams,
and slabs; and joints in work designed to contain liquids shall be dampened (but
not saturated) and then thoroughly covered with a coat of cement grout similar in

Construction of Bridge at Korangi Causeway 2300-35 Plain & Reinforced

Concrete
 proportions to the mortar in the concrete. The grout shall be as thick as possible
on vertical surfaces and at least 12 mm thick on horizontal surfaces. The fresh
concrete shall be placed before the grout has attained initial set.

6.8.5.7 When the concrete has not fully hardened, all laitance shall be removed by
scrubbing the wet surface with wire or bristle, and brushed, care being taken to
avoid dislodgement of particles of aggregate. The surface shall then be coated
with neat cement grout. The first layer of concrete to be placed on this surface
shall not exceed 150 mm in thickness, and shall be well rammed against old
work, particular attention being paid to corners and closed spots.

6.8.5.8 Stop ends for movement joints or construction joints shall be made by splitting
them along the lines of reinforcement passing through them, so that each portion
can be positioned and removed separately without disturbance or shock to the
reinforcement or the concrete. Stop ends made of expanded metal or similar
material may only be left permanently in the concrete with prior written approval
of the Engineer. Where such stop ends are used, no metal may be left
permanently in the concrete closer to the surface of the concrete than the
specified cover to the reinforcement. Wood strips inserted for architectural
treatment shall be kerfed to permit swelling without pressure on the concrete.

6.8.7 Expansion Joints

Expansion joints shall be provided wherever indicated on the Drawings or as

directed by the Engineer. In no case shall the reinforcement, or other embedded
items be run continuous or through an expansion joint. All expansion joints shall
be carefully placed so as not to be displaced during concreting. The method of
placing the expansion joints shall be strictly in accordance with the Drawings
and/or as directed by the Engineer. All materials for use in the expansion joints
shall have, prior approval of the Engineer before placing order for supply.

6.8.8 Embedded Items

6.8.8.1 Sleeves, inserts, anchors, and embedded items required for adjoining work or for
its support shall be placed prior to concreting.

All contractors whose work is related to the concrete or must be supported by it

shall be given ample notice and opportunity to introduce and/or furnish
embedded items before the concrete is placed.

6.8.8.2 All embedded items shall be positioned accurately and supported against
displacement. Voids in sleeves, inserts, and anchor slots shall be filled
temporarily with approved readily removable material to prevent the entry of
concrete into the voids.

7.0 FINISHING OF FORMED SURFACES

7.1 General

7.1.1 After removal of forms, the surfaces of concrete shall be given one or more of
the finishes specified below in locations designated by the Contract Documents.

7.1.2 When finishing is required to match a small sample furnished to the Contractor,
the sample finish shall be reproduced on an area at least 10 square metres (100
Sq.ft.) in an inconspicuous location Designated by the Engineer before
proceeding with the finish in the specified location.

7.1.3 Allowable deviations from plumb or level and from the alignment, profile grades,
and dimensions are specified in Clause 9. Tolerances for concrete construction
defined as ‘tolerances’, are to be distinguished from irregularities in finish as

Construction of Bridge at Korangi Causeway 2300-36 Plain & Reinforced

Concrete
 described herein. The finish requirements for concrete surfaces shall be as
generally specified in this clause and as indicated on the Drawings. Finishing of
concrete surfaces shall be performed only by workmen who are skilled in
concrete finishes. The Contractor shall keep the Engineer informed as to when
finishing of concrete will be performed. Unless inspection is waived in each
specific case, finishing of concrete shall be performed only in the presence of the
Engineer. Concrete surfaces will be tested by the Engineer where necessary to
determine whether surface irregularities are within the limits herein after specified.

Surface irregularities are classified as abrupt or gradual. Offsets caused by

displaced or misplaced form sheathing or lining or sections, or otherwise
defective form lumber will be considered as abrupt irregularities, and will be
tested by direct measurements. All other irregularities will be considered as
gradual irregularities, and will be tested by use of a template, consisting of a
straight edge or the equivalent thereof for curved surfaces. The length of the
template will be 2 metres (6 ft.) for testing of formed surfaces and 3 metres (10
feet) for testing of unformed surfaces.

7.2 As-cast Finishes

Unless otherwise specified or indicated on the Drawings the classes of finish shall apply
as follows:

7.2.1 Rough form finish:

No selected form facing materials shall be specified for rough form finish surfaces. The
holes and defects shall be patched. Fins exceeding 5 mm (1/4”) in height shall be
chipped off or rubbed off. Otherwise, surfaces shall be left with the texture imparted by
the forms.

7.2.2 Fair face finish:

Fair face finish applies to concrete formed surfaces, the appearance of which is
considered by the Engineer to be of special importance, such as surfaces of structures
prominently exposed to public view. Location of surfaces of concrete structures requiring
fair face finish are shown in the Drawings. Surface irregularities, measured as described
in sub-clause 7.2.1, 'Rough form finish', shall not exceed 5 mm (1/4”) for gradual
irregularities and 2.5 mm (1/8”) for abrupt irregularities, except that abrupt irregularities
will not be permitted at construction joints. Abrupt irregularities at construction joints and
elsewhere in excess of 2.5 mm (1/8”) and gradual irregularities in excess of 5 mm (1/4”)
shall be reduced by grinding so as to conform to the specified limits. Abrupt irregularities
at construction joints shall be ground on 1 to 20 ratio of height to length.

Unless otherwise approved, repair of imperfections in formed concrete shall be

completed within 24 hours after removal of forms. The form facing material shall produce
a smooth, hard, uniform texture on the concrete. It may be plywood, hardboard, metal,
plastic paper, or other approved material capable of producing the desired fair face
finish. The arrangement of the facing material shall be orderly and symmetrical, with the
number of seams kept to the practical minimum. It shall be supported by studs or other
backing capable of preventing excessive deflection. Material with raised grain, torn
surfaces, worn edge, patches, dents, or other defects, which will impair the texture of the
concrete surface shall not be used. The holes and defects shall be patched. All fins shall
be completely removed.

8.0 REPAIR OF DEFECTS

8.1 General

8.1.1 Any concrete failing to meet the specified strength or not formed as shown on
drawings, concrete out of alignment, concrete with surfaces beyond required

Construction of Bridge at Korangi Causeway 2300-37 Plain & Reinforced

Concrete
 tolerances or with defective surfaces which cannot be properly repaired or
patched in the opinion of the Engineer shall be removed at Contractor's cost.

The Engineer may reject any defective concrete and order it to be cut out in part
or in whole and replace at the Contractor's expense.

8.1.2 All ties, bolt holes, and all repairable defective areas shall be patched
immediately after form removal.

8.2 Repair of Defective Areas

8.2.1 Defective and honeycombed concrete shall be removed down to sound

concrete. The area to be patched and an area at least 150 mm (6”) wide
surrounding it shall be dampened to prevent absorption of water from the
patching mortar. A bonding grout shall be prepared using a mix of approximately
1 part cement to 1 part fine sand passing No.25 BS Sieve and shall then be well
brushed into the surface.

8.2.2 The patching mixture shall be made of the same material and of approximately
the same proportions as used for the concrete, except that the coarse aggregate
shall be omitted and the mortar shall consist of not less than 1 part cement to
2-1/2 parts sand by weight. White Portland cement shall be substituted for a part
of the gray Portland cement on exposed concrete in order to produce a colour
matching the color of the surrounding concrete, as determined by a trial patch.

8.2.3 The quantity of mixing water shall be no more than necessary for handling and
placing. The patching mortar shall be mixed in advance and allowed to stand
with frequent manipulation with a trowel, without addition of water, until it has
reached the stiffest consistency that will permit placing.

8.2.4 After surface water has evaporated from the area to be patched, the bond coat
shall be well brushed into the surface. When the bond coat begins to loose the
water sheen, the premixed patching mortar shall be applied. The mortar shall be
thoroughly consolidated into place and struck off so as to leave the patch slightly
higher than the surrounding surface to permit initial shrinkage; it shall be left
undisturbed for at least 1 hour before being finally finished. The patched area
shall be kept damp for at least 7days. Metal tools shall not be used in finishing a
patch in a formed wall, which will be exposed.

8.2.5 Where as-cast finishes are specified, the quantity of patched area shall be
strictly limited. The combined total of patched areas in as-cast surfaces shall not
exceed 0.2 square metre in each 100 square metres of as-cast surface. This is
in addition to form tie patches, if the project design permits ties to fall within as-
cast areas.

8.2.6 Any patches in as-cast architectural concrete shall be indistinguishable from

surrounding surfaces. The mix formula for patching mortar shall be determined
by trail to obtain a good colour match with the concrete when both patch and
concrete are cured and dry. After initial set, surfaces of patches shall be dressed
manually to obtain the same texture as surrounding surfaces.

8.2.7 Patches in architectural concrete surfaces shall be cured for at least 7 days.
Patches shall be protected from premature drying to the same extent as the
body of the concrete.

8.3 Tie and Bolt Holes

After being cleaned and thoroughly dampened, the tie and bolt holes shall be filled solid
with patching mortar. If architectural appearance requires, these holes may be filled
partially creating the desired round clear holes pattern on surfaces exposed to view.

Construction of Bridge at Korangi Causeway 2300-38 Plain & Reinforced

Concrete
8.4 Proprietary Materials

If permitted or required by the Engineer, proprietary compounds for adhesion or as

patching ingredients may be used in lieu of or in addition to the foregoing patching
procedures. Such compounds shall be used in accordance with the manufacturer's
recommendations with prior approval of the Engineer.

9.0 CONCRETE CONSTRUCTION TOLERANCES

All tolerances shall be as per ACI 117.

Where tolerances are not stated in the specifications or drawings for any individual
structure or feature thereof, maximum permissible deviations from established lines,
grades, and dimensions shall conform to the following. The Contractor is expected to set
and maintain concrete forms so as to ensure complete work within tolerance limits.
These allowable tolerances shall not relieve the Contractor of his responsibility for
correct fitting of indicated materials and components. These tolerances are not
cumulative.

9.1 Variation from the plumb (or the specified batter for inclined walls). (allowable variation)

9.1.1 In the lines and surfaces of columns and walls, and in arises

In any 3 metres (10’) of length or height 6 mm (1/4”)

Maximum for the entire length or height 25 mm (1”)

9.1.2 For exposed corner columns, control joint grooves and other conspicuous lines

In any bay or 6 metres (20’) maximum 6 mm (1/4”)

Maximum for the entire length or height 13 mm (1/2”)

9.2 Variation from the level or from the grades indicated on the drawings.

In beam soffits, and in arises measured before removal of supporting shores.

In any 3 metres (10’) of length 6 mm (1/4”)

In any bay or in any 6 metres (20’) maximum 10 mm (3/8”)

Maximum for the entire length 19 mm (3/4”)

9.3 Variation of the linear structure lines from established position in plan and related
position of columns and walls.

In any bay or 6 metres (10’) + 13 mm (+ ½”)

Maximum for the entire length + 25 mm (+ 1”)

9.4 Variation in cross-sectional dimensions of columns and beams and in the thickness of
slabs and walls.

Up to 12" (300mm) - 6 mm (-1/4”)

+10 mm (+3/8”)

More than 12" (300mm) - 10 mm (-3/8”)

+13 mm (+1/2”)

Construction of Bridge at Korangi Causeway 2300-39 Plain & Reinforced

Concrete
9.5 Footings

9.5.1 Variation in dimensions in plan - 13mm (-1/2”)

Plus (plus variation applied to concrete only,

not to the reinforcing bars or dowels).
(formed) + 50mm (+2”)

9.5.2 Misplacement or eccentricity

2 percent of the footing width in the

direction of misplacement but not more
than (applies to concrete only, not to
reinforcing bars or dowels). + 50mm (+2”)

9.5.3 Reduction in thickness

Minus 5 percent of specified thickness - 5%

10.0 ACCEPTANCE OF STRUCTURE

10.1 General

10.1.1 Completed concrete work, which meets all applicable requirements will be
accepted subject to the other terms of the Contract Documents.

10.1.2 Completed concrete work, which fails to meet one or more of the requirements
and which has been repaired to bring it into compliance will be accepted subject
to the other terms of the Contract Documents.

10.1.3 Completed concrete work, which fails to meet one or more of the requirements
and which cannot be brought into compliance may be accepted or rejected as
provided in these Specifications or in the Contract Documents. In this event,
modifications may be required to assure that remaining work complies with the
requirements.

10.2 Dimensional Tolerances

10.2.1 Formed surfaces resulting in concrete outlines smaller than permitted by the
tolerances of clause 9 shall be considered potentially deficient in strength and
subject to the provisions of sub clause 10.4.

10.2.2 Formed surfaces resulting in concrete outlines larger than permitted by the
tolerances of clause 9 may be rejected and the excess material shall be subject
to removal. If removal of the excess material is permitted, it shall be
accomplished in such a manner as to maintain the strength of the section and
to meet all other applicable requirements of function and appearance.
Permission is required if excess material is to be removed in accordance with
this clause.

10.2.3 Concrete members cast in the wrong location may be rejected if the strength,
appearance or function of the structure is adversely affected as decided by the
Engineer or if misplaced items interfere with other construction.

10.2.4 Inaccurately formed concrete surfaces exceeding the limits of Clause 9 or of

Clause 5.5 of Section 'Formwork' shall be removed and replaced, and those that
are exposed to view, may be rejected, or shall be repaired, or removed and
replaced, as directed by the Engineer.

Construction of Bridge at Korangi Causeway 2300-40 Plain & Reinforced

Concrete
10.3 Appearance

10.3.1 Architectural concrete with surface defects exceeding the limitations described in
relevant Clauses of this section shall be removed and replaced.

10.3.2 Other concrete exposed to view with defects which adversely affect the
appearance of the specified finish may be repaired only by approved methods.

10.3.3 Concrete not exposed to view is not subject to rejection for reason of defective
appearance.

10.4 Strength of Structure

10.4.1 Strength of the structure in place will be considered potentially deficient if it fails
to comply with any requirement which is relevant to the strength of the structure,
including but not necessarily limited to the following conditions:

- Concrete strength requirements not considered to be satisfied in accordance

with Clause 6 hereof.
- Reinforcing steel size, quantity, strength, position or arrangement at variance
with the requirements as specified under section 'Reinforcement' in the
Contract Documents.
- Concrete, which differs from the required dimensions or location in such a
manner as to reduce the strength.
- Curing less than that specified.
- Inadequate protection of concrete from extremes of temperature during early
stages of hardening and strength development.
- Mechanical injury, construction fires, premature removal of formwork, likely to
result in deficient strength.
- Poor workmanship likely to result in deficient strength.

10.4.2 Structural computations and/or additional testing may be required when the
strength of the structure is considered potentially deficient.

10.4.3 Core tests may be required when the strength of the concrete in place is
considered deficient.

10.4.4 If core tests are inconclusive or impractical to obtain or if structural computations

do not confirm the safety of the structure, load tests may be required and their
results evaluated, in accordance with ACI Standard 318.

10.4.5 Concrete work judged inadequate by structural computations or by results of a

load test shall be reinforced with additional construction, if so directed by the
Engineer or shall be replaced, at the Contractor's expense.

10.4.6 The Contractor shall bear all costs incurred in providing the additional testing
and/or computations required by this section.

Construction of Bridge at Korangi Causeway 2300-41 Plain & Reinforced

Concrete
11.0 MEASUREMENT AND PAYMENT

11.1 General

Except otherwise specified herein or elsewhere in the Contract Documents, no

measurement and payment will be made for the under mentioned specified works related
to the relevant items of the Bill of Quantities. The cost thereof shall be deemed to have
been included in the quoted unit rate of the respective items of the Bill of Quantities.

11.1.1 All types of formwork.

11.1.2 All types of expansion, construction and contraction joints including joint fillers,
sealant, caps & grease.
11.1.3 All sampling, mixing and testing as specified.
11.1.4 Concrete mix design.
11.1.5 Vapour barrier.
11.1.6 Impervious sheeting, burlap covering, liquid membranes compound, additives,
admixtures, non-shrink grout, epoxy resins and water stops.
11.1.7 Anchor bolts and other embedded parts.
11.1.8 All submittals including shop drawings, co-ordination drawings etc.
11.1.9 Repair and replacement of defective work.
11.1.10 Surface texture, skid resistant surfaces & surface test.
11.1.11 Curing
11.1.12 Installation / fixing in position of all precast / prefabricated concrete elements, as
shown on drawings.
11.1.13 Tie bars, dowel bars, dowel bar sleeves and welded wire mesh.
11.1.14 Providing and laying Duracrete fiber or equivalent as specified.

11.2 Plain and Reinforced Concrete (Except Railing)

11.2.1 Measurement

Measurement of acceptably completed works of respective type of plain and

reinforced concrete will be made on the basis of actual volume in cubic meter of
concrete actually provided, placed, consolidated, finished, cured in position,
complete as shown on drawings or as directed by the Engineer.

11.2.2 Payment

Payment will be made for acceptable measured quantity of plain and reinforced
concrete on the basis of unit rate per cubic meter quoted in the Bill of Quantities
and shall constitute full compensation for all the works related to the item.

11.3 Non-Shrink grout

11.3.1 Measurement

Measurement of acceptably completed works of Non-Shrink grout will be made

on the basis of actual volume in cubic meter of Non-Shrink grout actually
provided and placed in position as shown on drawings or as directed by the
Engineer.

11.3.2 Payment

Payment will be made for the acceptable measured quantity of Non-Shrink grout
on the basis of unit rate per cubic meter quoted in the Bill of Quantities and shall
constitute full compensation for all the works related to the item.

Construction of Bridge at Korangi Causeway 2300-42 Plain & Reinforced

Concrete
11.4 RCC Edge Barrier

11.4.1 Measurement

Measurement of acceptably completed works of RCC Edge Barrier including

reinforcement will be made on the basis of actual length in running meter of RCC
Edge Barrier actually provided and placed in position as shown on drawings or
as directed by the Engineer.

11.4.2 Payment

Payment will be made for the acceptable measured quantity of RCC Edge
Barrier on the basis of unit rate per running meter quoted in the Bill of Quantities
and shall constitute full compensation for all the works related to the item.

11.5 Noise/Visual barrier

11.5.1 Measurement

Measurement of acceptably completed works of Providing and fabrication,

erection of noise/visual barrier including primary column, grits and aluminum
panel 0.7mm thick conforming to ASTM D209 including fixing and all other
accessories required for installation and fixing complete in all respect will be
made on the basis of actual length in running meter of Barrier actually provided
and placed in position as shown on drawings or as directed by the Engineer.

11.5.2 Payment

Payment will be made for the acceptable measured quantity of noise/visual

barrier on the basis of unit rate per running meter quoted in the Bill of Quantities
and shall constitute full compensation for all the works related to the item.

11.6 Gantry of Steel Pipe

11.6.1 Measurement

Measurement of acceptably completed works of Height Restriction Gantry of

Steel pipe (schedule 80) structure with laminated refractive sheet of 3-3.5m high
for Clearance and 13.5m wide located near round about. Including all cost
incurred in the civil works for installation as per the specifications and directions
of the engineer complete in all respect will be made on the basis of lump sum
actually provided and placed in position as shown on drawings or as directed by
the Engineer.

11.6.2 Payment

Payment will be made for the acceptable measured quantity of Height

Restriction Gantry on the basis of lump sum quoted in the Bill of Quantities and
shall constitute full compensation for all the works related to the item.

11.7 Reinforced Concrete for Pile

17.4.1 Measurement

Measurement of acceptably completed works of reinforced cement concrete in

piles shall be made on the basis of running meter measured from the cut-off
level to the tip of pile.

Construction of Bridge at Korangi Causeway 2300-43 Plain & Reinforced

Concrete
 17.4.2 Payment

Payment will be made for acceptable measured quantity of reinforced cement

concrete in piles on the basis of unit rate per running meter quoted in the Bill of
Quantities and shall constitute full compensation for all the works related to the
item.

*** End of Section 2300***

Construction of Bridge at Korangi Causeway 2300-44 Plain & Reinforced

Concrete
 SECTION 2315

EXPANSION JOINTS

1.0 SCOPE

The work under this section of the specification consists of furnishing all plant,
labour, equipment, appliances and materials and in performing all operations in
connection with the supply, manufacture, transporting, placing and finishing
expansion joint as shown in the drawings, as per manufacturer’s recommendation as
specified herein and as required by the site conditions or as directed by the
Engineer, for a complete job.

2.0 GENERAL

Expansion joint furnished under this section of Specification shall be the standard
products of a manufacturer regularly engaged in the production of such devices and
shall be the manufacturer’s latest design that complies with the specified
requirements. Contractor shall submit manufacturer’s Data and Test Reports for
approval from Engineer prior to procurement. In addition detailed drawings and
installation manual of the approved product shall also be submitted prior to
installation.

3.0 PRODUCTS

3.1. Design Requirements

3.1.2 Expansion Control

a. Provide integrally molded units of neoprene and bonded

steel components or rubber and bonded steel components,
cast under pressure and heat, arranged to provide for the
expansion and contraction movements of structures and
having a wear-resistant surface.

b. Provide steel of sufficient strength to bridge the gap in the

deck while supporting a wheel load of 94 kN over a contact
2
area of 0.3X0.6m with maximum plate deflection of 1/800
of the maximum opening when fully extended.

c. There shall not be a change in the surface configuration as

a result of expansion and contraction movements.

d. Expansion and contraction movements shall be taken

entirely by deformation of the neoprene or rubber.

e. Make other provisions as necessary to provide a weather-

tight installation resistant to the penetration of debris.

f. Provide units which can be readily cut and fitted to gutter

curb and upstand configurations.

g. Provide for joint movements perpendicular and parallel to

the joint, as shown, and for + 6mm vertical misalignment.

The parallel movement shall allow for at least 25% of the

total perpendicular movement.

Construction of Bridge at Korangi Causeway 2315-1 Expansion Joints

 h. Provide for locking or keying between seal units in each
joint.

3.2 Materials

Expansion joints selected for the project shall be DK New Monocell Joint
(DK NMC-50) including comptable gutter, curb and upstand units, or
approved equivalent.

Furnish manufacturer’s standard anchors, fasteners, set screws, spacers,

flexible seal and filler materials, adhesive and other accessories compatible
with material in contact, as shown or required for complete installations.

3.3 Fabrication

Furnish the basic profile and operating units as shown in drawing. Select
units comparable to those shown, or required, for the joint size and to
absorb variations in adjacent surfaces and structural movement. Furnish the
longest practicable lengths to minimize the number of end joints. Provide
mitered corners where joints change direction or abut other material
systems.

Reassemble items in the shop to the greatest extent possible so as to

minimize field splicing and assembly of units. Disassemble units only to the
extent necessary for shipping and handling limitations. Clearly match mark
units for reassembly and co-ordinated installation.

4.0 EXECUTION

4.1 Inspection

Examine the areas in which, and conditions under which, expansion joint
seals are to be installed. Do not proceed with the work until unsatisfactory
conditions have been corrected.

4.2 Installation

Seal the joint to prevent intrusion of moisture and other contaminants.

Provide for anchoring by either bolts or studs forming a mechanical

connection between components molded in the expansion joint seal and the
structure.

Comply with manufacturer’s written instructions and recommendation,

including preparation of substrate, installations, and protection of installed
units.

5.0 MEASUREMENT AND PAYMENT

5.1 General

Except otherwise specified herein or elsewhere in the Contract Documents

no measurement and payment will be made for the under mentioned items
related to this section. The cost thereof shall be deemed to have been
included in the quoted unit rate of the items of the Bill of Quantities under
this section.

5.1.1 Preparation of surface and sealing of joint.

5.1.2 Anchoring of joint with structure.

Construction of Bridge at Korangi Causeway 2315-2 Expansion Joints

 5.1.3 Protection of installed joint.

5.1.4 Concrete for filling the gap between slab and expansion joint.

5.1.5 Baker rod

5.2 Expansion Joint

5.2.1 Measurement

Measurement of acceptably completed works of expansion joints

including Non shrink grout & anchoring system etc will be made on
the basis of running metre of the expansion joint actually provided
and fixed, as shown on the Drawings or as directed by the
Engineer.

5.2.2 Payment

Payment will be made for acceptable measured quantity of

expansion joint including Non shrink grout & anchoring system
etcon the basis of unit rate per running metre quoted in the Bill of
Quantities & shall constitute full compensation for all the works
related to the item.

5.3 Polyurethene Sealant

5.3.1 Measurement

Measurement of acceptably completed works of polyurethene

sealant will be made on the basis of actual length in running meter
of the polyurethene sealant actually provided and fixed, as shown
on the Drawings or as directed by the Engineer.

5.3.2 Payment

Payment will be made for acceptable measured quantity of

polyurethene sealant on the basis of unit rate per running meter
quoted in the Bill of Quantities & shall constitute full compensation
for all the works related to the item.

5.4 Bituminous Impregnated Soft Board

5.4.1 Measurement

Measurement of acceptably completed works of bituminous

impregnated soft board will be made on the basis of running meter
of the bituminous impregnated soft board actually provided and
fixed, as shown on the Drawings or as directed by the Engineer.

5.4.2 Payment

Payment will be made for acceptable measured quantity of

bituminous impregnated soft board on the basis of unit rate per
running meter quoted in the Bill of Quantities & shall constitute full
compensation for all the works related to the item.

*** End of Section 2315 ***

Construction of Bridge at Korangi Causeway 2315-3 Expansion Joints

 SECTIONS – 3000

STRUCTURAL STEEL WORKS

1.0 SCOPE

The work under this section of the Specifications consists of furnishing all material,
labour, plant, equipment and appliances, fabricating, erecting, installing, testing, painting
and all other items incidental to Structural steel work for a complete job as shown on the
drawings, specified herein and/or as directed by the Engineer.

2.0 APPLICABLE CODES AND STANDARDS

Latest edition of the following codes and standards are applicable to the work of this
section:

AISC, 1969 Specifications for the design, fabrication and erection of structural steel
for buildings.

ANSI / AISC 360 Specification for Structural Steel Buildings.

AISC 303 Code of Standard Practice, for Steel Buildings and Bridges.

AISC Specifications for structural joints using ASTM A325 or A490 bolts.

AISC and SSPC Guide to shop painting of Structural Steel.

ASTM A6 Standard specifications for general requirements for rolled structural

steel bars, plates, shapes and sheet piling.

ASTM A36 Standard Specification for Carbon Structural Steel.

ASTM A53 Standard Specification for Pipe, Steel, Black & Hot Dipped, Zinc Coated,
Welded and Seamless Steel Pipes

ASTM A307 Standard Specification for Carbon steel bolts and studs and threaded
bolts 60000 PSI tensile strength.

ASTM A325 Standard Specification for Structural bolts, Steel, Heat treated withdrawn
and replace by ASTM F3125. 120/105 ksi minimum tensile strength.

ASTM A653 Specifications for steel sheet zinc coated (galvanized) or zinc iron alloy
coated galvannealed by the hot dipped process,alloyed coating

ASTM A490 Standard Specification for Structural Heavy Hex bolts, alloy steel, heat
treated ,150 ksi minimum tesnsile strength with Type 1 and Type 3
weathering steel bolting class.

ASTM A354 Standard Specification for quenched and tempered alloy steel bolts,
studs and other externally threaded fasteners.

ASTM A501 ASTM A501-89

\ ASME SA501 Standard Specification for Hot formed welded and seamless carbon
steel structural tubing.

Construction of Bridge at Korangi Causeway 3000-1 Structural Steel Works

 ANSI / NAAMM Metal Bar Grating MBG 531

ASTM A563-07 Standard Specification for Carbon and alloy steel nuts.

ASTM A572 Standard Specification for High - Strength Low - Alloy Columbium –
Vanadium Structural Steel for plates, Structural shapes, Sheet Piling and
Bars

ASTM E109 Method for Dry powder magnetic particle inspection.

ASTM A653 Standard Specification for sheet steel, Zinc coated (Galvanized) or zinc
alloy coated (Galvannealed) by hot dip process.

AWS D1.1 Specifications for welding of steel structures.

ASCE/SE-1 Minimum Design Load for Buildings and other Structures.

ANSI/AISC 358 Prequalified Connections for Special and Intermediate Moment Frames
for Seismic Applications.

ANSI
B18.22.1 Plain Washers.

AISI American Iron and Steel Institute (Relevant Standards)

SSPC – SP6 Steel structures painting council – surface preparation specifications.

NACE The National Association of Corrosion Engineers

3.0 MATERIALS

Except otherwise stated on the drawings, the material specifications shall conform to the
following standards. Wherever necessary the Contractor may use equivalent alternative
material subject to approval of the Engineer.

3.1 Structural Steel

- Structural steel shall conform to the requirements of ASTM A-36, or ASTM

A-572.

- Carbon Steel pipes shall conform to the requirements of ASTM A 53 Class B,

ASTM A501 or shall be made of plates spirally welded.

- All material shall be supplied charpy V-Notch testing in accordance with

ASTM A6, Supplementary Requirement S5.

- Grating shall conform to ANSI / NAAMM MBG 531.

3.2 Welding

All welding shall confirm to AWS D1.1 specifications.

Welding electrodes shall match the base metal and shall conform to the requirements of
AWS A5.1 specifications.

3.3 High Strength Bolts

All shop connections, except as noted herein or on the drawings, shall be made with
High Strength Bolts in friction type connections, or by welding.

Construction of Bridge at Korangi Causeway 3000-2 Structural Steel Works

 High strength bolts, heavy hexagonal nuts and hardened washers shall conform to the
requirements of ASTM A325. All field connections, except noted, shall be made with high
strength bolts in friction type connection.

3.4 Washers

Washers shall conform to the requirements of ANSI B18.22.1 and shall be of structural
grade steel appropriate for the type of bolts for which they are used. For oversized holes,
the washers shall be large enough to cover the entire hole by at least 6mm or as directed
by the Engineer.

3.5 Studs

Steel Studies Shear Connectors shall conform to the requirements of Structural Welding
Code-Steel, AWS D1.1.

3.6 Paints

3.6.1 All material shall be acceptable, proven first grade products and shall meet or
exceed the minimum standards of specified manufacturers like Jotun, SIPCO,
PATSA and ICI paints.

During painting works an approved Quality Control inspector or a technical

representative shall be provided by the manufacturer to oversee the painting and
coating application. The Quality Control Inspector shall be liable to confirm in
writing to the Engineer of the correct use of their product and the DFT by
approved Thickness Gauge Meter, on job site as per Specification.

3.6.3 Anti-corrosive Surface tolerant epoxy primer by JOTUN or approved equivalent.

3.7 Copper Slag Abrasive

Copper Slag abrasive or grit or approved equivalent

4.0 CONNECTIONS

All connections shall be designed and detailed for 75% of the effective capacity of the
member. A minimum of two bolts or equivalent welding shall be used per connection.

Shop connection may be welded or bolted. Field connections shall be bolted unless
noted otherwise on design drawings or approved by the Engineer.

5.0 ALLOWABLE STRESSES

Allowable design stresses for structural steel members and their connections, including
temporary bracings and shorings shall be in accordance with AISC Specifications.

6.0 SHOP DRAWINGS

6.1 Shop drawings shall be submitted by the Contractor, for structural steel works, for
acceptance in accordance with the requirements or the Contract Documents.

6.2 Shop drawings furnished for this section shall conform to the best standards of the
construction industry. Shop drawings shall be prepared by and under the supervision of
competent engineering personnel. Prior to submittal, the Contractor shall check each
shop drawing for compliance with the requirements of the Contract Documents.

6.3 Shop drawings shall include plans, elevations, sections and complete details to describe
clearly, at an ample scale, all work to be provided. Drawings shall be accurately
dimensioned and shall be noted clearly.

Construction of Bridge at Korangi Causeway 3000-3 Structural Steel Works

6.4 All connections shall be designed and detailed as, per sub-section 4 above, by the
Contractor on the shop drawings. Design calculations for connections shall be made as
per AISC specifications and shall be submitted along with the shop drawings after
checking and signing by the Contractor for approval of the Engineer.

6.5 The shop drawings shall include

(i) An erection scheme, in suitable size, having the following information:

- Location of erection elements in respect of axis and Marks as well as

picking points of these elements with respect to each other or with the
existing steel or reinforced concrete structures.

- Joints showing erection welding sizes and lengths, bolts diameter and
numbers.

- Chart showing list of assembling marks having columns such as Mark,

Description, Quantity, Weight of each Mark, total weight and Remarks
with grand total in the end.

- Chart showing List of Erection Bolts, Nuts and Washers in tabulated

form, detailing information such as size, quantity, weight and their grand
totals.

- Quality of materials.

- Quality and type of welding electrodes.

- Measures to be adopted against unscrewing of bolts.

- Painting instructions.

- Erection sequence.

- References to relevant drawings.

- Except in special cases all scheme drawings shall be made in single

fairly thick lines.

- The recommended scale of erection scheme is 1:50, 1:100, 1:200, for

joints 1:5, 1:10 or 1:20.

(ii) Fabrication drawings in suitable size shall contain the following information:

- Each Shop Assembly (Mark) shall be drawn separately showing

necessary lines, elevations, sections with reference to axis, center lines,
location of holes, cleats, plates, lugs etc. fully dimensioned with part
numbers.

- Bolts and holes sizes.

- Welding symbols and welded joints requirements, in accordance with

AISC manual of steel construction and AWS specifications.

- Geometrical Setting out dimensions necessary for the assembly of an

element. Location and details of joints as calculated by the Contractor.

- Instruction for welding, dimensions of weld, edge preparations methods

of welding, and methods for control of distortions.

Construction of Bridge at Korangi Causeway 3000-4 Structural Steel Works

 - List of symbols for bolts and holes used.

- List of symbols for welds used.

- Edge distance (general).

- Welding sizes and lengths (general).

- Standards and quality of materials.

- Type and quality of welding electrodes.

- Tests for welding.

- Reference to related erection scheme drawings.

- Reference to design and working drawings.

- Parts list.

- Instructions for surface preparation, painting, primer and finish coats.

- Recommended scales for fabrication drawings are preferably 1:10 or

1:20, and for joints and details 1:1, 1:2, or 1:5.

7.0 FABRICATION

The Contractor shall notify the Engineer about any problems or doubts/errors, if any, in
the drawings for clarifications/rectification well in time to prevent any fabrication errors.
Fabrication shall not be commenced until approval has been obtained from the Engineer.

7.1 Straightening of Material

Rolled material, before being worked upon shall be straightened within tolerances as per
ASTM specifications A6. Straightening necessarily shall be done by mechanical means
or by the application of a limited amount of localized heat. The temperature of heated
0
areas, as measured by approved methods, shall not exceed 1200 F (650 °C).

7.2 Cutting

As far as practicable cutting shall be done by shearing. Oxygen cutting shall be done
where shear cutting is not practicable and shall preferably be done by Machine. All
edges shall be free from notches or burs. If necessary, the same shall be removed by
grinding.

7.3 Holes Punching/Drilling

Holes shall be punched where thickness of the material is not greater than the diameter
of bolt + 3mm. Where thickness of the material is greater, the holes shall either be drilled
or sub-punched and reamed to size. Die for all sub-punched holes and drill for all sub-
drilled holes shall be at least 2mm smaller than the nominal diameter of the rivet or bolt.

7.4 Welding

7.4.1 All execution and inspection of welding shall be done in accordance with the
provisions of the American Welding Society Specifications. No welding for
piping/electrical supports shall be made transversely to any tension flanges or
beams or columns.

Construction of Bridge at Korangi Causeway 3000-5 Structural Steel Works

 7.4.2 Maximum and minimum size and lengths of fillet welds shall be in accordance
with AISC specifications, or as mentioned on drawing.

7.4.3 Surface to be welded shall be free from loose scale, slag, rust, grease, paint or
any other foreign matter.

7.4.4 Butt welds shall be full penetration welds, unless otherwise specified and
permitted.

7.4.5 Avoid the use of temporary welded attachments during fabrication as much as
possible. After fabrication is completed, remove flush with the base material
without encroaching on the minimum required base material thickness. After the
surface has been restored, examine all areas from which temporary attachments
have been removed by the same methods required for permanent fillet welds.

7.4.6 Do not begin structural welding until joint elements are tacked in intimate contact
and adjusted to dimensions shown with allowance for any weld shrinkage that is
expected. Weld heavy sections and those having a high degree of restraint with
low hydrogen type electrodes. No member shall be spliced without approval.

7.4.7 For notch-toughness specified material, all weld metal, processes and preheat
requirements shall be compatible to assure notch-tough composite weld metal.

7.4.8 Shop splices of webs and flanges in built-up girder shall be made before the
webs and flanges are joined to each other.

7.5 Tolerances

Tolerances for Structural Steel shall be as per AISC Specifications unless noted
otherwise.

8.0 WELDER QUALIFICATIONS

8.1 All welders contracted to perform work shall be required to show written evidence that
they have been properly tested in compliance with the approved welding procedures.

8.2 Welders shall have been qualified in the proposed procedure by an established
laboratory acceptable to the Engineer within the preceding 90 days.

8.3 All welders shall be qualified for the type of weldment, grade of steel, thickness of steel,
welding process and welding position that they are employed to weld. Welders and
welding operators that have not been performance qualified, for all material and
thickness ranges used on the job, shall be restricted to welding only that portion of the
work for which they are qualified.

8.4 Engineer reserves the right to have welders or welding operators prequalified or
removed from the job as he deems necessary during the progress of work. Engineer’s
decision regarding the qualifications of any welder shall be final.

9.0 WELDERS IDENTIFICATION

9.1 Each welder shall be assigned a unique identifying number or symbol that he shall use to
identify all welding resulting from his skills.

9.2 Stenciled markings shall be applied within 40mm of the weld using low stress
concentration dies. Written symbols are also acceptable.

9.3 A record shall be kept of these symbols by the Contractor. The records shall show
welder’s name, symbol assigned, procedures to which qualified, employment and test
dates. This record shall be available to the Engineer’s Representative at all times.

Construction of Bridge at Korangi Causeway 3000-6 Structural Steel Works

10.0 TEST ASSEMBLY

10.1 Fabricated components such as Beams, Girders, Bracing, as and where required by
planning, shall be test assembled in the shop prior to transportation to site.

10.2 Test assembly work and procedure should be planned during fabrication process.

10.3 Each test assembly shall be got inspected from the Engineer’s Representative and shall
be dismantled only after his approval in writing.

11.0 SURFACE PREPARATION / PAINTING

11.1 Surface Preparation

- These Specifications withdrawn shall govern the procedures and materials required
for surface preparation and coating of the specified structures.

- All fabrication and assembly of a particular section shall be completed before surface
preparation begins.

- All blast cleaning on metal surface should be carried out by Copper Slag abrasive
and grit should not be recycled to avoid contamination of surface in accordance with
the SSPC specification required for that particular area. Blasting anchor profiles shall
be consistent with manufacturer's recommendations.

- All blasting should be scheduled in a manner which enables paint to be applied in

accordance with the manufacturer's recommendations and on the same day as
blasting occurs.

- All welded area and appurtenances shall be given special attention for removal of
welding flux in crevices. Welding splatters, slivers, laminations and under laying mill
scale exposed during blasting shall removed or repaired. Bolt holes shall be drilled
and de-burred prior to blasting. Sharp edges shall be ground or filed to provide a
visible radius.

- The abrasives used for blasting will be sized to give the specified anchor profile as
determined by this specification. A mesh size will be used as prescribed for
thickness of paint to be applied. The maximum particle size shall be no larger than
that passing a 16 mesh screen.

- No acid washes or other cleaning solutions or solvents may be used on metal

surfaces after being blasted. This includes any inhibitive washes intended to prevent
rusting.

- All oil and/or grease contamination shall be removed by water based degreaser
before starting to blast like glo-flo heavy duty degreaser or equivalent.

- No intermediate or finish coating shall be applied prior to fabrication without prior

approval from Engineer.

- Blasting shall be done is an area removed from painting operations and freshly
coated surfaces to prevent contamination. Contaminated coatings shall be re-blasted
by Contractor to bare metal and reapplied.

- After blasting Contractor shall thoroughly clean all blast grit and dust from both
internal and external surfaces, including removal from crevices, recesses etc.

11.2 Coating Application

Construction of Bridge at Korangi Causeway 3000-7 Structural Steel Works

 - Coating application will be done according to paint manufacturer's recommendations
included with the materials and will be subject to inspection by Engineer.

- The blast-cleaned surfaces shall be coated with primer during the same day as
blasted and at least one hour prior to sundown of the day, and also before any
rusting occurs. A minimum of 150mm (6 inches) around edges of sand blasted area
will be left un-primed unless adjoining a coated surface. Any steel/metal that is not
primed and is wet by rain or moisture shall be re-blasted prior to application of
primer.

- All coating shall be allowed to dry thoroughly, but not less than the manufacturer's
specified time, prior to application of a succeeding coat.

- The surface shall be clean, dry and free from dust before application of any coat of
paint.

- All coating materials furnish by Contractor shall be furnished in unopened, clearly

identifiable containers. Mixing of different coatings shall not be permitted. Containers
shall remain closed until required for use. No paint shall be used that has expired its
shelf life.

- All coating film thickness shall be as specified and shall be checked by the Engineer
or his Representative.

- Damage to intermediate coats, prior to application of the next coat, shall be repaired
by Contractor to provide the coating sequence and film thickness as specified.

- After the prime coat has been applied, all hard-to-spray areas such as corners.
edges and welds, may be brush painted with the same paint and film thickness.

- The finished job shall not contain sags, runs, wrinkles, spots. blister or other
application flaws.

- Holidays in the final coat at edges, corners, welds and inaccessible areas may be
protected by spraying or hand brushing an additional layer of topcoat provided
excessive build up does not occur.

- All components shall be thoroughly stirred before, during and after mixing. The
mixed coatings shall be continuously stirred by mechanical spray pot agitators or
other approved means. The volume to be mixed shall be accurately measured. All
mixing shall be done in clean containers, free from traces of grease, other type
paints, or other contaminates. All containers shall be kept covered to prevent
contamination by dust, dirt or rain.

11.3 Repair of Damaged Area (Touch-UP)

- All external surfaces where coating is damaged during fabrication, transportation and
erection shall be repaired as follows:

- Top coat damaged, but base coat undamaged, will be repaired by removing
damaged coating with sand paper or other means acceptable to the Engineer (wire
brushing will not be acceptable) and applying top coat as specified.

- Coating damaged to base metal where blasting is not approved shall be

mechanically cleaned as specified in other Section and applying a three coats
system as specified in relevant sections.

- Care will be taken to avoid damaging the coatings surrounding repaired areas and to
assure complete tie-in of the coating with surrounding areas.

Construction of Bridge at Korangi Causeway 3000-8 Structural Steel Works

 - Remove damaged areas by spot blast and feather into surrounding coating with
sandpaper. Clean all loose materials from surface.

- Contractor shall repair the coating on all damaged areas prior to final acceptance of
the Engineer.

11.4 Galvanizing (Zinc Coating)

Galvanizing, wherever specified, shall be applied in a manner and of a thickness and

quality conforming to the requirements of ASTM A123 standard specifications for zinc
(Hot dipped galvanized) coating on products fabricated from rolled, pressed and forged
steel shapes, plates, bars and strips.

Components shall be galvanized i.e. zinc coated after complete fabrication i.e. welding,
drilling etc. the process shall consist of removal of rust and mill scale by pickling in
hydrochloric acid or sulphuric acid followed by water wash and prefluxing in tanks
containing zinc ammonium chloride and then fluxing with ammonium chloride. The fluxed
components shall then be passed through a drying oven prior to immersion in a bath of
virtually pure molten zinc.

12.0 PAINT AND COATING SYSTEMS FOR STEEL GATE AND STEEL METAL WORKS

The paints and coating systems have been specified hereunder for steel/ metal works
like pipe support, angle iron support in trenches, manufactured by Jotun paint or
approved equivalent as approved by the Engineer and all such surfaces as shown on the
Drawings and/or as directed by the Engineer. All paint applications to be carried out by
airless spray.

12.1 Exterior Paint System for Steel Structures

12.1.1 Surface Preparation

Abrasive blasting to Near White with copper slag in accordance with SSPC-
SP10 and SSPC-AB1 to provide 40 to 60 microns anchor profile.

12.1.2 Paint System

Primer: Surface tolerant epoxy mastic to be applied at 70 microns DFT.

1st Coat: Surface tolerant epoxy mastic paint to be applied in two layers,
each layer of thickness 100 microns DFT of approved color.
(JOTAMASTIC 87 or approved equivalent).

2nd Coat: Two components polyurethane enamel of 60 microns DFT of

approved color applied after erection. (HARDTOP XP AS or
approved equivalent).

13.0 INSPECTION AND TESTS

13.1 Manufacturer’s Test Certificate for all material used shall be furnished by the Contractor
for Engineer’s scrutiny and approval.

13.2 Rolling tolerance of all shapes and profile according to AISC shall be in accordance with
the provisions of ASTM A6 specifications. These shall be checked by the Contractor
before commencing work and shall be rejected if found not within limits.

13.3 Materials shall be tested for conformance with the specified standards at an approved
testing laboratory as and when directed by the Engineer.

Construction of Bridge at Korangi Causeway 3000-9 Structural Steel Works

13.4 Contract surfaces of connections using high strength bolts in friction type connections
shall be got inspected and approved from the Engineer before bolting.

13.5 All bolted connections shall be got inspected and approved from the Engineer for types,
size, number of bolts and installation including tightening.

13.6 Inspection and Testing - Welding

13.6.1 General

Welding shall be inspected and tested by an approved testing laboratory during

fabrication and erection of structural steel as follows:

The testing laboratory shall be responsible for conducting and interpreting the
tests. It shall state in each report whether or not the test specimens conform to
all requirements of the Contract Document and shall specifically note any
deviations therefrom.

Certify all welders and make 100 percent visual inspections and tests as follows:

- Record types and locations of all defects found in the welding work.

- The measures required and performed to correct such defects.

In addition to the requirements of AWS D 1.1, paragraph 8.15, each weld shall
be visually free of slag, inclusions and porosity.

In addition to visual inspection of all welds magnetic particle, ultra-sonic and

radiographic inspection shall be made of all welds as specified below. Magnetic
particle tests shall be made on the root pass and finished weld.

The method of magnetic particle test shall be in accordance with ASTM E109.
Any type of crack or zone of in-complete fusion or penetration shall not be
acceptable.

Radiographic testing technique and standards of acceptance shall be in

accordance with AWS D 1.1.

Ultra-sonic testing shall be performed in accordance with AWS D 1.1.

Welding inspection and test report showing evidence of the quality of welding
shall be submitted by the Contractor. For each section of weld inspected and
tested, furnish a report which clearly identifies the work, the welder’s
identification, the areas of inspections and test, the acceptability of the welds,
and signature of the inspector or laboratory incharge. Each report shall be
completed at the time of inspection or test. For radiographic examination, furnish
a complete set of radiographs in addition to the reports. All inspection and
testing shall be carried out in presence of the Engineer or his representative.

13.6.2 Test Methods

Use the following test methods as specified. The following list is in descending
order. When a particular test method is specified for a joint and the method is
impractical to use, use the next highest method practicable. The alternative
method will be subject to approval, NDT procedures and techniques shall be in
accordance with AWS D 1.1, section 6.7.

a) Radiographic Method: In addition to the requirements of AWS D 1.1,

comply with ASTM E94.

Construction of Bridge at Korangi Causeway 3000-10 Structural Steel Works

 b) Ultrasonic method.

c) Magnetic particle method.

d) Liquid Penetration Method: Visible-dye, solvent removable method only.

13.6.3 Members Designated for Tests

a) Built – up Members

Examine 100 percent of flange-to-flange and web-to-web welding by the

radiographic method. For all web-to-flange and pipe column seam
welding, examine ten percent of each welder’s work as follows:

- Full penetration groove welds by the ultrasonic.

- Fillet welds and partial penetration groove welds by the

magnetic particle method.

b) Moment Connection Joints

- Examine 100 percent of all flange-to-flange and web-to-web

welding as follows:

Full penetration groove welds by the ultrasonic method or other method

as designated by the Engineer.

Fillet welds and partial penetration groove welds by the magnetic particle
method.

- For all web-to-flange welding, examine ten percent of each

welder’s work as follows:

Full penetration groove welds by the ultrasonic method or radiographic

method as approved by the Engineer.

Fillet welds and partial penetration groove welds by the magnetic particle
method.

c) Column Base Plates

Examine 100% of all welding for connection of base plate to column.

d) Bracing Connections

Examine 100 percent of all welding for connection of diagonal bracing as

follows:

- Groove welds by the ultrasonic method.

- Fillet welds by the magnetic particle method.

13.6.4 Requirement for ten percent Examination

a) Examine a 300mm section of weld in each 3m increment of each

welder’s work as directed by the Engineer. If the examination meets the
acceptance standards of AWS D 1.1, the 3m of weld represented will be
accepted.

Construction of Bridge at Korangi Causeway 3000-11 Structural Steel Works

 b) If the examination fails to meet the acceptance standards, examine two
additional 300mm sections in the 3m increment as directed by the
Engineer. If both of these examinations meet the acceptance a
standards, the 3m of weld represented will be accepted. Repair the
defects detected in the first examination and re-examine.

c) If one or both of the examinations fails to meet the acceptance

standards, examine the remaining weld of the 3m increment. Repair the
areas that do not meet the acceptance standards and re-examine.

13.6.5 Repair and Re-Testing of Welds

Repair defective welds in accordance with AWS D 1.1, or replace the weld, and
Re-test repaired and replaced welds by the same method and acceptance
standard used to examine the original weld. In addition, when defective welds
are found, the testing laboratory shall determine the cause of the defective
welding and institute immediate corrective action.

All defective welding shall be repaired or replaced at the Contractor’s expense.

13.7 Rejection

Neither the fact that the materials have been tested nor that the manufacturers test
certificates have been furnished shall affect the liberty of the Engineer to reject material
found not according to these specifications.

Materials or workmanship not in conformance with the provisions of these specifications

shall be rejected at any time, after delivery or during the progress of the work or the
completion and erection at site.

14.0 ERECTION

14.1 Bracing

All steel structures shall be carried up true and plumb within the limits defined in the
AISC code of standard practice and temporary bracing shall be introduced wherever
necessary to take care or all construction loads to which the structure may be subjected
including the equipment and the operation of the same. Such bracing shall be left in
place as long as required for safety.

Wherever piles of materials, erection equipment and other loads are carried during
erection, proper provision shall be made by the Contractor to take care of the stresses
resulting form such loads.

14.2 Alignment

No permanent bolting or welding shall be done at site during erection until as much of
the structure as will be stiffened thereby has been properly aligned and approved by the
Engineer.

14.3 Joints Using High Strength Bolts

All structural joints using high strength bolts shall be executed and inspected in
accordance with “AISC Specification for structural joints using ASTM A325 or A490
bolts”. High strength bolts and nuts, loosened after tightening, shall be discarded and
replaced with unused bolts and nuts.

Construction of Bridge at Korangi Causeway 3000-12 Structural Steel Works

15.0 MEASUREMENT AND PAYMENT

15.1 Except otherwise specified herein or elsewhere in the Contract Documents, no

measurement and payment will be made for the under mentioned specified works related
to the relevant items of the Bill of Quantities. The cost there of shall be deemed to have
been included in the quoted unit rate of the respective items of the Bill of Quantities.

15.1.1 Nuts, bolts, screws, washers, weld metal and welding rods.

15.1.2 Testing of materials and welds, and repair of defects.

15.1.3 Surface preparation including cleaning with blasting.

15.1.4 All Painting works.

15.1.5 Galvanizing

15.1.6 Fabrication

15.1.7 Erection

15.1.8 Hardware and fixing accessories etc.

15.1.9 All embedded parts unless otherwise specified in the Bill of Quantities

15.2 Railing

15.2.1 Measurement

Measurement of acceptably completed Works of Heavy duty railing including

epoxy coating, fabrication, erection/ embedding and embedded parts including
fixing and all fixing accessories complete in all respect will be made on the basis
of actual length in meter, according to approved shop drawings, after verification
at site to the satisfaction of the Engineer that the items fabricated, supplied and
erected in position conform with the Contract and approved shop drawing.

15.2.2 Payment

Payment will be made for acceptable measured quantity of Heavy duty railing on
the basis of unit rate per meter quoted in the respective item of the Bill of
Quantities and shall constitute full compensation for all the Works related to the
item.

*** End of Section 3000 ***

Construction of Bridge at Korangi Causeway 3000-13 Structural Steel Works

 SECTION – 3100

MISCELLANEOUS STEEL WORKS

1.0 SCOPE

The work under this section of Specifications consists of supply of all material, labour,
plant, equipment and appliances required for Miscellaneous Steel works such as
embedded items, steel pipe railing and any other work shown in the drawings and as
directed by the Engineer.

2.0 APPLICABLE STANDARDS

Latest edition of the following standards are relevant to these Specifications, wherever
applicable:

AISC Code of Standard practice.

ASTM A-36 for structural steel.

ASTM A-53 steel pipe for railing.

AISC/SSPC Guide to Shop painting for structural steel.

AWS D1.1 Structural Welding Code - Steel Specifications for welding of steel
structures.

3.0 DRAWINGS.

3.1 Design Drawings.

Design working drawings shall be supplied to the Contractor. These shall contain
main dimensions, sizes of members, typical details, etc.

3.2 Shop Drawings.

Shop drawings shall be prepared by the Contractor from the working drawing
supplied, taking into consideration the instructions given by the Engineer and
submitted to the Engineer for his approval. No work shall commence until shop
drawing is approved by the Engineer.

4.0 MATERIAL

Except otherwise stated in the drawings, the material specifications shall conform to the
following standards. Wherever necessary the Contractor may use equivalent alternative
material subject to approval of the Engineer.

4.1 Structural Steel

Structural Steel shall conform to the requirements of ASTM A-36 or equivalent.

Pipe for hand rail shall conform to the requirements of ASTM A-53.

4.2 Welding

Welding Electrodes shall conform to the specifications for mild steel covered
Arc-welding Electrodes, AWS A5.1 latest edition. Equivalent locally
manufactured electrodes may be used subject to the approval of the Engineer.

Construction of Bridge at Korangi Causeway 3100-1 Miscellaneous Steel

Works
5.0 FABRICATION

The Contractor shall notify the Engineer about any problems or doubts/errors discovered
in the drawings supplied by the Engineer for clarification/rectification well in time to
prevent any fabrication errors. Fabrication shall not be commenced until approval has
been obtained from the Engineer.

5.1 Straightening of Material

Rolled material, before being worked upon must be straightened. Straightening

necessarily shall be done by mechanical means or by the application of a limited
amount of localized heat.

5.2 Cutting

As far as possible cutting must be done by shearing. Oxygen cutting shall be

done where shear cutting is not possible and shall preferably be done by
Machine. All edges shall be free from gauges, notches or burs. If necessary the
same shall be removed by grinding.

5.3 Holes Punching/Drilling

Holes shall be punched where thickness of the material is not greater than the
diameter of bolt by + 1/8 inch. Where the thickness of the material is greater, the
holes shall either be drilled or sub-punched and reamed to size. The dia for all
sub-punched holes and the dia. of all drilled holes shall be at least 1/12 inch
smaller than the nominal diameter of the rivet or bolt.

5.4 Welding

5.4.1 General: The execution and inspection of welding will be done in

accordance with the provisions of the American Welding Society Code
for Welding in Building construction, D1.1.

5.4.2 Maximum and minimum size and lengths of fillet welds shall be in
accordance with AISC specifications.

Surface to be welded shall be free from loose scale, slag, rust, grease,
paint or any other foreign matter except mill scale which withstands
vigorous wire brushing.

5.5 Tolerances

The maximum variation in the distance from centre to centre of holes for rivets or
bolts shall not be greater than 1mm.

5.6 Methodology

Fabrication shall be carried out using all the necessary tools, plant and
equipment in accordance with methodology for fabrication approved by the
Engineer.

6.0 INSPECTION AND TESTS

6.1 The inspection of welding shall be performed in accordance with the American
Welding Society specifications and as directed by the Engineer.

6.2 Materials and workmanship not in reasonable conformance with the provisions
of these specifications shall be rejected at any time during the progress of the
work or the completion and erection at site.

Construction of Bridge at Korangi Causeway 3100-2 Miscellaneous Steel

Works
7.0 ERECTION/INSTALLATION

Erection/Installation work shall be carried out by using required tools, plant and
equipment in accordance with methodology for erection approved by the Engineer.

8.0 SURFACE PREPARATION/PAINTING

8.1 Surface Preparation

8.1.1 All steel shall be cleaned free from loose scale, rust, burs, slag, etc. by
means of sand blasting and/or other approved means as recommended
by the manufacturer of paint.

8.1.2 The sand used for this purpose shall conform to the type as specified in
SSPC-SP 6. It should be free from earth, dust, clay and moisture. For
this, the Contractor shall submit the gradation (no less than that passing
through a 16 mesh screen U.S. sieve series) and source of sand along
with the sample for approval of the Engineer prior to commencing the
sand blasting operation.

8.1.3 The size of sand particles and air pressure size of the hose nozzle shall
be correlated to give proper and acceptable surface.

8.2 Painting

8.2.1 Immediately after surface preparation all material shall be applied with
two coats of red lead oxide primer and two coats of synthetic enamel.

8.2.2 One final coat of paint shall be applied after erection of all components
is complete.

8.2.3 The type of primer and paints to be applied shall be as specified in

section 8.3. The Contractor shall use the best quality of the type of paint
specified and shall get the same approved by the Engineer.

8.2.4 All painting shall be in accordance with the paint manufacturer's

specification/ recommendations.

8.2.5 The above is applicable to all steel work covered under this section of
specification.

8.2.6 Steel work/Surfaces not to be painted

i) Steel work to be encased/embedded in concrete or surface in

contact with concrete shall not be painted, but shall be given a
cement wash after surface preparation.

ii) Bolt and nuts threads shall be protected by greasing till they are
tightened and painted.

8.3 Primer and Paint

All structural steel components, unless specified otherwise, shall be applied with
i. Primer: Surface Tolerant Epoxy of 70 Micron DFT
st
ii. 1 Coat: Surface Tolerant Epoxy mastic paint to be applied in
the layers, each layer of thickness 100 micron DFT of approved
color. (Jotamastic 87 or approved equivalent)
nd
iii. 2 Coat (Top Coat): Two component polyurethane enamel of 60
micron DFT of approved color applied after erection. (hardtop
XP or approved equivalent)

Construction of Bridge at Korangi Causeway 3100-3 Miscellaneous Steel

Works
9.0 GALVANIZING

Steel platform, pipe works supports, ladder, etc. specified as well as screws and nuts
associated shall be hot-dip galvanized, electrolytically galvanized or sheradized, as
appropriate to the particular element.

Galvanizing shall be performed in accordance with VDE Standard 0210.

Material: For galvanizing, only original blast-furnace raw zinc shall be applied, which
shall have a purity of 98.5%.

The thickness of the zinc coat shall be:

- for screws, washers, nuts and similar hardware a minimum of 60 micron.

- for all other parts, except for parts intermittently or permanently submerged in
water, a minimum of 70 micron

- for parts intermittently or permanently submerged in water, a minimum of

140 micron, in accordance with "VDEW, Druckrohrleitungen - Association of
German Electricity Utility Companies, Steel Pen-stocks".

Cleaning: All material to be galvanized shall be cleaned carefully of rust, loose scale, dirt,
oil, grease, and other foreign substances. Particular care shall be taken to clean slag
from welded areas.

Galvanizing of plates and shapes: Where pieces are of such lengths that they cannot be
dipped in one operation, great care shall be exercised to prevent warping.

Material on which galvanizing has been damaged shall be re-dipped unless the damage
is local and can be repaired by soldering or by applying a galvanizing repair compound;
in this case, the compound shall be applied in accordance with the manufacturers'
instructions.

Soldering shall be done with a soldering iron using 50/50 solder (tin and lead). Surplus
flux or acid shall be washed off promptly and the work shall be performed so as not to
damage the adjacent coating or the metal itself. Any member on which the galvanized
coating becomes damaged after having been dipped twice shall be rejected.

10.0 MEASUREMENT & PAYMENT

10.1 General

Except otherwise specified herein or elsewhere in the Contract Documents, no

measurement and payment will be made for the under mentioned specified work
related to the relevant items of the Bill of Quantities. The cost there of shall be
deemed to have been included in the quoted unit rates of the respective items of
the Bill of Quantities.

10.1.1 Nuts, bolts, screws, rivets, heads, fillets, welds and welding rods.

10.1.2 Surface preparation and painting works.

10.1.3 All embedded parts

10.1.4 Galvanizing, if required

10.1.5 Glazing

Construction of Bridge at Korangi Causeway 3100-4 Miscellaneous Steel

Works
 10.1.6 MS Sheets

10.1.7 Hardware, fixing accessories etc. for metal doors

10.2 Steel Dowel Bar

10.2.1 Measurement

Measurement of acceptably completed Works of Galvanized Mild steel

dowel Bar including fixing and fixing accessories etc will be made on the
basis of each number, after verification at site to the satisfaction of the
Engineer that the items fabricated, supplied and erected in position
conform with the Contract and approved shop drawing.

10.2.2 Payment

Payment will be made for acceptably completed Works of Galvanized

Mild steel on the basis of unit rate per each, quoted in the respective
item of the Bill of Quantities and shall constitute full compensation for all
the Works related to the item.

*** End of Section 3100 ***

Construction of Bridge at Korangi Causeway 3100-5 Miscellaneous Steel

Works
 SECTION - 5100

PLUMBING

1.0 SCOPE

The work under this section consists of providing all material and equipment and
performing all the work necessary for the complete execution and completion, including
testing and commissioning of all systems of plumbing works as shown on the Drawings
and/or as specified herein and/or as directed by the Engineer. The systems included in
plumbing works are as follows:

(i) Cold and Hot Water Supply

(ii) Sanitary Drainage

All the above named systems shall be completed in all respects including extension of
these internal systems upto the specified limits outside the building as indicated on the
drawings.

2.0 GENERAL

All the materials and equipments shall be of the specifications mentioned herein and the
Contractor shall submit the sample, necessary catalogues, sketches, the name of
manufacturer and guarantee if necessary, before installation. The system shall be
installed after the Engineer approves it. All material and equipment shall be new and
unused.

It is specifically intended and must be agreed to by each Contractor submitting a bid, that
any material or labour which is usually furnished as a part of such equipment and which
is necessary for its proper completion and best operation shall be furnished as a part of
this Contract without any additional cost whether or not shown in detail on the drawings
or described in detail, in the specifications.

Approval of material and equipment by the Engineer shall not absolve the Contractor of
the responsibility of furnishing the same of proper size, quantity, quality and all
performance characteristics to efficiently fulfill the requirements and intent of the
Contract Documents.

The Contractor shall be responsible for his work until its completion and final
acceptance, and shall replace any of those that may be damaged, lost or stolen without
any additional cost. All openings left in floor for passage of lines of water supply, soil,
waste, vent, etc. shall be covered and protected.

All open ends of pipes shall be properly plugged to prevent any foreign material from
entering the pipe.

Misuse of plumbing fixtures to be installed under this Contract is prohibited during the
currency of the contract.

All metal fixture trimmings shall be thoroughly covered with non-corrosive grease, which
shall be maintained until all work is completed.

Upon the completion of work, all fixtures and trimmings shall be thoroughly cleaned,
polished and left in first class condition.

Before erection, all pipes, valves, fittings, etc. shall be thoroughly cleaned of oil, grease
or other material.

Construction of Bridge at Korangi Causeway 5100-1 Plumbing

 All special tools for proper operation and maintenance of the equipment provided under
this Contract shall be delivered at no additional cost.

The Contractor shall allow in his bid for cost of all cutting, making holes and subsequent
making it good to the desired finish as per approval of the Engineer. No separate
payment shall be made for this item.

The Contractor shall allow in his bid for the cost of providing protective painting or
coating as specified in the relevant sections and no claim shall be entertained for this
item.

All pipes shall be properly installed as shown on the drawings and/or as directed by the
Engineer, and shall be as straight as possible forming right angles and parallel lines with
the walls and other pipelines. The position, gradients, alignment and inverts shall be as
shown on the drawings and/or as directed in writing and set out by the Engineer.

The arrangement, positions and connections of pipe fittings and appurtenances shall be
as shown on the drawings. The Engineer reserves the right to change the location etc.
Special precautions shall be taken for the installation of concealed pipes as shown on
the drawings and/or as required. Should it be necessary to correct piping so installed, the
Contractor shall be held liable for any injury caused to other works in the correction of
piping. The Contractor shall closely coordinate with other works during the entire stage of
execution.

A minimum distance between different services shall be maintained as shown on the

Drawings and/or as approved by the Engineer.

Pipes should be installed in such a manner that minimum distance should always be
maintained between pipe and wall, beams, columns, etc. Pipes shall be supported on
hangers and brackets as shown on the drawings or as directed by the Engineer.

Waste-water outlet from each fixture shall be individually trapped.

Each vent terminal shall extend to the outer air and be so installed as to minimize the
possibilities of clogging and the return of foul air to the building.

When the roughing-in is completed, the plumbing system shall be subjected to test prior
to concealing the roughing-in, in order to ascertain that all threads and connections are
watertight.

Cast iron soil and drainage fittings for change in direction shall be used as follows:

Vertical to horizontal: short sweep or long-turn for diameter 75 mm and larger; long
sweep or extra-long-turn for less than 75 mm dia.

Horizontal to vertical: quarter bend or short turn.

All fittings with hubs shall be aligned so that the hub faces upstream.

No drainage or vent piping shall be drilled.

All exterior openings provided for the passage of piping shall be properly sealed with
snugly fitting collars of metal or other approved rodent-proof material securely fastened
into place.

Joints at the roof, around vent pipes, shall be made watertight by the use of lead, copper,
galvanized iron, or other approved flashings or flashing material. Exterior wall openings
shall be made watertight.

Construction of Bridge at Korangi Causeway 5100-2 Plumbing

 Each length of pipe and each pipe fitting, trap, fixture, and device used in a plumbing
system shall have cast, stamped or indelibly marked on it the maker's mark or name, the
weight, type, and classes of the product, when such marking is required by the approved
standard that applies.

Where different sizes of pipes, or pipes and fittings are to be connected, the proper size
increasers or reducers or reduced fittings shall be used between the two sizes.

Any fitting or connection which has an enlargement, chamber, or recess with a ledge,
shoulder, or reduction of pipe area that offers an obstruction to flow through the drain
pipe is prohibited.

Each fixture trap shall have a water seal of not less than 50mm and not more than
100mm.

Full S, bell; crown vented traps and traps/depending for their seal upon the action of
movable parts are prohibited.

No fixture shall be double trapped.

Where fixture comes in contact with wall and floors, the joint shall be watertight.

Piping in ground shall be laid on a firm bed for its entire length.

Piping in the plumbing system shall be installed without undue strains and stresses.
Vertical piping shall be securely held to keep the pipe in alignment and carry the weight
of the pipe and contents. Horizontal piping shall be supported to keep it in alignment and
prevent sagging. Hangers and anchors shall be of metal of sufficient strength to maintain
their proportional share of pipe alignments and prevent rattling. Hangers and anchors
shall be securely attached to the building under construction. It must be clearly
understood that the Contractor shall be fully responsible for hangers and supports and
shall obtain prior approval of design as to the shape, material, dimensions, spacing etc.

Piping in concrete or masonry walls or footings shall be placed or installed in sleeves,

which will permit access to the piping for repair or replacement. Roof drain leaders
installed inside columns shall be permanently embedded in concrete.

The indirect waste piping from food handling equipment etc. shall so discharge that the
air gap between the indirect waste and the building drainage system is at least twice the
effective diameter of the drain served.

3.0 COLD & HOT WATER PIPES AND PIPE FITTINGS

3.1 Scope

The work under this section of the specifications consists of providing all plant,
equipment, appliances, material and labour for proper supply and installation of
G.I. Pipes and pipe fittings for cold and hot water supply including jointing,
clamping, cleaning, painting etc. both above ground and underground and
embedded in walls as shown on the Drawings or as specified herein.

3.2 G.I. Cold and Hot Water Pipes & Fittings

3.2.1 Material

The galvanized pipes shall be of Class 'B' and conform to British

Standard Specifications 1387 for "Steel Tubes and Tubulars suitable for
screwing to BS 21 pipe threads".

Construction of Bridge at Korangi Causeway 5100-3 Plumbing

 All screwed tubes and sockets shall have BS pipes thread in accordance
with BS 21. In order to prevent damage to the leading thread, the ends
of the sockets shall be chamfered internally.

A complete and uniform adherent coating of zinc will be provided for

galvanized pipes.

Every tube shall be tested at the manufacturer's works to a hydraulic test

pressure of 4.90 MPa and shall be maintained at the test pressure
sufficiently long for proof and inspection.

Tubes, which are bundled, shall be secured together by rope or soft iron
or other suitable material.

The threads of all tubes shall be effectively covered with good quality
grease or other suitable compound, and each tube above 50mm inches
nominal bore shall have a protecting ring affixed to the unsocketed
screwed end.

All pipe fittings upto 75 mm dia. shall be of malleable cast iron. Pipe
fittings above 75 mm dia. shall be of approved material and
specifications as decided by the Engineer.

3.2.2 Installation

The run and arrangement of all pipes shall be as shown on the Drawings
and as directed during installation. All vertical pipes shall be erected
plumb and shall be parallel to wall and other pipes. All horizontal runs of
piping shall be kept close to walls. If required to change the location etc.
during the currency of the work, the Contractor will do so at no additional
cost.

Screwed joints in G.I. pipes shall be made perfectly tight, without the use
of any filler except approved jointing compound or tape. Wherever
required to make flanged joints, they shall conform to BS 10 Table D.

Furnish and install all pipe passing through floors and walls with sleeves
of G.I. sheet, 18 gauge, the inside dia. of which shall be at least 15 mm
greater than the outside of the pipe passing through it. Sleeves in
exterior walls and pits shall have anchor flanges and space between
pipe and sleeve shall be caulked and sealed watertight. At waterproof
locations, an approved water-proof type pipe sleeve shall be provided.

All embedded cold water supply piping shall be wrapped with approved
anti-corrosion polyethylene tape. All exposed piping shall be painted
with two coats of enamel paint over a coat of red oxide primer.

3.2.3 Pipe work Supports

All supports, clips, steel rods and hangers shall be of mild steel painted
with two coats of approved metallic zinc primer.

All clips and brackets shall be equipped with 1/3mm sectional rubber
liners (shore-hardness A 40+50).

Pipe work supports shall be installed in order to allow free movement

due to expansions and contraction. Supports shall be arranged adjacent
to joints, changes of direction and branches.

Construction of Bridge at Korangi Causeway 5100-4 Plumbing

 Each support shall carry the overall weight of pipe work and water to be
borne by it. The intervals between pipe supports shall not exceed the
following:

--------------------------------------------------------------------------------
Maximum interval between supports (meters)
--------------------------------------------------------------------------------
Steel pipes
--------------------------------------------------------------------------------
Nominal Horizontal Horizontal Vertical
dia. mm Bare Insulated
---------------------------------------------------------------------------------

15 2.0 2.0 2.0

20 2.4 2.4 2.4
25 2.7 2.7 2.7
32 2.7 2.7 2.7
40 3.0 3.0 3.7
50 3.4 3.4 4.1
65 3.7 3.7 4.4
75 3.7 3.7 4.4
100 4.1 4.1 4.6
125 4.4 4.1 4.8
150 4.8 4.4 5.5
200 5.0 4.6 6.0
--------------------------------------------------------------------------------

Single pipes hung from floor slabs shall be supported on rod hangers.
Where two or more pipes are involved a channel or angle from shall be
fitted to the underside of slab by two hangers and the pipes shall be
supported from the channel iron by rod hangers and flat iron hands.

All hanger rods shall have double nuts and beveled washers to allow the
hanger rod to swing.

Multiple pipe runs along walls shall be supported on purpose made

substantial angle and channel frames securely fixed to the wall, floor
and ceiling as necessary. All pipes shall be arranged to slide on the
steel supports and U-bolts shall be provided to form a rigid guide.

Exposed pipe work shall be supported on channel, angle iron or with U-

bolts to form a rigid guide.

All U-bolts, except used as anchors, shall have a pair of nut and
washers on each leg with the supporting steel flange clamped tight
between the pair of nuts to form a rigid guide and allowing the pipe to
slide axially. U-bolts shall be provided on alternate pipe bracket.

Small pipe work running along skirtings shall be supported by standard

built-in or screw-on type clips.

Pipes shall be individually supported. Pipes shall not hang from other
pipes.

Points at which pipes pass through walls, floors, connections to plant,

equipment and heat emitters, etc. do not constitute points of supports for
the pipes.

Construction of Bridge at Korangi Causeway 5100-5 Plumbing

 Vertical pipes shall be supported at the base or at anchor points to
withstand the total weight of the riser. Brackets from risers shall not be
used as a means-of support for the riser.

Supports for insulated water pipe work shall be arranged that the
supporting steel work does not come into contact with the pipe surface.

Vibration isolators to be provided with the hangers as approved by the

Engineer.

3.2.4 Testing and Commissioning

For testing and commissioning refer Section 5180.

3.3 Measurement and Payment

Measurement for G.I. cold water and hot water pipes shall be in running meter
length and the work to be done shall include earth work, providing and fixing of
pipe, pipe fittings, jointing, hangers, clamps and brackets, sleeves, insulation,
cutting and breaking concrete and then making it good, applying protective
painting, coating, cleaning, testing and disinfecting etc. and the measurement
will be for the full work specified herein. Payment will be made at the unit rate of
bid per running meter length of G.I. cold water and hot water pipes. The amount
bid shall be the full payment for completion of the work in all respects as
specified herein.

Payment will be made at the unit rate of bid per running meter length of G.I. cold
and hot water pipes.

The amount bid shall be the full payment for completion of the work in all
respects as specified herein.

4.0 SOIL, WASTE, VENT & RAIN PIPES & PIPE FITTINGS

4.1 Scope

The work under this section of the specifications consists of providing all plant,
equipment, appliances, material and labour for supply and proper installation of
soil, waste, and vent pipes and pipe fittings including, clamping, cleaning,
painting etc., as shown on the drawings or as specified herein.

4.2 Cast Iron Soil, Waste & Rain Water Pipes and Fittings

4.2.1 Material

The cast iron pipe shall conform to British Standard 416 for “Cast Iron
spigot and socket soil, waste and ventilating pipes and fittings" with
socket and spigot or hubless ends. Cast iron pipe below ground shall
conform to BS. 437 "cast iron spigot and socket drain pipe and fittings"
with socket and spigot ends. The joint shall be lead caulked or
elastomeric (Rubber Ring) to BS 2494.

Cast iron pipes shall be centrifugally (spun) cast.

The quality of material shall be according to B.S.S. No.1452 for

Grade 10.

Construction of Bridge at Korangi Causeway 5100-6 Plumbing

 The contractor shall supply coated pipes and fittings. The coating
composition shall be of tar basis or a mixture of natural bitumen with a
suitable hardener and natural asphalt. The coatings shall be smooth,
tenacious, sufficiently hard, not to flow when exposed to a temperature
of 63°C and not so brittle at zero degrees centigrade that it chips soft
when scribed lightly with the point of a penknife.

Every pipe shall be tested at the manufacturer's work to a hydraulic test

pressure of 0.07 MPa. Every pipe and fitting shall ring clearly when
tested for soundness by being struck all over with a light hammer.

4.2.2 Installation

All cast iron soil pipes and fittings shall be installed to the lines and
grades shown on the drawings or as directed by the Engineer. When
required to be installed above ground floor level, suitable and substantial
number of hangers and supports of approved type and make shall be
provided. No piping shall be hung from the piping of other systems.
Clamps shall be provided on not more than 1500mm centres or a
minimum of one hanger per each length of pipe whichever is smaller.
Where excessive numbers of fittings are installed, additional clamps will
be provided.

All steel clamps, hangers and support etc. shall be given one coat of red
oxide primer and two coats of synthetic enamel paint. All exposed C.I.
soil/vent pipes shall be given two coats of synthetic enamel paint.
Materials for painting shall be high quality product of well-known
manufacturer and will be approved by the Engineer before using. The
instructions of the manufacturer regarding all painting work shall strictly
be adhered to.

Caulked joints for cast iron bell-and-spigot soil pipe shall be firmly
packed with oakum or hemp and filled with molten lead not less than 25
mm deep and not to extend more than 1/8 inches below the rim of the
hub. Rubber ring joints shall also be allowed. No paint, varnish, or other
coatings shall be permitted on the jointing material until after the joint
has been tested and approved.

Pipes passing through walls, floors, etc. shall be provided with sleeves
of approved design. All vent pipes to be installed in the system shall be
provided with approved cowl and will rise at least 750mm above the roof.

4.2.3 Testing and Commissioning

For testing and commissioning refer Section 5180.

The Contractor shall furnish and pay for all devices, materials, supplies,
labour and power required in connection with all tests. All tests shall be
made in the presence of and to the satisfaction of the Engineer.

The Contractor shall also be responsible for the repair of this work &
other trades work that may be damaged or disturbed by the tests.

Defects disclosed by the tests shall be repaired. Defective work shall be

replaced with new work without extra cost to the Employer. Tests shall
be repeated as directed, until all work is proven satisfactory.

Construction of Bridge at Korangi Causeway 5100-7 Plumbing

 4.3 Measurement and Payment

Measurement for C.I. pipes, pipes shall be in running meter length and the work
to be done shall include earth work, providing and fixing of pipe, pipe fittings,
jointing, cutting and breaking concrete and then making it good, applying
protective painting, cleaning, testing and the measurement will be made for
complete work specified herein.

Payment will be made at the unit rate of bid per running meter length of pipe.
The amount bid shall be full payment for the work specified herein.

5.0 PLUMBING FIXTURES

5.1 Scope

The work under this section of the specifications consists of providing all material
and labour for supply and proper installation of plumbing fixtures of wash basins,
kitchen sinks, laboratory sinks, water closets, urinals, etc. along with all their
accessories, water inlet connection, waste outlet connection etc. complete in all
respect as specified herein or as shown on the Drawings and/or as directed by
the Engineer.

5.2 Materials and Installation

5.2.1 General Requirements

Materials shall conform to the latest referenced standard specifications

and other provisions stipulated herein and shall be new and unused.

All fixtures shall be of best quality and finish and shall be of approved
manufacture, shape and size.

Prior to procurement of the materials, the Contractor shall be required to

prepare and submit to the Engineer for his approval, a complete
schedule of materials to be used in the works together with a list of the
names and addresses of the manufacturers and the trade names of the
materials. The schedule shall include diagrams; drawings and such
other technical data as may be required by the Engineer to satisfy him
as to the suitability, durability, quality and usefulness of the material to
be purchased.

Approval of the schedule shall not be construed as authorizing any

deviations from the specifications unless the attention of the Engineer
has been invited to the specific changes. If the material or equipment
offered under this provision is, in the opinion of the Engineer, equal to or
better than specified, it will be given consideration.

Plumbing fixtures shall have smooth impervious surfaces, be free from

defects and concealed fouling surface. They shall be true to line, angles,
curves and colour etc. Normally they shall be of local make and of the
best quality available, provided. All taps and cocks to be installed with
plumbing fixtures shall be chrome plated (CP) and shall be of
appropriate class to work without damage or leakage on the specified
pressure of potable water system, which is 128 psi.

When any fixture is provided with an overflow, the waste shall be so

arranged that the standing water in the fixture cannot rise in the over
flow when the stopper is closed or remain in the overflow when the
fixture is empty.

Construction of Bridge at Korangi Causeway 5100-8 Plumbing

 Plumbing fixtures shall be installed in a manner to afford easy access for
cleaning. The space between the fixture and the wall shall be closely
fitted and pointed so that there is no chance for dirt or vermin to collect.

When practical, all pipes from fixtures shall be run to the nearest wall.
Where fixture comes in contact with wall and floors, the joint shall be
watertight.

Wall hung fixtures shall be rigidly supported by metal supporting

members so that no strain is transmitted to the connections. Flush tanks
and similar appurtenances shall be secured by approved non-corrosive
screws or bolts.

Fixtures shall be set level and in proper alignment with reference to

adjacent walls. No water closet shall be set closer than 380 mm from its
centre to any sidewall. No urinal shall be set closer than 300 mm from its
centre to any side wall or partition nor closer than 600 mm centre to
centre.

The supply lines or fittings for every plumbing fixture shall be so installed
as to prevent backflow.

All cuttings, making holes etc and making it good shall be included in the
work.

All fixtures shall be tested for soundness, stability or support and

satisfactory operation.

5.2.2 Wash Basins

Washbasin shall be Vitreous China (with or without pedestal) of

approved manufacture, shape and size. It shall be installed as a
complete unit including 15mm CP mixer or 15m CP pillar cock, as
applicable, 15 mm CP stop-cocks, CP brass chain with 40 mm rubber
plug, CP brass bottle trap for individual wash basin and CP brass P trap
for battery of wash basins as applicable, CP brass strainer, heavy cast
iron brackets with bolts, screws etc. plastic water inlet connection pipe,
CP brass steel waste outlet and/or waste pipe, joints jointing and sealing
material, etc, with all other minor accessories required to complete the
job in all respect.

5.2.3 Water Closets (Orissa)

Squatting (Asian/Orissa) type water closet of Vitreous China shall be of

approved make, shape and size. It shall be installed as a complete unit
including 15 mm CP stopcock, plastic water inlet connection pipe. Plastic
water cisterns installed at low level including inter connecting flush
piping and sealing material etc. with all other minor accessories.

5.2.4 Water Closets (European Type)

European type water closet (coupled or non coupled) shall be of vitreous

China of approved manufacture, shape and size.

Flush tank shall be of low level type, trap shall be cast integral with pan.
The seat shall be of smooth non-combustible non-absorbent materials
like Bakelite and of the open front type fixed to the pan with hinges. The
toilet paper roll holder shall be of CP brass with CP brass brackets and
screws etc. and fixed to the wall adjacent to water closet.

Construction of Bridge at Korangi Causeway 5100-9 Plumbing

 The fittings shall also include 15 mm C.P. stopcock, plastic water inlet
connection pipe nuts bolts etc. required for installation.

5.2.5 Kitchen Sinks

Kitchen sink shall be stainless steel of approved make single bowl or

double bowl with integral drain board, of 915 mm x 510 mm size. It shall
be installed as a complete unit with arrangement for both cold and hot
water supply and shall include 15 mm CP stop-cocks, 15 mm CP mixer,
water inlet connection, CP brass strainer, CP brass/steel waste outlet
and uPVC waste pipe, heavy cast iron brackets with bolts screws etc.
joints, jointing and sealing material, etc., with all other minor
accessories.

5.2.6 Battery Room Sink

Sink shall be Vitreous China (without pedestal) of approved

manufacture, shape and size. It shall be installed as a complete unit
including 15mm CP mixer or 15m CP pillar cock, as applicable, 15 mm
CP stop-cocks, CP brass chain with 40 mm rubber plug, CP brass
strainer, heavy cast iron brackets with bolts, screws etc. CP brass steel
waste outlet and/or waste pipe, joints jointing and sealing material, etc,
with all other accessories required to install the sink in all respect.

5.3.7 Testing and Commissioning

For testing and commissioning refer Section 5180.

5.4 Measurement and Payment

Measurement for washbasins, water closets, kitchen sinks, urinal, shower head
and mixer of shower, and cleaner's sink will be made as per actual number
acceptably provided and installed. The Contractor's bid against these items shall
include supply and installation of complete unit as specified herein, inclusive of
all work from inlet connection of water supply to outlet connection with the
sanitary system, complete as per Contract Documents and/or as directed by the
Engineer.

Payment for wash basins, water closets, kitchen sink, urinal, shower head and
mixer of shower, and cleaner's sink shall be made at the applicable unit price per
number bid for the respective item in the Bills of Quantities. The specified here
in. The amount bid shall be full payment for all the work specified herein.

6.0 MISCELLANEOUS ITEMS

6.1 Scope

The work under this section of the specifications consists of providing all material
and labour, equipment, appliances etc., for supply and proper installation of
miscellaneous plumbing items of valves, cocks, floor traps, floor drain,
cleanouts, mirror, electric water cooler, gas water heater, float valve, foot valve
as specified, herein or as shown on the Drawing or as directed by the Engineer.
The Contractor shall furnish appropriate catalogues and literature and obtain
approval of the Engineer before purchase.

Construction of Bridge at Korangi Causeway 5100-10 Plumbing

 6.2 Material and Installation

6.2.1 Bronze Valves

All valves of four inch. diameter and smaller shall be of bronze unless
otherwise specified conforming to BS 5154 and shall be of appropriate
class for the working pressure of the system on which they are installed.
Open and shut indicators shall be marked on the handle. The ends may
be screwed or flanged. All valves shall be of imported of Western
Europe origin or Japan.

6.2.2 Taps and Cocks

All the taps and cocks shall be of brass, gun metal or other equally
suitable corrosion resisting alloy conforming to BS 1010 and shall be
imported in addition be chrome plated. The nominal size specified shall
be the nominal bore of the seating. The area of the waterway throughout
the body shall be not less than the area of a circle of diameter equal to
the nominal size of tap/cock. Washers for cold water cocks shall be of
specially selected leather, rubber asbestos composition or other equally
suitable material. Every tap/cock shall be tested, complete with its
component parts, to a hydraulic pressure of at least 1.96 MPa During
test it shall neither leak nor sweat.

6.2.3 Floor drains

Floor drains shall be of cast iron, uPVC or of other anti-corrosive metal.

They shall have minimum water seal of 50 mm and shall be provided
with removable bucket strainer and cleanout. The traps shall be of self-
clearing type. The open area of the strainer shall be at least equal to the
cross section area of the drain line to which it connects. Floor drains
shall have provision for connection above the water seal. Floor drain
shall be well set in position so that there is no leakage at the joint
between trap and the floor.

6.2.4 Cleanouts

Cleanouts of cast iron or uPVC shall be of the same nominal size as that
of the pipe on which it is installed with a brass cover. Cleanouts shall be
turned up through floors by long sweep fittings, wherever the space so
permits. Top finish of cleanout shall be flush with the floor by means of
finished metal plate secured in position and screwed firmly to the plug.

Cleanout shall be so installed that there is a clearance of at least

300mm for pipes less than 75 mm diameter and at least 500 mm for
pipes of 75mm and larger diameter, for the purpose of rodding.

Cast, iron pipe used with cleanout shall be measured and paid under
cast iron pipe item. All other work of ferrule, plug, concrete work, frame
and cover etc. shall be measured and paid under cleanout item.

6.2.5 Glass Mirror

The glass mirror shall be of best quality and of size, as approved by the
Engineer, securely fixed on hard board packing and of first class quality.
The mirror shall be fixed on wall as shown on the drawing or as directed
by the Engineer.

Construction of Bridge at Korangi Causeway 5100-11 Plumbing

 6.2.6 Towel Rail

The towel rail shall be of size as approved by the Engineer of chrome-

plated steel and shall be fixed to wall with chrome-plated brackets.

6.2.7 Electric Water Cooler

Cabinet shall be of heavy gauge mild steel construction painted with

non-corrosive paint from inside and with special hammer finish paint
from outside.

Push button type water taps shall be chrome plated. Drain pot shall be
made of hard plastic with stainless steel tray. Back panel shall be easily
removable for cleaning and servicing. Top cover shall be of scratch proof
Formica.

Water storage tank shall be either of stainless steel or copper alloy,

tinned inside and outside with present insulation to maintain water
temperature, with special arrangement for cleaning the tank.

Condensing until shall be heavy duty, of renowned make, hermetically

sealed with thermal overload protection for refrigerant F-12 and capillary
expansion with valves for easy gas charging.
Thermostat and other control necessary for proper functioning of the unit
shall be provided. When water connection and floor drain not shown on
the drawing for water cooler and is required, it is to be provided at no
additional cost by the contractor.

The thermostat shall control the temperature of cooled water between

+11°C to +20°C.

Water storage tank shall be rated for working pressure of 4 kg./cm2 and
test pressure of 6 kg./cm2.

6.2.8 Gas Water Heaters

Hot water heater shall be automatic, storage type and gas operated
including all necessary fittings and accessories for complete installation
& operation.

The minimum requirement of material and finish for the inner and outer
shells shall be as given in the table below. Thicknesses of the outer and
inner shells shall be adequate to withstand the rated pressure, but shall
not be less than the thicknesses given in the table below:

Heater Inside Outside

Capacities Shell Material Finish Finish
Less than Inner * 14 SWG Steel Galvanized Galvanized
50 Gallons
Outer 22 SWG Steel Galvanized Galvanized and
finished with
synthetic enamel
50 to 100 Inner 12 SWG Steel Galvanized Galvanized
Gallons
Outer 22 SWG Steel Galvanized Galvanized and
finished with
synthetic enamel

Construction of Bridge at Korangi Causeway 5100-12 Plumbing

 Over 100 Inner Galvanized Galvanized
Gallons 10 SWG and lined with
Steel at least 1.5mm.
thick copper sheet
Outer 22 SWG Steel Galvanized Galvanized and
finished with
baked
enamel
• SWG - Standard Wire Gauge

The annular space between outer vessel & inner vessel shall be filled with
fibre glass, glass wool or similar insulation material with thermal conductivity
of not more than 0.04 W/M-°C.

The working & test pressure of the heater shall be 5 bars and 10 bars
respectively. The burner capacity shall be adequate for delivering water at
not less than 70oC at rated output capacity.

Heater shall be provided with following accessories:

(i) Thermostatic control

(ii) Safety pilot
(iii) Temperature & pressure relief valve
(iv) Burner
(v) Drain valve
(vi) Auto-shut off in case of failure of pilot lamp

6.2.9 Electric Water Heaters

Cylindrical Pressure Type : Domestic water heaters shall be factory

assembled package units. The inner container shall be constructed of cold
rolled copper with all joints and seams lapped and brazed, suitable for a
working pressure of 6 bars and shall be tested to 10 bars. Full automatic
controllers to be provided.

a) The Insulated Container

The insulated container shall be contained within a steel casing

finished with oil grey primer coat suitable for a finishing coat of paint
after installation. The heater shall be provide with a copper sheated
heated element with capacity to heat the full water contents of the
o o
heater from 10 C to 60 C in a period of one (1) hour. The heater
shall be fitted with an integral, manual reset, safety cut out
thermostat.

The water heater shall be manufactured in accordance with 3456

(Part 2.3) and shall have been tested in accordance with B.S.S.
3999 (Part 2).

b) A Temperature Control System

This system shall be provided consisting of an immersion sensor

located in the heater controlling the heater output in steps (of 5kw or
o
less) to maintain an average water temperature of 60 C. The step
controller circuit shall be provided with a recycle control to prevent
all steps of the heater coming into operation at one time. The step
controller together with isolator, individual contractor, and fuses for
each heater step, “Heater On” indicator lamp, and shall other
electrical elements necessary for proper and safe operation of the

Construction of Bridge at Korangi Causeway 5100-13 Plumbing

 heater shall be contained in a sheet steel, enameled, dust proof
enclosure. All electrical elements and the manufacture and
assembly of the electrical control unit shall be in accordance with all
relevant Electrical Specifications. The heaters shall have the
capacities shown in the schedules and drawings.

c) Electrical heater will be provided with all accessories as mentioned

for gas water heater and as required by installation & operation.

6.2.10 Floor Traps

Floor traps shall be of cast iron, uPVC or of other anti-corrosive metal.

They shall have minimum water seal of 50 mm. And shall be provided
with removable nickel bronze strainers. The traps shall be of self-
cleaning type. The open area of the strainer shall be greater than the
cross section area of the drain line to which it connects. Floor traps shall
be well set in position so that there is no leakage at the joint between
trap and the floor.

6.2.11 Float Valve

Float valve shall be of copper alloy, piston type and conform to BS 1212.
Float shall be of copper conforming to BS 1968.

6.2.12 Foot Valve

Foot valve shall be installed on the suction line of the pumps where
required or indicated on the drawing. Foot valve shall be of brass, and
shall be provided with integral strainer. Foot valve shall be provided with
a spring loaded vertical check disc with gasket for tight shut-off.

6.2.13 Cowel

All vent pipe terminating above the building shall be provided with best
quality cast iron cowel and a stainless clamp for clamping of water
proofing membrane as approved by the Engineer.

6.2.14 Toilet Paper Holder

The toilet paper holder shall be approved by the Engineer of chrome

plated and shall be fixed to the wall low level chrome plated screws.

6.2.15 Fiber Glass Water Tank

Fiber glass tank shall be of specified capacity and shall be installed at

location shown on drawings or directed by the Engineer.

Fiber glass tank shall be of thermo setting polyester resin reinforced with
glass fiber. Resin shall be rapid curing and suitable for tropical climate. It
shall conform to BS-3496, type E. The material shall have adequate
strength, rigidity and resistance to impact. The tank shall be painted with
heat reflecting metallic paint. The tank shall be non-toxic to water. It shall
be impervious to water.

Construction of Bridge at Korangi Causeway 5100-14 Plumbing

 The tank shall have the following provisions:

One manhole opening with cover of not less than 500mm diameter or
square size.

Outlets for connection of filling, overflow, drain and supply pipe.

Outlets for connection of vent pipe with cowel or wise mesh.

Built-in feet for supporting the tank.

6.3 Measurement and Payment

Measurement for payment for valves, taps & cocks, floor drain floor traps,
cleanouts, glass mirror, towel rail, electric water cooler, gas water heater, electric
water heater, floor traps, float valve, foot valve, and cowel shall be made on the
basis of actual number acceptably provided and installed in position. The
Contractor's bid against these items shall include providing and installation
complete as specified herein and/or as shown on the Drawings.

Payment for valves, taps and cocks, floor drain, cleanouts, glass mirror, towel
rail, electric water cooler, gas water heater, electric water heater, floor traps,
float valve, foot valve and cowel shall be made at the applicable unit rate per
number bid in the Bills of Quantities. The bid amount shall be full payment for the
works specified herein and as shown on the drawings.

7.0 UPVC PIPE & FITTINGS

7.1 uPVC Waste and Vent Pipes & Fittings

Unplastised PVC pipes conforming to ASTM D-1785 Schedule 40 & fittings

conforming to D-2466 for soil, waste and vent shall be non-pressure pipes.
Fittings and specials compatible to use with UPVC pipes and jointing with
elastomeric (Rubber ring) or solvent cement joint. Clamps hangers and supports
shall be as recommended by manufacturer. For testing and commissioning refer
section 5180.

7.2 Measurement and Payment

Measurement for UPVC pipes, pipes shall be in running meter length and the
work to be done shall include earth work, providing and fixing of pipe, pipe
fittings, jointing, cutting and breaking concrete and then making it good, applying
protective painting, cleaning, testing and the measurement will be made for
complete work specified herein.

Payment will be made at the unit rate of bid per running meter length of pipe.
The amount bid shall be full payment for the work specified herein.

8.0 PVC PIPE & FITTINGS

8.1 PVC Pipe Sleeves Fittings

PVC pipes conforming to ASTM D-1785 Schedule 40 & fittings conforming to D-

2466 for soil, waste and vent shall be non-pressure pipes. Fittings and specials
compatible to use with UPVC pipes and jointing with elastomeric (Rubber ring)
or solvent cement joint. Clamps hangers and supports shall be as recommended
by manufacturer. For testing and commissioning refer section 5180.

Construction of Bridge at Korangi Causeway 5100-15 Plumbing

 8.2 Measurement and Payment

Measurement for PVC pipes, pipes shall be in running meter length and the work
to be done shall include earth work, providing and fixing of pipe, pipe fittings,
jointing, cutting and breaking concrete and then making it good, applying
protective painting, cleaning, testing and the measurement will be made for
complete work specified herein.

Payment will be made at the unit rate of bid per running meter length of pipe.
The amount bid shall be full payment for the work specified herein.

*** End of Section 5100 ***

Construction of Bridge at Korangi Causeway 5100-16 Plumbing

 SECTION - 5180

TESTING AND COMMISSIONING

1.0 SCOPE OF WORK

The work under this section of specifications includes furnishing all plant, labour, equipment,
appliances and materials and performing all operations required in connection with testing and
commissioning of all water line, drainage system and fixture etc. in parts and as a whole as specified
herein or as shown in the Contract Documents or as directed by the Engineer.

2.0 GENERAL

The testing shall include a complete visual inspection of the whole plumbing and fire fighting system
and verification or performance as stipulated in the material specification and of correct functioning of
the electrical and control systems.

All supply documents, operating instructions, acceptance documentation and maintenance regulations
shall be checked to ensure that they correspond with equipment described and also all certificates
such as that of the inspection authorities, test certificates and data about quality, temperature and
pressure shall be submitted.

3.0 HYDRAULIC PRESSURE TEST

On completion of the pipe work installation or sections thereof as required, pressure test shall be
made before the application of insulation. The pressure tests shall be taken by sectors. All equipment
and accessories shall be provided and the Engineer shall be given notice that the work is ready for
testing. Tests shall be made by pumping up the system to the required pressure then closing the
valves between the pump and the section under test. The valve shall remain closed for the duration of
the test and the pump shall be disconnected. Test pressure, as detailed below shall be applied as
detailed for a period two hours or longer, at the discretion of the Engineer. If, at the end of period,
there is no drop in pressure and no evidence of leak or other faults, the test will be considered
satisfactory.

Should any fault be revealed by the test, leaks are to be recorded. Faults shall be made good and the
pipe work retested as many times as necessary until satisfactory results are obtained. No additional
charges shall be allowed for retesting of any section of the works found at fault.

After all the pipes and fixtures have been properly laid and tested, they shall be flushed clean with
water and then disinfected with water solution of chlorine of at least 50 ppm strength for a contact
period 6 hours. The system will be finally flushed with clean water.

4.0 TEST PRESSURE AND PROCEDURE

Fill pipes slowly with potable water to exclude all air. Apply test pressure of 1.5 times the maximum
working pressure.

There must be no measurable loss of pressure for at least 30 minutes.

5.0 MEASUREMENT AND PAYMENT

No payment shall be made for the works involved within the scope of this section of specification
unless otherwise specifically stated in the Bills of Quantities or herein. The cost thereof shall be
deemed to have been included in the quoted unit rate of other item of the Bills of Quantities.

*** End of Section 5180 ***

Construction of Bridge at Korangi Causeway 5180-1 Testing & Commissioning

 SECTION – 5190

HYDRAULIC MODEL (PHYSICAL & MATHEMATICAL) STUDY

1. SCOPE

The Contractor shall submit, as a minimum, the following documents and drawings related to
the hydrology & hydraulic physical model study and river training work:

1. Hydrology and Hydraulic Physical Model and Study Report (with complete
calculations), after obtaining the final approval from the relevant Authorities.
2. Topographic / Riverine Survey drawings for the river at scale 1/1000 (AutoCAD and
PDF) as per the requirements for conducting the Physical Model Study.
3. Soft copies of mathematical model / all reports / maps / layout, etc.
4. Any other requirement of Indus Research Centre at Hyderabad or Hydraulic Research
Institute at Nandipur.

1.2 OBJECTIVE

1. The objective of this work is to validate the mathematical hydraulic model study
conducted for Malir River upstream adjacent to the existing Jam Sadiq Bridge.
2. The Contractor shall prepare a Hydrology and Hydraulics Study for the new bridges
over Malir River.

1.3 HYDROLOGY & HYDRAULIC PHYSICAL MODEL, RIVER TRAINING

The Contractor shall build a physical model, at scale 1/40 or 1/50, prepared (based on
the mathematical study report, Sindh Irrigation Department Requirements) by a reputed
and competent hydraulic research institute / department in Pakistan (such as Indus
Research Centre at Hyderabad or Hydraulic Research Institute at Nandipur), using the
riverine survey data, flood hydrology report, historic data of Karachi/Malir River, existing
outfalls of storm water drains disposal, high tide conditions of the sea, maximum
discharge, catchment areas, rainfall pattern of Karachi, old studies/reports conducted
for the Malir River for 100 years return period, etc.

The physical model shall be operated after calibration for variable water flow
discharges, including the maximum and historical discharges, to study the behavior of
the river and to recommend the most appropriate location, length, skew angle of bridge,
type and sizes and geometry of river training works such as guide banks, flood bunds,
cunette, spurs, etc. and also the afflux at different water flow condition including
maximum discharge for which the bridge and river training works shall be designed.

Up to date topographical surveys (riverine survey), geotechnical/sub-soil investigations

shall be used for the physical, hydrological and hydraulic model studies.

The Contractor shall design River Training works (including without limitation clearing &
grubbing, excavation, cut, fill, levelling, dressing, jungle cutting, grouted riprap, granular
filter layer, granular sub base layer) and embankment with its protection (stone pitching
and geo membrane) following the recommendations of the Hydraulic/Physical model
study for maximum possible discharge for 100-year return period. For the assessment
of water surface profile, steady-state simulations at maximum possible discharge shall
be carried out for the following three (3) scenarios:

1. Scenario 1: Existing / Base Conditions

2. Scenario 2: Proposed Bridge with All Proposed Works – Malir Expressway Structures
at Right Bank of Malir River with the Korangi Causeway Bridge and New Bridge
adjacent to Jam Sadiq Bridge under BRT Yellow Line project.

Construction of Bridge at Korangi Causeway 5190-1 Hydraulic Model

 Protection works for pile caps and retaining walls against soil and surrounding water,
abutment stem against backfilling and surrounding water shall be designed for
maximum possible discharge for 100-year return period. The scour depth shall be
recalculated by the Contractor as per the recommendation of the hydrological and
hydraulic model study.

The Contractor shall be responsible for securing approval from relevant Authorities on
the Physical Model Study.

The Contractor shall be responsible for constructing alternative earthen channel(s) to

divert the existing channels of Malir River as required for construction works, ensuring
efficient flow of water in dry season.

The Contractor shall undertake protection works required for the rainy season,
especially monsoon season, prior to the rainfall event as per the metrological
department’s forecast.

2.1 MEASUREMENT

Measurement of acceptably completed work shall be computed by actual measurement

mentioned in the Bill of Quantities will be made on the basis of job completed as directed
by the engineer.

2.2 PAYMENT

Payment of acceptable measured quantity will be made on the basis of Job quoted in the
Bill of Quantities and shall constitute full compensation for all the works related to the
item.

*** End of Section 5190 ***

Construction of Bridge at Korangi Causeway 5190-2 Hydraulic Model

 SECTION - 5213

POLYETHYLENE (PE) PIPES AND PIPE FITTINGS

1.0 SCOPE

The work under this section of the specifications includes furnishing all plant, labour, equipment,
appliances, materials and in performing all operations required in connection with providing and
laying of polyethylene Pipes and Pipe fittings, in accordance with the Contract or as directed
by the Engineer and the manufacturer's recommendations.

2.0 GENERAL REQUIREMENTS

2.1 Pipes and fittings shall be new and unused.

2.2 Where manufacturers of pipes and fittings are specified, they shall be of the same manufacturers
unless otherwise approved by the Engineer.

2.3 Where more than one similar item of pipes and fittings are specified, they shall be of the same
manufacturer.

2.4 The Contractor shall submit to the Engineer for approval the following information regarding the
specified/proposed items of pipes and fittings.

(i) Name and address of the manufacturers

(ii) Country of origin, make and model
(iii) Dimensions and wall thicknesses of pipes and fittings
(iv) Material and thicknesses of coating and linning
(v) MTC - mill test certificate from the manufacturers
(vi) Method of jointing, testing and commissioning
(vii) Manufacturer has the following Accreditations:
- ISO 9001 and 14001
- Third Party International Inspection Certificate.
- Manufacturer’s Submittal of QA/QC Document.

2.5 Approval by the Engineer shall not be construed as authorizing any deviation(s) from the
specifications unless they are specifically brought to notice of the Engineer.

2.6 Approval by the Engineer shall not relieve the Contractor from any of his contractual responsibility
regarding satisfactory performance and other requirements of the works.

3.0 SPECIAL REQUIREMENTS

3.1 Pipes and fittings shall be suitable for the intended use.

3.2 Every pipe shall be tested at the manufacturer's works to specified hydraulic test pressure. The
test pressure shall be maintained for sufficiently long time for proof and inspection.

3.3 Each pipe and fitting shall be permanently marked or engraved giving the following information:-

i Manufacturers Name or Trademark

ii Manufacturing date
iii Manufacturing number
iv Nominal diameter in mm
v Class or pressure rating
vi Manufacturers Inspection mark
vii Standards according to which the pipes and fittings have been manufactured.

Construction of Bridge at Korangi Causeway 5213-1 Polyethylene (PE) Pipes & Pipe Fitting
 viii Heat number should be embossed on all pipes, fittings and flanges

3.4 Unless otherwise specified, diameters of pipes and fittings shall be nominal. Actual inside and
outside diameters and tolerances in diameters of pipes and fittings shall be according to the
specified standards.

3.5 Unless otherwise specified, service ratings of pipes and fittings shall not be less than the
maximum pressure to which they will be subjected to.

3.6 Unless otherwise specified, wall thicknesses of the pipes shall be according to the class,
schedule or duty of the pipes. The wall thicknesses shall be measured at locations excluding the
jointing ends. The tolerances in wall thicknesses shall be according to the specified standards.

Wall thicknesses of fittings shall not be less than those of corresponding pipes to which they are
joined together.

3.7 Pipes and fittings ends shall be matching and compatible with each other and with the ends of
valves and appurtenances to which they are joined.

3.8 Unless otherwise approved by the Engineer, pipes and fittings, jointing materials etc. shall be of
the same manufacturers as those of the pipes and fittings.

4.0 MATERIALS

4.1 General

Materials shall conform to the latest referenced specifications and/or other provisions specified
herein. Materials shall be new and unused. In cases where manufacturers are specified,
materials shall be of the same manufacturers. In all other cases, the Contractor shall submit
the names of the manufacturer from whom he intends to buy. Other information such as
diagrams, drawings and descriptive data shall be supplied as desired by the Engineer. Approval
of materials under this provision shall not be construed as authorising any deviations from
specifications.

4.2 Manufacturing

The material from which the pipe is produced shall consist substantially of polyethylene, to which
may be added only those additives that are needed to facilitate the manufacture of the polymer,
and production of sound, durable pipe of good surface finish, mechanical strength. None of
these additives shall be used separately or together in quantities sufficient to constitute a toxic
hazard, or to impair the fabrication of welding properties of the pipe, or to impair its chemical and
physical properties.

4.3 Pipe

Pipes shall conform to International Standards Organisation (ISO) recommendations, I.S.O-4427

: and shall be of specified class capable of withstanding the specified working pressure and
test pressure.

4.4 Quality

The pipe shall not have any detrimental effect on composition of the water flowing through them.
The quantities of any toxic substances extracted from the internal wall, of the pipes shall not
exceed the values specified in ISO 4427:1966(E).

4.5 Fittings

Compatible fittings and specials for use with polyethylene Pressure Pipes shall be of the
appropriate class and shall conform to ISO 3458, 3459, 3501, 3503 or BS 5114.

Construction of Bridge at Korangi Causeway 5213-2 Polyethylene (PE) Pipes & Pipe Fitting
5.0 HANDLING AND STORAGE

5.1 General

The Contractor shall be responsible for proper handling, as per manufacturers recommendations,
of pipes and pipe fittings etc. All the material shall be stacked in accordance with the
manufacturer's recommendations at approved places as directed by the Engineer.

5.2 Transport

Transportation of pipes shall be done in such a way that they are secure and that no more than
an absolute minimum of movement can take place on the vehicle during transit. The same care
is needed if pipes are to be transferred from one vehicle to another, how short the final journey
may be.

5.3 Off-loading

Cranes shall be used for off-loading. Whole sequence of operations shall be carried out
smoothly and without snatch. Rope or nylon slings, lifting beams with flattened hooks or scissor-
dog shall be used. Hooks and dogs shall be well paded to prevent the pipe being damaged and
shall be fitted with locking device. Steadying ropes are essential.

5.4 Storage

Pipes, and fittings damaged during handling, transporting or lowering shall be rejected and
replaced at the contractor's expense. Storage shall be under shade so that all polyethylene pipes
& fittings are not exposed to sunlight and extreme heat.

5.5 Stringing and Inspection

Stringing, consists of placing pipes on the ground in line ready for laying. Care is again needed to
prevent damage during this operation.

The turned ends of all pipes shall be inspected to ensure that they are free from any local
irregularities which could affect the water tightness of the joint. All pipes shall also be
visually inspected for evidence of impact damage. When such damage is detected, a
thorough examination of internal surface in region of the pipe ends shall be made for sign of
hair cracks. Damaged pipes, joints, and fittings shall be rejected and replaced at the expense of
the Contractor.

6.0 JOINTING

Jointing shall be made by butt fusion or electrofusion, socket fusion using plain/socket ended
polyethylene fittings except for joining of valves and appurtenances.

7.0 HYDROSTATIC PRESSURE TEST

The completed pipeline or each completed section as convenient to the Contractor or as

necessary in Engineer's opinion due to differences in elevation shall be subjected to specified
hydrostatic test pressure. All fittings, specials, valves, etc. shall also be subjected to hydrostatic
testing while installed in the pipeline. The test reach in no case shall exceed 500 meters.

Before testing, the pipeline shall be cleaned as specified in British Standard CP 2010 : Part-1.
Before starting of the test, the whole of the pipeline shall be inspected.

After filling, the pipeline shall be left under lower pressure for a period in order to achieve
conditions as stable as possible for testing. More water shall be pumped in until the test
pressure is reached and then the section shall be completely closed off. The test pressure shall
be applied and maintained for at least 4 hours.

Construction of Bridge at Korangi Causeway 5213-3 Polyethylene (PE) Pipes & Pipe Fitting
 If the pressure measurements are not made at the lowest point of the section, an allowance shall
be made for the static head between the lowest point and the point of measurement to ensure
that the specified works test pressure is not exceeded at the lowest point. If a drop in pressure
occurs, the quantity of water added in order to re-establish the test pressure shall be carefully
measured.

If any abnormal movement, distortion, squirm, or leakage is detected, the test pressure shall be
dropped immediately, and cause of such abnormal behaviors shall be investigated and rectified,
in consultation with the approval of the Engineer.

The test will be considered as satisfactory, if the quantity of water required to be added to
maintain test pressure does not exceed 100 litters per meter of diameter per kilometer of
pipeline per day for each 100 ft (30 meter) head of test pressure.

8.0 MEASUREMENT AND PAYMENT

8.1 General

Except otherwise specified herein or elsewhere in the Contract Documents no separate

measurement and payment will be made for the under mentioned works related to the
relevant items of the Bills of Quantities but shall not be limited to the following. The cost thereof
shall be deemed to have been including in the quoted unit rate of the respective items of Bills
of Quantities.

8.1.1 Submission of sample

8.1.2 Transportation

8.1.3 Stacking and stringing

8.1.4 Jointing/welding

8.1.5 Cutting, turning and jointing of pipes

8.1.6 Pipe fitting (tee, bend, flanges, adopters, blank flanges etc.)

8.1.7 Flushing, Testing and Disinfection & Commissioning of pipe line

8.2 Measurement of Polyethylene Pipe

Measurement of acceptable completed works of supply, erection and installation of pipes

including fittings will be made on basis of actual length in running meter of pipes provided
and installed in position as shown on the drawings or as directed by the Engineer.

8.3 Payment

Payment will be made for acceptable measured quantity of supply, erection and installation of
polyethylene pipes including fittings on the basis of unit rate per running meter quoted in the bills
of quantities and shall constitute full compensation for all the works related to the item.

Construction of Bridge at Korangi Causeway 5213-4 Polyethylene (PE) Pipes & Pipe Fitting
 SECTION 5233

RCC & CAST IRON COVERS WITH FRAMES

1.0 SCOPE OF WORK

The work to be done under this section of the specifications consists of furnishing all plant, labour,
equipment, appliances, materials and performing all operations required in connection with the installation
of RCC & C.I. cover with frame, gratings and ladder rungs, complete as specified herein, as shown on the
drawings and or as directed by the Engineer.

2.0 CAST IRON COVERS WITH FRAME

Cast iron cover and frame shall be of the sizes and duty as specified on the drawings. The specified size
means the clear opening. The cover shall be complete with frame. Top of cover shall be roughened in an
approved pattern. Locking and licking arrangement shall also be provided. The frame shall be well set in
place at the time of pouring of concrete. The cover shall tightly fit in the frame. It shall be airtight and
water-tight. The duty, weight, test and working load for 600mm circular or square C.I. cover and frame
shall be as per relevant Class of BS EN 124 or as follows: -

Class/Duty of Gross* Peak or Services

Cover and Frame Weight Test Load Working Load
(Approx.)

Extra Heavy Duty ---------- 900 KN 300 KN

Heavy Duty 225-285 Kg 400 KN 135 KN

Medium Duty 130-140 Kg 50 KN 17 KN

Light Duty 70-80 Kg 10 KN 3.5 KN

* The column of gross weight is indicative only for the duty of manhole. The Contractor shall ensure that
the manhole is rated for above mentioned test load irrespective of the weight.

3.0 LADDER RUNGS

Galvanized steel ladder rungs with epoxy coating shall be fabricated to the size specified on the drawings
or as directed by the Engineer. The galvanized mild steel ladder rungs with epoxy coating shall be fitted
by approved fittings at locations shown on the drawings or as directed by the Engineer.

4.0 CAST IRON GRATING AND FRAME

All cast Iron grating and frame shall be of the sizes and duty as specified on the drawings. The specified
size means the clear opening. Cast iron grating shall be complete with frame. They shall be of heavy-duty
type (225-285kg) to resist heavy traffic loads. The casting shall be sound and free from all defects. The
frame shall be set in place at the time of pouring of concrete. Opening in gratings shall be in an approved
pattern.

Construction of Bridge at Korangi Causeway 5233-1 Cast Iron Covers with

Frames & Ladder Rungs
5.0 RCC COVER WITH FRAME

RCC cover and frame shall of sizes as specified on the drawings. The specified size means the clear
opening. The cover shall be complete with frame. Top of cover shall be specified reinforced concrete on
steel frame as shown on drawing the outer frame shall be cast iron and shall well set in place at the time
of pouring of concrete. The cover shall be air-tightened and water tight.

6.0 MEASUREMENT AND PAYMENT

6.1 General

Except otherwise specified therein or elsewhere in the contract documents, no separate measurement
and payment will be made for the under-mentioned works related to the relevant BOQ items but shall not
be limited to the following. The cost thereof shall be deemed to have been included in the quoted unit rate
of the respective items of the Bills of quantities:

- Lock and key

- Applying bituminous paint
- Anchor bars, grouting materials etc

6.2 Cast iron cover with frame, Cast iron Grating Cover and galvanized MS ladder rungs

Measurement

Measurement of acceptable completed work of Cast iron cover with frame, Cast iron Grating Cover and
galvanized MS ladder rungs will be made on the basis of actual number of covers with frame and MS
ladder rungs provided and installed in position as shown on the drawings or as directed by the Engineer.

Payment

Payment for the acceptably measured number of Cast iron cover with frame, Cast iron Grating Cover and
galvanized MS ladder rungs shall be made on the basis of unit rate per number quoted in the bills of
quantities and shall constitute full compensation for all the works related to the item.

*** End of Section 5233 ***

Construction of Bridge at Korangi Causeway 5233-2 Cast Iron Covers with

Frames & Ladder Rungs
 SECTION – 5240

PUMPING MACHINERY

1. SCOPE

The work to be done under this section of the specifications includes furnishing all labour, equipment,
appliances and materials and in performing all operations required in connection with the installation
of pumping machinery including all accessories as specified herein or shown on the Drawings or as
directed by the Engineer.

2. MATERIALS AND PRODUCTS

Materials and machinery shall conform to the latest referenced specifications and other provisions
specified herein and shall be new and unused. In case where manufacturers are specified, materials
and equipment will be of the same manufacturers. In all other cases the Contractor shall submit the
names and addresses of the Manufacturers and trade names of the materials and equipment that he
intends to buy. Other information such as diagram, drawing and descriptive data will be supplied if so
desired by the Engineer. Approval of materials and all the machinery under this provision shall not be
construed as authorising any deviations from the specifications. The approval of machinery of
manufacturer other than that specified will be purely on the discretion of the Engineer. The Engineer
will fully ascertain the facts and satisfy himself as to the performance of the machinery offered by the
Contractor.

3. SPECIAL REQUIREMENTS OF PUMPS

The Contractor shall furnish with each pump properly identified characteristic curves prepared and
certified by the manufacturer showing capacity, head, efficiency and brake horsepower throughout the
entire range of the pump.

The pumps shall have stable throttling curves and be suitable for unrestricted parallel operation.

All pumps shall be electric driven.

The pumps and their drives shall not overload or trip when operating against zero pressure.

The design, construction and materials shall be such that damage as a result of cavitation is
completely eliminated.

Pumps shall have bearings and be suitable for continuous as well as intermittent operation without
external sealing or cooling water. The pumps shall be such that they shall come into operation at once
after a prolonged shutdown period without having to take special measures. Pumps shall be capable
of delivering specified quantity of water at the specified pressure.
Pumps shall be tested at site before their final acceptance.

Pumps shall be installed at positions shown on the Drawings and/or as directed by the Engineer.

Pumps and their drives shall be in perfect alignment when installed in position.

4. PUMP AND MOTOR

4.1 Submersible Drainage Pump

The pump shall consist of submersible drainage (non-clogging) pump of the specified
capacity and head and shall be integral sealed unit with strainer.

Pump material shall be as under:

Casing : Cast Iron/Stainless Steel

Impeller : Stainless Steel

Construction of Bridge at Korangi Causeway 5240-1 Pumping Machinery

 Shaft : Stainless Steel
Bearing : Pre-lubricated bearing
Motor : Air filled water tight

The pumps shall be installed inside the sewage/drainage pit as shown on drawing. The
discharge flange shall be threaded to BS 21 and shall be rated for working pressure of 10
2
kg/cm .

The motor shall have a built-in over load protection, low voltage, overheating and phase
failure.

5. INSTALLATION

The drainage pump shall be installed at the location shown on the drawing or as per Manufacturer’s
recommendations.

6. PUMP ACCESSORIES

Pumps shall be provided inclusive of the following accessories:

i) Strainer on pump suction.

ii) Reducer/enlarger is necessary if the pump discharge size is different from discharge piping
and the item is not given separately in the BOQ.

7. MOTOR PROTECTION

Motors of 3kw or less power shall be started direct on line. Larger motors shall be started by star-delta
starter.

Motor shall be protected against under voltage over voltage, overload, over-heating and phase failure.

Motor shall be rated for normal operation against a voltage fluctuation of + 10% and frequency
fluctuation of + 2Hz.

8. CONTROL

8.1 Submersible Drainage Pump and Motor

For Submersible pumps, one pump shall be duty and one shall be duty cum standby or as
shown on the drawings. Duty shall however change between the pumps on each start/stop
cycle of the pump. The submersible drainage pumps shall be operated with high and low
water level switches/transducers as shown on the drawings.

9. MAINTENANCE MANUALS AND TOOLS

A book or books containing the complete information in connection with the assembly, operation,
lubrication, adjustment and repair of the pumping equipment, electric motor, together with detailed
parts list with drawings or photographs shall be furnished in duplicate.

For the pump room, special tools necessary for maintenance and repair of the pumps and electric
motors including tools kits, grease guns etc. with accessories shall be furnished.

The manufacturer’s recommended list of spare parts to be stocked by the CLIENT shall be submitted
by the Contractor to the Engineer for approval. Such spare parts will also be furnished by the
Contractor.

Construction of Bridge at Korangi Causeway 5240-2 Pumping Machinery

 All the maintenance manuals, tools, spare parts etc., shall be supplied by the Contractor at no cost of
the CLIENT and all cost shall be deemed to be included by the Contractor in his bid against item of
pumping set.

10. MEASUREMENT AND PAYMENT

10.1 Pumping Machinery

10.1.1 Measurement

Measurement for payment of pumping machinery along with strainer, level

switches/transducers, gate valves, check valves, pump lifting guide rail/arrangement,
Motor Control Electric Panel (weather protected), shall be that in one set acceptably
provided and installed in position; the Contractor's bid against these items shall
include cost of providing and installing the pumping machinery including the pumps,
electric motors, all accessories, manuals, tools, spare parts, etc., as shown on the
Drawings, as specified herein or as directed by the Engineer.

10.1.2 Payment

Payment will be made for acceptable measured quantity of pumping machinery along
with strainer, level switches/transducers, gate valves, check valves, Motor Control
Electric Panel (weather protected), and pump lifting guide rail/arrangement shall be
that in one set on the basis of unit rate per set quoted in the Bill of Quantities. The
amount bid shall be full payment for the work specified.

Construction of Bridge at Korangi Causeway 5240-3 Pumping Machinery

 SECTION - 6411

WATER PROOFING AND BUILT-UP ROOFING

1.0 SCOPE

The work under this section of the Specifications consists of furnishing all plant, labour,
equipment, appliances and materials and in performing all operations in any floor and at any
height in connection with water-proofing, expansion joint filling including pre-fabricated cover
assemblies and built-up roofing, with water proof treatment to foundations and basement
structures complete in strict accordance with this section of the specifications and the
applicable drawings and subject to the terms and conditions of the Contract.

2.0 SUBMITTAL

2.1 Shop Drawings: Shop drawings shall be submitted showing layout and all the details for
construction.

2.2 Samples of all materials proposed for use under this section, shall be submitted to the
Engineer for approval.

3.0 MATERIALS

3.1 Bitumen 10/20 grade shall be according to BSS.

3.2 Bitumen priming oil shall be of the approved manufacturer.

3.3 HY-Grip primer or equivalent

3.4 Self adhesive membrane HY-Grip (P2000-SBS) or equivalent.

3.5 Polyethylene building film visqueen standard or approved equal. The film shall be 200
micron thick.

3.6 Felt shall be asphalt impregnated jute based as per BS 747. The number of ply shall be
3 or as specified in the Drawings or as approved by the Engineer.

3.7 Cement and aggregates shall be in accordance with specifications for "Plain and reinforced
concrete".

3.8 Water proofing agent shall be in accordance with specifications or as directed by the
Engineer.

3.9 High Density Extruded Polystyrene (Thermopore) board shall have a density as shown on
the drawings.

3.10 Polyethylene sheets 1mm thick.

3.11 Polysulphide sealant of approved manufacturers

3.12 Flexible cementiteous water proofing AQUAFIN-TC 07 & AQUAFIN -2K/M or approved
equivalent

3.13 Aluminum Flashing

3.14 Precast concrete pavers

3.15 Liquid Water Proofing Membrane

3.16 Modified bitumen sheet membrane 2mm thick (torch or approved equivalent)

Construction of Bridge at Korangi Causeway 6411-1 Water Proofing and Built-Up

Roofing
4.0 DELIVERY STORAGE AND HANDLING

Materials shall be protected from damage during loading shipment delivery and storage
Non-staining materials shall be used for blocking and packing.

5.0 PREPARATORY WORK

5.1 All scuppers and roof drains shall be placed and metal flashing flanges etc. shall be
provided in time to be installed alongwith the roofing assembly.

5.2 All surfaces, to be treated shall be dust free and dry. Application of roof finishes shall not
start unless the preparatory work has been inspected and approved by the Engineer.

6.0 WATER PROOFING TREATMENT IN FOUNDATIONS AND SURFACES IN CONTACT

WITH EARTH

All surfaces to be bitumen painted shall be thoroughly cleaned of any accretion, dust, dirt
etc. by scraping, wire brushing or as directed by the Engineer. The surface shall be primed
with a coat or asphalt oil used at the rate of not less than 1 gallon /100 square feet. Two
coats of hot bitumen paint shall be applied at the rate of 1 kg/Sq.m. each coat. The first coat
shall be allowed to dry for about 6 hours before applying the second coat. During operation
of painting great care shall be taken to avoid air bubbles. The manufacturers shall be taken
to avoid air bubbles. The manufacturer's instructions and Engineer's directions shall be
followed.

7.0 APPLICATION OF WATER PROOFING TO UNEDERGROUND WATER RETAINING

STRUCTURES

7.1 Water proofing shall not be applied during rain or while surfaces are damp, it shall be
applied only to surfaces that are clean and dry.

7.2 Hy-Grip primer or approved equivalent shall be applied as per manufacturer’s

recommendations.

7.3 After primer, one layers of self adhesive membrane Hy-Grip (P2000-SBS or approved
equivalent) shall be applied as per manufacturer’s specifications. The Contractor shall
protect the membrane from damages during laying and subsequent operation and shall
replace at his own cost all damaged membrane to the satisfaction of the Engineer.

8.0 EXPANSION JOINT FILLING

Before filling of Expansion Joint the surface shall be thoroughly cleaned and filling/packing
material removed up to a depth of 50mm. Backer Rod shall then be inserted throughout the
length of joint and pressed in. The joint shall then be sealed with 2 part polysulphide
sealant.

9.0 EXPANSION JOINT COVER ASSEMBLIES

9.1 Products

9.1.1 Miscellaneous Metals

A. General: Provide miscellaneous metal items and systems complete including

incidental plates, angles, bolts, anchors and similar items, and welding required to
join items and systems together and to other materials.

B. Materials: Miscellaneous metal, unless otherwise indicated or specified, shall be

mild steel conforming to ASTM A 7 for structural steel, and ASTM A 27 for cast
steel.
C. Aluminum: 6063-T5 Alloy, C1-R1-204 clear and anodized.

Construction of Bridge at Korangi Causeway 6411-2 Water Proofing and Built-Up

Roofing
 D. Accessories: Manufacturer's standard anchors, fasteners, set screws, spacers,
flexible seal and filler materials, adhesive and other accessories compatible with
materials in contact, as shown or required for the complete installation.
E. Wearing Surfaces: Manufacturer's standard, of the type as recommended for use.

F. Protection: Cover exposed metal surfaces with the factory-applied adhesive paper
or polyvinyl chloride (PVC) protective strip-coating.

9.1.2 Premolded Expansion Joint Covers

A. Where required, provide manufacturer's standard premolded expansion joint covers

to suit the conditions as indicated on the Drawings.

B. Where required, provide manufacturer's standard UL listed fire rated expansion

joint cover assemblies.

1. Fire rating of joint shall be as indicated on Drawings.

2. Achieve the required fire rating by using manufacturer standard methods

and UL approved construction details.

9.1.3 Fabrication

A. General: Provide the basic profile and operating units for expansion joint covers as
shown on Drawings. Select units comparable to those shown or required for the
joint size and to absorb variations in adjacent surfaces and structural movement.
Provide the longest practicable lengths to minimize the number of end joints.
Provide hairline metered corners where joint changes direction or abuts other
material systems.

B. Wall Joint Cover Assemblies:

1. Provide concealed, continuously anchored members fastened to wall only

on one side of the joint. Extend cover to lap each side of joint with free
movement. Attach cover to the anchor member with the cover in close
contact with adjacent contact surfaces.

2. Provide flexible vinyl moisture seal on slippage side under exterior covers
and elsewhere as shown. Make other provisions as necessary to provide a
weather tight installation.

C. Floor Joint Cover Assemblies:

1. Provide continuous angle shape seating members with raised floor rim and
concealed bolt or stud anchors for casting into concrete.

2. Provide one on each side of flat joints; one only on floor side of corner
joints.

3. Provide recessed cover plates for flat joints to receive floor covering and
angle pattern cover plates for corner joints, unless otherwise shown. Lap
sliding angles of cover plates on seating members. Attach covers for flat
joints to one seating member; attach angle cover for corner joints to wall.

4. Fill space between edge of cover plate and raised rim of seating member,
flush to finished floor, with flexible filler material suitable to withstand floor
traffic, as recommended by the expansion joint manufacturer. Adhere filler
to seating member with waterproof adhesive or pressure-sensitive tape.

Construction of Bridge at Korangi Causeway 6411-3 Water Proofing and Built-Up

Roofing
 5. Provide continuous flexible vinyl moisture seals for weather tight joints, as
shown on the Drawings.

9.1.4 Construction Joints And Control Joints

A. Clean surface of concrete construction joints and remove laitance.

B. Wet Joints and remove the standing water.

C. Locate the construction joints in floors within the middle third of spans of slabs,
beams and girders. Offset joints in girders a minimum distance of two times the
width of intersecting beams.

D. Place beams, girders and haunches monolithically as a part of slab system, unless
otherwise shown on Drawings or Specifications.

E. Beams, girders or slabs supported by columns or walls shall not be cast or erected
until concrete in vertical support members is no longer plastic.

F. Spacing:

1. Space control joints in slab on grade at 6 m maximum interval on both

directions. The resulting concrete panel shall be approximately square.

2. In concrete walls having frequent openings, spacing control joints 6000

mm apart is considered maximum. Spacing in walls without windows shall
not be more than 7500 mm and a joint within 3000 mm of each corner is
desirable.

3. Vertical construction joint spacing in concrete walls shall not be more than
12 m and shall be located within the middle third of the span between
columns.
9.2 Execution

9.2.1 Installation

A. General: Conform to the manufacturer's instructions and recommendations.

B. Cutting, Fitting and Placement:

1. Perform the cutting, drilling and fitting required for the installation of the
items. Set the work accurately in location, alignment and elevation plumb,
level, true, measured from established lines and levels. Provide temporary
bracing or anchors in formwork for items which are to be built into concrete,
masonry or similar construction.

2. Install joint cover assemblies in true alignment. Set floor covers at

elevations to be flush with adjacent finished floor materials. Locate wall,
cleaning and soffit covers in continuous contact with adjacent surfaces.
Securely attach in place using the required accessories. Locate anchors
approximately 75 mm from each end, 300 mm on the center between ends
for the set screws and 450 mm on the center between ends for other
fasteners, unless closer spacing is recommended by the manufacturer.

3. Hold end joints to the minimum. Make end joints using strong, rigid,
mechanical splice plate in true alignment, with hairline joints.

Construction of Bridge at Korangi Causeway 6411-4 Water Proofing and Built-Up

Roofing
 9.2.2 Cleaning and Protection

A. Do not remove strip-protective material until finish work in adjacent areas is

complete. When protective material is removed, clean exposed metal surfaces in
accordance with the manufacturer's instructions.

10.0 BUILT-UP ROOFING

Built-Up Roofing shall comprise of:

Top Gard / Coat ‘Flexible Cementitious Water Proofing Aquafin - 2k/M or approved
equivalent’, on top slab surfaces that are clean, dry, and free of dust and dirt. Substrate
should be prepared by filling all the cracks and depressions. Over this waterproofing layer,
50 mm thick insulation boards high density extruded polystyrene sheets with a density not
less than 32 kg/m³ adhering to substrate by suitable means. The Polystyrene board layer
shall be protected with a 200-micron layer of polyethylene sheets adhering to the
polystyrene board with a suitable adhesive. Over polyethylene sheet, 50mm (minimum and
maximum as per slope shown on the drawing) Class 'C' concrete screed top protection. A
final layer of panel roof tiles of appropriate size and strength of Concrete not less than 3000
psi (cylindrical) with gravel shall be placed as shown on the drawings. Gravels shall be
uniformly graded with sizes ranging between 20 to 35mm. Spacing of the gravel rows shall
be after every eight to ten tiles.

11.0 MEASUREMENT AND PAYMENT

11.1 General

Except otherwise specified herein or elsewhere in the Contract Documents, no

measurement and payment will be made for the under mentioned specified works related to
the relevant items of the Bills of Quantities. The cost thereof shall be deemed to have been
included in the quoted unit rate of the respective items of the Bills of Quantities.

The rates quoted by the Contractor in the Bill of Quantities shall include work to be executed
under these specification in any floor and at any height except where otherwise specifically
stated in the relevant item of Bill of Quantities and the Contractor shall not be entitled to any
claim or claim any compensation on this account.

11.1.1 All preparatory work, scrapping, scratching, cleaning, cant strips, gravel strips, etc.

11.1.2 Formwork

11.1.3 Cementitious water proofing Aquafin-2K/M

11.1.4 Roof treatment including Class ‘C’ cement concrete

11.1.5 Coats of bitumen.

11.1.6 200 micron Polyethylene sheet including laps/overlaps.

11.1.7 Class 'C' cement concrete cant strip.

11.1.8 Backer rod/2 part polysulphide sealant, AQUAFIN TC-07 & Thermopore sheet filling (where
ever required) in expansion joint filling.

11.1.9 Felt
3
11.1.10 High Density Extruded polystyrene insulation board having density of 32 kg/m .

11.1.11 400x400x50mm thick precast concrete tiles.

Construction of Bridge at Korangi Causeway 6411-5 Water Proofing and Built-Up

Roofing
11.1.12 Gravels

11.1.13 Aluminum Flashing

11.1.14 Vapour Barrier

11.1.15 Liquid Water Proofing Membrane

11.2 Bitumen Painting/Coating

11.2.1 Measurement

Measurement of acceptably completed works of bitumen painting/coating will be

made on the basis of net actual area in square meter as shown on the Drawings or
as directed by the Engineer.

11.2.2 Payment

Payment will be made for acceptable measured quantity of bitumen

painting/coating on the basis of unit rate per square meter quoted in the Bills of
Quantities. The unit rate shall include all cost of surface preparation and shall
constitute full compensation for all the works related to the item.

*** End of Section 6411 ***

Construction of Bridge at Korangi Causeway 6411-6 Water Proofing and Built-Up

Roofing
 SECTION - 7190

MISCELLANEOUS ROAD WORKS

1. SCOPE

The work under this section of the specifications includes furnishing all plant, labour,
equipment appliances and materials and performing of all operations of miscellaneous
works i.e making of precast cement concrete fairface kerb stone, Gutter Block and Edge
Block complete in accordance with this section of the specifications and applicable
drawings and subject to the terms and conditions of the contract. The scope of work of
this section of specifications is also covered by detailed specification as laid down herein.

2. PRE CAST CEMENT CONCRETE FAIR FACED KERB STONE/GUTTER

BLOCK/EDGE BLOCK

2.1 Description

Under this item the contractor shall furnish and install in position the cement
concrete fair faced finished kerb stones/gutter blocks/edge stone as shown on
the drawings and in accordance with these specifications.

2.2 Materials

Cement concrete fair faced finished kerb stones/gutter block/edge block shall be
fair face and precast using Class 'C' concrete, conforming to the requirements as
stipulated in the section "Plain and Reinforced Cement Concrete". The formwork
shall conform to the requirements as stipulated in the section "Formwork".

2.3 Construction

The form facing-material shall produce a smooth, hard, uniform texture on the
concrete surface. It shall be smooth plane surface timber, steel or other
approved material supported by strong studs or other backings capable of
preventing deflection, deformations and to give straight edges and fair finish.
Concrete shall be tipped from the trolley slightly in advance of the working place
and then shoveled into position. The spreading shall be carried out very carefully.
Compaction shall be done with vibrator compactor. It shall operate only in the
mass of the concrete and should not be allowed to strike or displace the form.
The spreading and compacting shall proceed without stoppage or interruptions
and continue as quickly as possible so as to ensure that the curbs are monolithic
and without plane of weaknesses and fully leveled throughout its length. When
the initial set takes place, the surface shall be troweled smooth with a steel trowel
to make dense, neat, clean and smooth top surface.

2.4 Protections and Curing

Concrete placed within the form shall be protected from harmful injuries by heat
of the sun, rain, flowing water and all kinds of disturbance and mechanical injury
and shall not be allowed to dry out from the time it is placed until the expiry of the
minimum curing period of 14 days.

The Contractor shall exercise care in avoiding damage to kerbs while removing
the forms. Forms may be removed when concrete has sufficiently hardened, may
be in 48 hours. Under no circumstances the use of pry bars between the forms
and kerbs walls will be permitted.

Construction of Bridge at Korangi Causeway 7190-1 Miscellaneous Road

Works
 All formed surface defects, visible vertical surface projections and irregularities
shall be removed. The entire surface shall be rubbed, if required by the Engineer,
with a carborandum brick No. 16 or other abrasive material until even, smooth
and uniform surface appearance is made and washed and cleaned. Plastering of
surface, application of cement or other coating will not be permitted.

3. MEASUREMENT AND PAYMENT

3.1 General

Except otherwise specified herein or elsewhere in the Contract Documents, no

measurement and payment will be made for the under- mentioned specified
works related to the relevant items of BOQ. The cost thereof shall be deemed to
have been included in the quoted unit rate of the respective items of the Bill of
Quantities.

3.1.1 Earthworks, form work & concrete in foundations.

3.1.2 Preparation for application of paint and cleaning of pavement surfaces.

3.1.3 Cement sand mortar.

3.1.4 Fixing and installation of precast elements

3.2 Pre Cast Cement Concrete Fair faced Kerb Stone/Edge Stone/Gutter Block

3.2.1 Measurement

Measurement of acceptably completed works of pre cast cement

concrete fair faced kerb stone/Edge stone/Gutter block will be made on
the basis of actual length in running meter of kerb stone/edge
stone/gutter block provided and placed in position as shown on the
Drawing or as directed by the Engineer.

3.2.2 Payment

Payment will be made for acceptable measured quantity of pre cast

cement concrete fair faced kerb stone/edge block/gutter block on the
basis of unit rate per running meter quoted in the Bill of Quantities & shall
constitute full compensation for all the works related to the items.

*** End of Section 7190 ***

Construction of Bridge at Korangi Causeway 7190-2 Miscellaneous Road

Works
 SECTION - 7510

PRECAST CONCRETE PAVING BLOCKS / TILES

1.0 SCOPE

The work shall consist of precast concrete paving blocks intended for the construction of
low speed roads, parking areas, lay byes, industrial and other paved surfaces subjected
to all categories of static and vehicular loading and pedestrian traffic. Paving blocks
covered by these Specifications are designed to form a structural element and the
surfacing of pavements, having the block to block joints filled, so as to develop frictional
interlock and placed in conformity with the fines, grades, thicknesses and typical cross-
section shown on the drawings or as directed by the Engineer.

2.0 MATERIAL REQUIRMENTS

For execution of this item provisions made in BS 6717 shall be applicable. Detailed
requirement of materials and construction shall be as under:

2.1 Binders and Binder Constituents

Paving blocks shall be made using one or more of the following binders or binder
constituents complying with the requirements of the relevant standards:

Ordinary Portland Cement BS 12

Portland Blastfurnace Cement BS 146 : Part 2
Portland Pulverized Fuel ash Cement BS 6588
Pulverized fuel ash BS 3892: Part 1
Ground granulated Blast furnace slag BS 6699

Where pulverized fuel ash is used, the proportions and properties of the combination with
Portland Cement shall comply with BS 6588.

Where ground granulated blastfurnace slag is used, the proportions and properties of the
combination with Portland Cement shall comply with BS 146 : Part 2.

2.2 Aggregates

Paving blocks shall be made using one or more of the following aggregates complying
with the relevant standards:

Natural Aggregates (Crushed or BS 882 : 1983 (except grading

Uncrushed) requirements in clause 5)
Air Cooled blastfurnace slag BS 1047 : 1083 (except
grading requirements in 4.8)
Pulverized fuel ash BS 3892 : Part-1 or Part-2
Ground granulated blastfurnace slag BS 6699

2.2.1 Acid Soluble Material (Fine Aggregate)

When tested as described in BS 812 : Part 119, the fine aggregate (material passing a
5mm sieve complying with BS 410) shall contain not more than 25% by mass of acid
soluble material either in the fraction retained on, or in the fraction passing, a 600 µ m
sieve.

2.3 Water
The water shall be. of drinking quality or in accordance with the recommendations of
appendix A of BS 3148: 1980.

Construction of Bridge at Korangi Causeway 7510-1 Precast Concrete Paving

Blocks
2.4 Admixtures and Pigments
Proprietary accelerating, retarding and water reducing agents shall comply with BS 5075:
Part 1.

Pigments shall comply with BS 1014.

Calcium chloride shall comply with BS 3587

2.5 Finishes
The finish should be agreed between the manufacturer and the Engineer.

Concrete described as "natural colour shall contain no pigment.

In composite paving blocks the surface layer shall be formed as an integral part of the
block and shall be not less than 5 mm thick.

2.6 Binder Content

3
The cement content of the compacted concrete shall be not less than 380 kg/m for
equivalent durability, paving blocks made with binder constituents other than ordinary
Portland cement shall have higher binder content than paving blocks made in a similar
way using only Portland Cement. The Engineer will decide the additional binder content.
The compressive strength test will be the only guide to the amount of additional binder
needed.

2.7 Sizes and Tolerances

2.7.1 Sizes
Paving blocks shall have a work size thickness of not less than 60 mm. Type-R blocks
shall be rectangular with a work size length of 200 mm and a work size width of 100 mm.
Type-S blocks shall be of any shape fitting within a 295 mm square coordinating space
and shall have a work size width not less than 80 mm.

The preferred work size thicknesses are 60 mm, 65 mm, 80 mm & 100 mm.

A chamfer around the wearing surface with a work size not exceeding 7 mm in width or
depth shall be permitted.

All arises shall be of uniform shape.

2.7.2 Tolerances

The maximum dimensional deviations from the stated work sizes for paving blocks shall
be as follows:

length ± 2mm
width ± 2mm
thickness ± 3mm

Where a paving block includes profiled sides, the profile shall not deviate from the
manufacturer's specification by more than 2 mm.

2.8 Compressive Strength

2
The compressive strength of paving blocks shall be not less than 49 N/mM and the
2
crushing strength of any individual block shall be not less than 40 N/mM .

Construction of Bridge at Korangi Causeway 7510-2 Precast Concrete Paving

Blocks
2.9 Sampling

The following sampling procedure shall be used for the compressive strength test.

a) Before laying paving blocks, divide each designated section, comprising not
more than 5000 blocks, in a consignment into eight approximately equal groups,
Clearly mark all samples at the time of sampling in such a way that the
designated section or part thereof and the consignment represented by the
sample are clearly defined. Take two (2) blocks from each group.

b) Dispatch the sample to the test laboratory, taking precautions to avoid damage to
the paving blocks in transit. Each sample shall be accompanied by a certificate
from the person responsible for taking the sample, stating that sampling was
carried out in accordance with this Part of BS 6717.

c) Protect the paving blocks from damage and contamination until they have been
tested. Carry out any tests as soon as possible after the sample has been taken.

3.0 CONSTRUCTION REQUIREMENTS

3.1 Laying the Concrete Blocks

Before laying the concrete blocks sand cushion shall be placed on the prepared surface
of aggregate base course or lean concrete as per specification/drawings.

The total area will thereby be divided with nylon strings into sectors of not more than
1.5 square meters. This shall be done to control the alignment of paving blocks and to
avoid multiplication of deviation in sizes of paving blocks.

3.2 Tolerance

The surface will be tested with a four (4) meter straight edge by the Engineer at selected
locations. The variation of the surface from the testing edge of the straight edge between
any two (2) contacts with the surface shall at no point exceed four (4) millimeters when
placed on or parallel to the centerline or three (3) millimeters when placed perpendicular
to the centerline of the roadway. The top of the base shall not vary from the required
elevation by more than five (5) millimeters. All humps and depressions exceeding the
specified tolerance shall be corrected by removing the defective work and replacing it
with new material as directed by the Engineer.

4.0 MEASUREMENT AND PAYMENT

4.1 General

Except otherwise specified herein or elsewhere in the Contract Documents, no

measurement and payment will be made for the under mentioned specified works related
to the relevant items of the Bill of Quantities. The cost thereof shall be deemed to have
been included in the quoted unit rate of the respective item (s) of the Bill of Quantities.

4.1.1 Providing, fixing, striking etc. of formwork.

4.1.2 Curing and testing of concrete.
4.1.3 Sand cushion in bed/joints for laying paving blocks/ tiles.
4.1.4 Edge precast blocks and cut units.
4.1.5 Cast insitu concrete to stablise edge precast blocks.

Construction of Bridge at Korangi Causeway 7510-3 Precast Concrete Paving

Blocks
4.2 Cement Concrete Paving Blocks

4.2.1 Measurement

Measurement of acceptably completed works of cement concrete paving blocks will be

made on the basis of actual area in square meter of concrete paving blocks provided and
laid in position to the line, level and grade as shown on drawing or as directed by the
Engineer.

4.2.2 Payment

Payment will be made for acceptable measured quantity of cement concrete paving
blocks on the basis of unit rate per square meter quoted in the Bill of Quantities and shall
constitute full compensation for all the works related to the item.

4.3 Pre-Cast Fair faced Concrete Paving Tiles

4.3.1 Measurement

Measurement of acceptably completed works of pre-cast concrete paving tiles will be

made on the basis of actual area in square meter of concrete tiles provided and laid in
position to the line, level and grade as shown on drawing or as directed by the Engineer.

4.3.2 Payment

Payment will be made for acceptable measured quantity of pre-cast concrete paving tiles
on the basis of unit rate per square meter quoted in the Bill of Quantities and shall
constitute full compensation for all the works related to the item.

*** End of Section 2510 ***

Construction of Bridge at Korangi Causeway 7510-4 Precast Concrete Paving

Blocks
 SECTION - 8001

GENERAL SPECIFICATIONS FOR ELECTRICAL WORKS

1. SCOPE OF WORK

The works related to the Electrical system, which are included in the scope of this
Contract, are shown on the Drawings, stated in the Specifications and Bill of Quantities
and explained in these specifications. The works shall broadly include but not limited to
the following:

- LT Switchboard / LT Outdoor Distribution Board

- Light Fixtures
- Low Tension Cable
- Wiring Accessories
- Pipes and Conduits
- Earthing / Grounding System
- Miscellaneous items
- Coordination with the utility KELECTRIC and ensuring approval for required
0.415KV connection and termination of 0.415kV cables at Main Low Tension
Outdoor Distributors.

The Contractor shall also be responsible to supply any other equipment not specifically
mentioned in these documents but which is necessary for proper operation of the system
as intended in the scope of this Contract. The Contractor shall solely be responsible for
ensuring proper functional requirements of various equipment and shall be responsible
for furnishing any additional piece of equipment and for making modifications in the
equipment as desired and/or approved by the Engineer to achieve proper co-ordination
with various equipment offered in the bid and also with those installed by others.

Contractor shall timely carry out field survey to identify the route and exact location of
feeders which are to be connected with the proposed Main Low tension Outdoor
Distributors (MLTODs). However, the contractor is fully responsible to ensure timely
coordination and approval from with the utility (KELECTRIC) related to connection and
termination of 0.415kV suppy and cables at Main Low Tension Outdoor
Distributors(MLTODs).

The Contractor shall have good knowledge pertaining to such works and shall ensure its
implementation along with any additional requirements as spelled out in the tender
documents or as per the requirement of these authorities.

2. RULES & REGULATIONS

The entire electrical installation/work shall be carried out by licensed Contractor,

authorized to undertake such work under the provisions of the Electricity Act 1910 and
The Electricity Rules 1937 as adopted and modified upto date by the Government of
Pakistan.

All works shall be carried out in accordance withthe latest edition of the Regulations of
the Electrical Equipment of Buildings issued by the Institute of Electrical Engineers-
London, the Tender Documents, The Electricity Rules 1937 and bye-laws that are in
force from time to time. Any discrepancy between these Specifications and any other
rules and regulations shall be brought to the notice of Engineer for his instructions and
the decision of the Engineer shall be final and conclusive.

Construction of Bridge at Korangi Causeway 8001-1 General Specifications for Electrical Works
 The Contractor shall ensure that the connection of 0.415kV supply and cable with
theMain Low Tension Outdoor Distributors (MLTODs) is certified by / acceptable
toKELECTRIC.

3. AMBIENT CONDITIONS

All material and equipment supplied and installed shall be designed, manufactured and
tested to meet the following ambient conditions unless specifically stated otherwise for
any material/equipment.

Maximum indoor ambient temperature : 50 Degree Celsius

Minimum indoor ambient temperature : Zero Degree Celsius
Maximum outdoor ambient temperature : 50 Degree Celsius
Minimum outdoor ambient temperature : Zero Degree Celsius
Maximum Relative humidity : 90 Percent
Maximum Altitude of project : 5.467 meters
Design basic wind speed : 100 miles/hr
Fastest mile wind velocity as
Per UBC 1997
Seismic Zone : 2B as per UBC 1997

The atmospheric condition is highly humid. The wind loading shall also be considered as
per applicable local Codes and Standards.

All the offered/supplied electrical equipment, devices and material etc., shall be strictly in
line with the project site conditions.

4. STANDARDS

The latest standards, codes and recommendations of reputable institutions shall be

applicable for the material and equipment specified herein and for installation work. Such
institutions to be BSS, VDE, IEC, NEC, NFPAetc. In case the Specifications laid down
herein differ from those given in the standards, then the equivalent or better
specifications shall govern. Wherever applicable the equipment shall also conform to the
requirements of Pakistan Standards and Quality Control Authority (PSQCA) and
Pakistan Standard Institution (PSI).

Contractor shall maintain at the site office one copy of the standards/codes/
recommendations as applicable to the works and will furnish the same as and when
required by the Engineer / Employer.

5. SYSTEM DATA

Unless otherwise specified elsewhere, all equipment and material shall be designed to
operate satisfactorily with the following minimum requirements without any de-rating.

a) Voltage rating of equipment : LT: 400V, 3 phase +10%

230 V, 1 phase + 10%

b) Frequency : 50 Hz + 2 Hz

In general, the electrical colour coding of switchgear cubicles, control panels, desks etc.,
shall be in accordance with the respective IEC Recommendations.

Live parts of electrical connections shall be colour coded according to IEC 60445:2017 &
BS7671:2008 as follows:

Construction of Bridge at Korangi Causeway 8001-2 General Specifications for Electrical Works
 Conductor Coding Colour
Designation Alphanumeric

A.C. Network Phase 1 L1 red

Phase 2 L2 yellow
Phase 3 L3 blue
Neutral N black

D.C. Network Positive L+ white

Negative L- black

Earthing Protective Earth PE green/yellow

Earth E green/yellow

Control Cables

The Control Cables shall be manufactured according to specifications for L.T. Cables.
The Control Cables shall be of multi-core, PVC insulated type withstanding without
deterioration the conditions prevailing at the place of installation. The cross section of
cable shall be as per the requirement of the system.

All the cores should be numbered and/or colour coded or otherwise properly identified.
At-least 20% spare cores shall be provided in all Control Cables.

No separate payment is admissible for supplying, installing, testing and commissioning

of control cables and is deemed to have been included in the BOQ rates of the
respective equipment.
Distance in between power, communication and control cables shall be kept as per
requirements laid down by NEC800, NFPA 70 and BS EN 50174-2:2009+A2:2014.

6. EQUIPMENT

6.1. Equipment Manufacturer

All equipment and material supplied for the project shall be standard products of
reputable and ISO certified manufacturers having similar manufacturing
experience of at-least five years.

For imported equipment, required for the project, only authorized local
distributors/suppliers of the Original Equipment Manufacturer (OEM) shall be
considered.

For all Original Equipment Manufacturer (OEM) equipment, the Contractor shall
clearly identify the brand of the equipment, the country where the equipment has
been manufactured, as well as the local agent in Pakistan who is able to provide
local maintenance assistance.

Authorized Local agents reference shall include at least (but not limited to)

• Company name,
• Address in Pakistan,
• Contact persons,
• Phone numbers,
• Valid Email,
• Reference of the company in similar fields.
• Authorized Distribution Certificate from OEM.
• Certified Engineer's Certificate.

Construction of Bridge at Korangi Causeway 8001-3 General Specifications for Electrical Works
 After sales, service, spare and support of all offered local/imported equipment
and material shall be available with the manufacturer/authorized distributors.

OEM/Distributors failing the above-mentioned requirements are liable not to be

considered.

6.2. Country of Origin

Equipment manufactured in Israel and Indiaare not acceptable. The Contractor

shall clearly mention in his bid the origin of the equipment that he is proposing.
In case any subassembly or part assembly is from any country other than that
the country where the equipment has been manufactured, the Contractor shall
disclose this information with his bid. No relaxation/acceptance of equipment
from the non-listed countries will be entertained after award of Contract.

6.3. Quality Assurance

All materials and equipment shall be new, unused and of best quality. Standard
components of suppliers regularly engaged in their manufacture shall be offered.
All equipment and components shall have been thoroughly tested and proven in
actual use. Equipment shall have current year of manufacturing.

Manufacturers quality control shall be in accordance with the ISO 9000 - series
(or DIN equivalent) recommendations. Manufacturers whose quality control has
been certified according to ISO 9000 – series will only be acceptable. Certified
copy shall be attached to bid.

6.4. IP Degree of Protection

The equipment shall have IP degree of protection as follows, unless mentioned

otherwise:

- IP 42 for indoor areas

- IP 54 for indoor damp areas
- IP 65 for outdoor areas

After installation, the contractor shall be responsible to provide high performance

epoxy paint on all Switchboards and related electrical equipment. If properly
rated equipment is not available, the Contractor shall provide field enclosures to
attain the required IP degree of protection. If necessary cooling/exhaust fans and
/ or anti condensate heaters shall also be provided. No separate payment shall
be made to attain the required IP degree of protection and itdeemed to have
been included in the relevant BoQ item.

6.5. Protective Paint Coating for Electrical and EquipmentComponents

All outdoor metal works including but not limited to transformer, cable
trays,outdoor LTDistribution Boards, lighting poles etc., shall be coated with
protective paint system in accordance with ISO 12944 Corrosivity Category “C5”
with Medium Durability. The Priming coat(s) shall be Epoxy based and top coat
shall be polyurethane based with color shade, not other than RAL 7032 / 7035 or
as approved by the Engineer.

Appropriate bonding / adhesion material such as Etch Primer is recommended

for use with Galvanized Surfaces before application of above-mentioned
protective paint system.

The Contractor shall submit following documents pertaining to protective paint

system for approval of the Engineer.

Construction of Bridge at Korangi Causeway 8001-4 General Specifications for Electrical Works
 - Paint manufacturer’s confirmation that proposed paint system is compatible
with the intended surface to be coated.
- Paint manufacturer’s confirmation that proposed paint products are
compatible with each other.
- Paint products catalogues.
- OEM’s recommended surface preparation methodology.
- No. of coats.
- DFT per coat.
6.6. Nameplate

All equipment shall be provided with stainless steel name plates which shall be
mounted in a visible position. The entries on the name plate shall be indelibly
marked in English by engraving and shall include the data in accordance with
relevant IEC and other relevant standard applicable to each equipment. In
addition, any specified requirement stated in these specifications shall also be
complied.
The Contractor shall also supply all labels, instruction and warning plates
necessary for the identification and safe operation of the plant/site and all
instructions shall be in English and where specified in Urdu languages. All
labels, nameplates, instructions and warning plates shall be securely fixed to
items of plant and equipment with stainless steel rivets, plated self-tapping
screws or by other approved means. The use of adhesives will not be permitted.

6.7. Identification & Labeling

All devices, meters cabling, wiring and auxiliaries shall be properly labeled for
identification. Labeling of equipment shall be done by means of flameproof
material using indelible ink/marking. The labeling shall be such as to ensure
uniformity and shall facilitate study of control diagrams/ drawings during
operation and maintenance.

All labeling shall be of suitable size to be visible from the operating

conditions/positions at site.

6.8. Lamp Test Facility

All equipment / Switchboards / Motor Control Centers, etc. shall be provided with
common lamp test facility.

7. SHOP DRAWINGS,MATERIAL SUBMITTALS, AND TECHNICAL DATA TO BE

FURNISHED BY THE CONTRACTOR

7.1. The shop drawings, comprehensive material submittals and/or technical data to
be furnished by the Contractor for each electrical equipment shall include, but
not limited to the following:

a) Structural drawings showing foundations, RCC details dimensional plans,

elevation and sections on a suitable scale including loading details of the
equipment.

b) Electrical drawings showing:

- Line/Schematic diagrams of:

 LT Outdoor Distributors

Construction of Bridge at Korangi Causeway 8001-5 General Specifications for Electrical Works
  Detailed wiring / control diagrams, elevations / internal component
layout / Top & Bottom / Side views and other standard / required
details.

c) Complete shop drawings of all systems with necessary execution / fixing/

installation details such as no. of wires, size of conduit, cable routes, cable
schedules etc.for the following layouts unless required otherwise:
- Lighting Layouts
- Grounding Layouts
- LV Cabling details including complete cable routing / conduiting / piping
and other required details
- Manhole / Duct woks
- Danger Sign Board Dimensional and installation Details.

- Combined and Coordinated Layouts.

d) Equipment installation details for LT Outdoor Distribution Board(s)

e) Technical literature and manufacturer's characteristic data with the

description of materialsand weights of all equipment as instructed by the
Engineer.

f) As-Built Drawings of existing conditions.

g) Combined Services Layout Diagrams (Coordinated with existing services)

h) Foundation and Trench Arrangement Drawings

i) Technical submittals of Equipment for:

- LT Outdoor Distribution Boards

- Miscellaneous Items (Lighting Poles)
j) Technical submittals of Equipment along with material sample for:

- Light Fixtures
- LT Cables
- Wiring Accessories
- Conduits / Pipes & Fittings
- Earthing System
- Miscellaneous Items (Cable Trays / Ladders, Switch disconnector / LBS
with weatherproof Enclosure box)
For details, refer the relevant sections of the specifications to ensure
compliance as required therein.

Technical submittals of equipment for which the material sample is not

submitted, shall be liable to rejection.
k) Testing and commissioning time table

l) Testing and commissioning protocols

m) Design Calculations/ software-based simulations:

Construction of Bridge at Korangi Causeway 8001-6 General Specifications for Electrical Works
 Based on the final approved / selected equipment/ fixture/ protective device
etc. Contractor shall perform and submit calculations to the Engineer for
review and approval. In this regard, Contractor shall perform following
software based simulations, calculations, assessment,analysis unless
required otherwise by the Engineer.

- Illumination calculations (for Street lighting) based on finally selected light

fixtures.
- Voltage drop calculation for each feeder / circuit starting from Power
Supply source (Transformer) up to point of utilization.
- Comprehensive Short Circuit software design simulations /
calculationsdetermining the maximum possible short circuit current levels.
- Selective coordination Analysis based on finally selected circuit breakers
/ fuses.
The entire LV Distribution network, starting at PMTs/ utility LT suppy and
extending up to last downstream LT Outdoor Distribution Board /
Termination device (Circuit Breaker / Load Disconnecting Switch), shall
be properly coordinated through selection of appropriate type of circuit
breaker / fuse. No additional payment shall be admissible if any higher
rating of circuit breaker / fuse is required to achieve the selectivity.
- Thermal soil resistivity measurement through field testing at site
- Earthing calculations based on actual thermal soil resistivity measured at
site.
For details, refer the relevant sections of the specificationsto ensure
compliance as required therein.

No separate payment shall be admissible for performing any software-based

simulations, design calculations, analysis, measurement, field testing
assessment, etc.Cost incurrence associated with all such scope shall deem
to have been included in the item rate of the relevant BOQ item. Any
additional payment, whatsoever, shall not be admissible in this regard.

7.2. At least three (3) copies of the shop drawings, comprehensive material
submittals and/or technical data of the equipment shall be submitted to the
Engineer for review and approval.

The Engineer will review all drawings, material submittals, manufacturer's

catalogues and design calculations and make changes as required, in order to
assist in the overall job coordination and to ensure conformance to the technical
specifications and applicable standard. The Contractor shall ensure full
compliance as commented by the Engineer on the submitted drawing,
document, material submittal, technical data, calculations and schedules etc.

Engineer's approval must be obtained before any equipment, device & material
is purchased or material fabrication is commenced. The Engineer's approval will
be general and shall in no way relieve the Contractor of this responsibility for any
work required under the Contract.

7.3. One copy of each drawing and descriptive data will be returned to the Contractor
generally marked.

(a) "APPROVED"
(b) "APPROVED EXCEPT AS NOTED"
(c) "REVISE AND RESUBMIT"
(a) "NOT APPROVED"

Construction of Bridge at Korangi Causeway 8001-7 General Specifications for Electrical Works
 Each drawing, document, material submittal, technical data, calculations and
schedules etc., which is noted as "NOT APPROVED" shall be considered
Rejected and the Contractor shall offer alternates and re-submit after making
required corrections/ compliance for Engineer’s review and approval. The
Contractor shall submit four (4) copies of the alternative offer.

Each drawing, document, material submittal, technical data, calculations and

schedules etc.,which is noted as "REVISE AND RESUBMIT" shall be re-
submitted after making corrections/ compliance for Engineer’s review and
approval. The Contractor shall submit four (4) copies of each revised issue
thereof.

Minor corrections/modifications will be necessary in the drawings, documents,

material submittal, technical data, calculations and schedules etc. marked as
"APPROVED EXCEPT AS NOTED". The Contractor may proceed ahead.
However, he shall incorporate the changes, comments, corrections etc. as
marked but does not necessarily resubmit the drawings/submittals/documents
etc. for further approval. But if the Engineer considers necessary then he may
ask the Contractor for the resubmission to verify the incorporation of
changes/comments/corrections.

Contractor is bound to submit the revised submittal within 7 days.

7.4. The Contractor must consider 21 working days (from date of receipt by Engineer
to date of dispatch from Engineer's Office) for Engineer's review of each set of
drawings/material submittals/documents etc. in his consideration of schedule of
work and in the time allowed for completion of the Contract.
7.5. The Contractor shall be responsible for any discrepancies, shortcomings,
errors or omissions in any drawings or other particulars supplied by him whether
such drawings or particulars have been reviewed by the Engineer or not.

7.6. Any delay; in the approval of the submitted material submittal, drawing,
document, technical data, calculations, and schedules etc., which is caused due
to incompleteness, shortcomings, non-submission of required information / data
etc. shall be totally attributable to the Contractor and will not be considered a
reason for extension of time (EOT).

7.7. The symbols used for the simplified representation of electrical equipment
shown on the drawings must conform to applicable NFPA, NEC, IEEE, IEC,
and/or DIN etc. Soft copies of all the applicable codes / standards as specified in
relevant clauses of different specification sections will be provided by the
Contractorto the Engineer for his reference and record.

7.8. All circuit diagrams shall be drawn in a way that they can be assembled in a
standard hard core, non-detachable binder and can be unfolded without having
to be detached.

8. MANUFACTURER'S INSTRUCTIONS

The Contractor shall supply to the Engineer in properly bound form six (6) copies of
manufacturer's instruction manuals for installation, testing, commissioning, operation and
maintenance of the specified equipment including manuals of spare parts and tools of
the equipment. At least two copies of the documents shall be submitted in original. The
installation instructions shall be submitted 2 weeks prior to commencement of installation
of each equipment, and operation and maintenance instruction at the time of
commissioning. If the Contractor fails to provide the documents,The Engineer shall
withhold issuance of requisite certificates and deduct suitable amount from the payments
to the Contractor.

Construction of Bridge at Korangi Causeway 8001-8 General Specifications for Electrical Works
9. GUARANTEE

The Contractor shall furnish written guarantee of the manufacturer or supplier with
respect to satisfactory performance of each equipment. Guarantee shall be given for
replacement and repair ofpart or whole of the equipment, which may be found defective
in material or workmanship. The guarantee shall cover the duration of Defects Liability
Period as defined in the Conditions of Contract.This guarantee shall not relieve the
Contractor of his obligations and he will be fully responsible for the repair or replacement
of any defective material in time, so as not to cause any undue delay in carrying out the
repairs and/or replacements.

10. ASSOCIATED CIVIL WORKS

Except where separately stated in the Bill of Quantities the cost of all civil works
associated with any BOQ item of electrical works, such as excavation and backfilling of
earth, compaction of the earth, foundation pads, thrust boring, chiseling, making
openings, etc. shall deemed to be included in the price quoted against respective
electrical items.

All openings made in external/internal walls, slab, ceiling, etc. for electrical works shall
be filled in after installation of equipment, laying of trays/cables etc. with suitable heat
and fire-resistant mortar, suitably rated with respect to the building fire zones so as to
ensure no ingress of water, spread of fire from one fire zone to another. All unutilized
conduit/pipe/slab opening shall be sealed with same material. Such works will also
include repair of any damage to civil works caused by the Contractor during electrical
installation.

No separate payment for such works will be made. Such works will also include repair of
any damage to civil works caused by the Contractor during electrical installation.

11. INSTALLATION INSTRUCTIONS – GENERAL

The Contractor shall install all systems components and appurtenance in accordance
with manufacturer’s recommendation and provide all necessary interconnections,
services and adjustments required for a complete functional system.

The Contractor shall provide instrumentation and communication grounding as

necessary. All penetration shall be sealed to preclude the entry of water using a silicone
material.

The Contractor shall furnish all labour, materials, tools and equipment required to install,
connect, test and commission all electrical equipment specified herein, whether or not
such equipment is furnished by him or by others.

For all equipment to be installed by the Contractor, the Contractor shall supply and install
all erection materials such as foundation bolts, washers, nuts, etc. as required and
without any additional costs.

The Contractor shall set out the works himself as per Specifications and Drawings and
shall properly position the equipment on specified foundation/location. In general, the
manufacturer's instructions for installation shall be followed. Any defect or faulty
operation of equipment due to the Contractor not following the manufacturer's
instructions shall be corrected and repaired by the Contractor at his own cost.

For any deviation from the working drawings that are deemed necessary by the
Contractor due to site conditions, he shall submit the details and obtain the Engineer
approval before starting such works.

Construction of Bridge at Korangi Causeway 8001-9 General Specifications for Electrical Works
12. FACTORY ACCEPTANCE TESTS (FAT)

12.1 Scope

Factory tests are to be carried out in the presence of both the Employer and the
Engineer. All type and routine tests onLT Outdoor Distributor, L.T Cables,
Control Cables,Plugs, Receptacles, Miscellaneous Itemsand all other equipment
shall be performed at the manufacturer's works in the presence of the Engineer
and the Employer or their representative.

Type tests may be waived off in case test certificates are submitted as certified
by an Engineer approved standard laboratory of international repute; but merely
producing the type test certificates will not relieve the manufacturerto carry out
the required standard/routine tests.

The Contractor shall submit the test procedure to the Engineer/Employer for
approval at least 4 (four) weeks before carrying out the tests.Factory test
procedures shall be drawn in accordance with relevant code/standards,
standards practices and manufacturer’srecommendation.

The Contractor shall inform the Engineer/Employer about the date and time of
test of each equipment at least two weeks in advance to allow time to the
Engineer and the Employer for preparation and travelling. This shall, however,
be done after the Contractor has got the test procedures duly approved by the
Engineer.

The Contractor shall make necessary arrangements and provide all the facilities
required for the representatives of Employer / Engineer for conductingsuch
inspection, atthe Contractor’s cost. The cost of travel shall be responsibility of
the Contractor.

The witnessing of test by the Engineer and the Employer shall not absolve the
Contractor from his responsibility for the proper functioning of the equipment,
and for furnishing the guarantees referred to in clause 9.0. All test results shall
be supplied in quadruplicate.All observations agreed on and discrepancies noted
during the inspection are to be corrected by the Contractor prior to shipment of
the equipment. Only tested equipment will be released for shipment. All test
results shall be supplied in quadruplicate.

Equipment to be supplied under this Contract shall be subject to inspection and

testing by one representative of Employer and one representative of Engineer at
its point of original manufacture or final shop assembly before its packing & and
dispatch to site. The Contractor shall make necessary arrangements and provide
all the facilities required for the representatives of Employer / Engineer for
conducting such inspection, at Contractor’s cost. The cost of travel of Employer’s
and Engineer’s representatives shall be the responsibility of the Contractor.

The Contractor shall submit tests procedures for approval of Engineer well in
advance to the set date of pre-shipment inspection. All relevant submittals, shop
drawings and requisite technical data should be approved by the Engineer prior
to the start of production.

The Contractor shall give at least 3 (three) weeks’ notice to the

Employer/Engineer for attending such inspections/tests.

All domestic FATs shall be carried out in the presence of the Employer and the
Engineer or their representatives.

Construction of Bridge at Korangi Causeway 8001-10 General Specifications for Electrical Works
 12.2 L.T Outdoor Distribution Boards

Contractor shall submit the proforma / list for essential routine tests in
accordance with the latest edition of IEC 62271-1 & 62271-200 which are to be
carried out on the proposed HT Switchboard at the manufacturer’s / assembler’s
premises during FAT for Engineer’s review during submittal review stage.

Routine tests on the proposed L.T Distribution Boards / L.T Outdoor Distribution
Boards shall be carried out at the manufacturer’s / assembler’s premises as per
relevant international standards.

Each circuit breaker shall be operated electrically and mechanically. All

interlocks and control circuits shall be checked for proper connections in
accordance with the wiring diagrams given by the manufacturer.

The Contractor shall properly identify the phases of all switchgear and cables for
connections to give proper phase sequence. Trip circuits shall be checked for
correct operation and rating of equipment served. The correct size and function
of fuses, disconnect switches, number of interlocks, indicating lights, alarms and
remotecontrol devices shall be in accordance with approved manufacturer
drawings. Nameplates shall be checked for proper designation of equipment
served. Protective relays shall be tested and set at site prior to commissioning of
the equipment. Lamp test facility will also be checked.

12.3 L.T Cables

Contractor shall submit the proforma / list for essential routine tests in
accordance with the latest edition of IEC 60502-1 / BS 6346 which are to be
carried out at the manufacturer’s premises on the offered size / rating / types of
600/1000 volt grade Multicore L.T Cables, for Engineer’s review during submittal
review stage.

Contractor shall submit the proforma / list for essential routine tests in
accordance with the latest edition of BS 6004 which are to be carried out at the
manufacturer’s premises on the offeredsize / rating / types of 450/750 volt grade
Single-core L.T Cables as well as on the offered size / rating / types of 300/500
volt grade Single-core / Multi-core L.T Cables, for Engineer’s review during
submittal review stage.

13. SITE ACCEPTANCE TEST (SAT) / FIELD TESTING

13.1 Scope

Upon completion of the installation, the Contractor shall perform field tests on all
equipment, cables, materials and systems. All tests shall be conducted in the
presence of the Engineer or his representative for demonstrating equipment or
system compliance with Specifications. The Contractor shall submit for
Engineer's approval complete details of tests to be performed describing the
procedure, test observations and expected results.

The Contractor shall furnish all tools, instruments, test equipment, materials, etc.
and all qualified personnel required for the testing, setting and adjustment of all
electrical equipment and material including putting the same into operation.

All tests shall be made with proper regard for the protection of the personnel and
equipment and the Contractor shall be responsible for adequate protection of all
personnel and equipment during such tests. The cost of any damages or
rectification work due to any accident during the tests shall be the sole
responsibility of Contractor.

Construction of Bridge at Korangi Causeway 8001-11 General Specifications for Electrical Works
 The Contractor shall record all test values of the tests made by him on all
equipment. Four (4) copies of all test data and results certified by the Engineer
shall be given to the Engineer for record purposes. These shall also include
details of testing method, testing equipment, diagrams, etc.

The witnessing of any tests bythe Engineerdoes not relieve the Contractor of his
guarantees for materials, equipment and workmanship, or as any other
obligations of Contract.

13.2 Insulation Resistance Test

Insulation resistance test shall be made on all electrical equipment by using a

meggar of 500 volts for circuitsupto 250 volts and 1000 volt for circuits between
250 and 500 volts. For testing of 11 kV circuits, upto 5 kV meggar shall be used.
The exact voltage shall be as advised by the equipment manufacturer unless
otherwise advised by the Engineer.

The insulation resistance values of cables, switchgears, etc., shall be as per

BSS, IEEE, NEC, ICEA and Pakistan Electricity Rules.

Before making connections at the ends of each cable run or joint between
cables, the insulation resistance test of each cable section shall be made. All
cables shall be subjected to high voltage test as per recommendations of
standard to which the cable is manufactured. Each conductor of a multi-core
cable shall be tested individually with each of the other conductor of the group
and also with earth. If insulation resistance test readings are found to be less
than the specified minimum in any conductor, the entire cable shall be replaced
and tests repeated on new cable. If cable joint is provided, then each cable
section shall be tested, and joint made only after the tests have been made
satisfactorily. Finally, the completed cable length including the joints shall be
tested.

The switchgears shall be given an insulation resistance measurement test after

installation, but before any wiring is connected. Insulation tests shall be made
between open contacts of circuit breakers, switches and between each phase
and earth.

If the insulation resistance of the circuit under test is less than the specified
value, the cause of the low reading shall be determined and removed. Corrective
measures shall include dry-out procedure by means of heaters, if equipment is
found to contain moisture. Where corrective measures are carried out, the
insulation resistance readings shall be taken after the correction has been made
and repeated twice at 12 hours interval. The maximum range for each reading in
the three successive tests shall not exceed 20% of the average value. After all
tests have been made, the equipment shall be reconnected as required. Polarity
test shall be made on single pole switching devices.

13.3 Earth Resistance Test

Earth resistance tests shall be made by the Contractor on the earthing system,
separating and reconnecting each earth connection.

If it is indicated that soil treatment or other corrective measures are required to

lower the ground resistance values, the Engineer will determine the extent of
such corrective measures.

The electrical resistance of the ECC together with the resistance of the earthing
leads measured from the connection with earth electrode to any other position in
the complete installation shall not exceed one Ohm. Earth resistance test shall
be performed as per Electrical Inspector's requirements. Where more than one

Construction of Bridge at Korangi Causeway 8001-12 General Specifications for Electrical Works
 earth electrodesare installed, the earth resistance test of each electrode shall be
measured by means of resistance bridge instrument.

The complete lightning protection system shall be tested for continuity and earth
resistance. The combined earth resistance at any point in the lightning protection
system shall not exceed 10 ohms.

13.4 Completed Tests

After any equipment has been tested, checked for operation, etc., and is
accepted by the Engineer the Contractor shall be responsible for the proper
protection of that equipment so that subsequent testing of other equipment do
not cause any damage to the already tested equipment.

13.5 Expenses

All expenses, i.e., traveling, documentation, boarding and lodging, allowances

etc. for carrying out the tests and witnessing by the Engineer and Employer shall
be borne by the Contractor and are deemed to have been included in the BOQ
rates of the respective equipment(s) by the Contractor.

14. SPECIAL TOOLS

The contractor shall provide special tools as indicated in Appendix-C and as may be
deemed essential for assembly, adjustment, dismantling, installation and operation
&maintenance (O&M) reasons.The total amount of Special Tools shall be carried to
relevant BoQ item.

15. STATEMENT OF COMPLIANCE

Contractor shall submit an overall in writing compliance signed and stamped with the
items of these specifications in the form of Statement of Compliance. No consideration
will be given to the bid without this important document at the bidding stage. However,
during the material submittal review stage, contractor shall submit his own proposal and
OEMs parawise compliance of relevant specification section along with each material
submittal. In absence of such compliance from the contractor and his proposed OEM,
the submittal shall be considered incomplete and will lead to rejection.

16. WARRANTY OF GOODS

The Contractor shall provide warranty of equipment as specified under the respective
section of specification for the period defined in the specifications. Effectiveness of
duration of warranty from Original Equipment Manufacturer (OEM) shall commence from
the effective date of Taking over Certificate issued by the Engineer. All warranties are to
be endorsed in the name of the Employer and an undertaking shall be submitted
from Original Equipment Manufacturer (OEM) and local representatives for ensuring
compliance of services to the Employer during Warranty Period.

17. APPENDICES TO BE FILLED IN BY THE TENDERER

The details regarding equipment manufacturers, deviations, technical data, special tools,
spare parts etc. are to be furnished in the appendices attached with form of tenders, in
accordance with the provision of the Clause “Requirements of Electrical Works” given in
the instructions to Tenderer.

18. PAYMENT

No separate payment shall be made for work involved within the scope of this section
unless specifically stated in the Bill of Quantities or herein.

*** End of Section - 8001 ***

Construction of Bridge at Korangi Causeway 8001-13 General Specifications for Electrical Works
 SECTION - 8132

LOW TENSION SWITCHBOARDS / LT OUTDOOR DISTRIBUTION BOARDS

1. SCOPE OF WORK

The work under this section consists of supplying, installing, testing, connecting,
commissioning of all material and services of the complete LT Switchboards/LT Outdoor
feeder pillar as specified herein and/or shown on the Bidding Drawings and given in the
Bill of Quantities.

The Contractor shall discuss the electrical layout with the Engineer and coordinate at site
with other services for exact route, location and position of the LT Switchboards/
LT Outdoor Distribution Boards.

The LT Switchboards/ LT Outdoor Distribution Boards shall also comply with the General
Specifications for Electrical Works Section-8001 and with other relevant provisions of the
Bidding Documents.

2. GENERAL

The LT switchboard shall be factory manufactured / assembled / routine tested either by

an Original Equipment Manufacturer (OEM) itself or by some other approved
manufacturer / assembler.

The LT Switchboards/ LT Outdoor Distribution Boards shall be of sheet steel fabricated,

floor/wall mounting, cubicle type, totally enclosed, dust tight and vermin proof. It shall be
complete in all respect with material and accessories, factory assembled, tested and
finished all according to the specifications and to the normal requirements. All wiring and
equipment for control, protection, indication, etc. required for the safe and intended
operation of the systems as specified herein or shown on the drawings shall be furnished
by the Contractor.

The outdoor LT Switchboard/ LT Outdoor Distribution Boards shall be IP-65 rated

All metal works on LT Switchboards installed outdoor / LT Outdoor Distribution Boards

shall be coated with protective paint system in accordance with ISO 12944 Corrosivity
Category “C5” with Medium Durability.

The Priming coat(s) shall be Epoxy based and top coat shall be polyurethane based with
color shade not other than RAL 7032 or 7035.

The Contractor shall submit following documents pertaining to protective paint system for
approval of the Engineer:

- Paint manufacturer’s confirmation that proposed paint system is compatible with the
intended surface to be coated.
- Paint manufacturer’s confirmation that proposed paint products are compatible with
each other.
- Paint products catalogues.
- OEM’s recommended surface preparation methodology.
- No. of coats.
- DFT per coat

Construction of Bridge at Korangi Causeway 8132-1 Low Tension Switchboards /

LT Outdoor Distribution Boards
 The LT Switchboards/ LT Outdoor Distribution Boards with all components and
accessories shall be suitable for front operation only and shall:

- be design verified assemblies as per the latest edition of IEC 61439.

- be suitable for addition of units, on either side.
- be suitable for extension of Busbar / interfacing with other L.T. Switchboard
- have a rated service short circuit breaking capacity, (Ics) at 415 V AC conforming to
IEC 60947-2 and / or as shown on the drawings.
- be provided with adequate clearance from live parts so that flashovers cannot be
caused by switching, vermin, pests, etc.
- have all components rated for insulation class of 600-volt minimum.
- be designed for flush mounting of all instruments on the front side.
- have incoming and outgoing cable termination arrangement, terminal blocks, line-up
terminals, etc.
- have all incoming and outgoing connections from the bottom or with appropriate
provision for top entry as per site requirements.
- have the components mounted so as to facilitate ease of maintenance from the
front.
- have wiring diagram in the pocket on the inside of each door of the panel.
- be suitable for 400 volts AC, 3 phase 4 wire, 50 Hz system.
- be labeled with stainless steel nameplate on the front side of door for each incoming
and outgoing circuit.
- have doors grounded by flexible copper cable/strip.
- have arrangements for extension of panel in future.
- have common lamp test facility for all lamps.

3. APPLICABLE STANDARDS/CODES

The latest editions of the following standards and codes shall be applicable for the
materials specified within the scope of this Section:

IEC 61439 - Low Voltage Switchgear and Control gear

Assemblies (All Parts)

IEC 60947-3 - Low Voltage Switchgear and Control Gear-Switches,

Disconnector, Switch-disconnector and Fuse Combination Units.

IEC 60947-2 - Low Voltage Switchgear and Control Gear-Circuit

Breakers for Moulded Case Circuit Breakers (MCCBs) and Air
Circuit Breakers (ACBs)

IEC 60831 - Shunt Power Capacitors of self- heating type AC systems having
a rated voltage upto and including 1000V

IEC 60073 - Basic safety principles for man-machine interface, marking and
identification. Coding principles for indicators and actuators

IEC 61869-2 - Instrument Transformers – Additional requirements for Current

Transformers

Construction of Bridge at Korangi Causeway 8132-2 Low Tension Switchboards /

LT Outdoor Distribution Boards
 IEC 61869-3- Instrument Transformers – Additional requirements for Inductive
Voltage Transformers

IEC 60051-1, - Direct acting indicating analogue electrical measuring

2, 3, 5 & 8 instruments and their accessories

IEC 60898-1 - Electrical Accessories- Circuit breakers for over current

protection for household and similar installations – Circuit
breakers for AC operation

IEC 60051-2 - Direct acting indicating analogue electrical measuring

instruments and their accessories. Special requirements for
ammeters and voltmeters

IEC 60871-1 - Shunt Power Capacitors for AC power systems having a rated
voltage above 1000V - General

IEC 60947-4-1 - Low Voltage switchgear and control gear – Contactors and
motor starters – Electromechanical contactors and motor
starters.

BS EN 60529 - Degrees of protection provided by enclosures (IP Code)

BS EN 13601 - Copper and copper alloys: Copper rod, Busbar and wire
for general electrical purposes.

IEC 60269 - Low Voltage fuses

.
BS 88-2 - Low Voltage Fuses. Supplementary requirements for fuses for
use by authorized persons (fuses mainly for industrial
application). Examples of standardized systems of fuses A to K.

ISO-12944-2 - Corrosion Protection of Steel Structures by Protective Paint

Systems

4. MATERIAL

4.1 Sheet Metal Work

The Switchboards shall be fabricated, welded, grinded, finished with angle iron
framework and cladded with 14 SWG MS sheet. It shall be suitably divided into
panels and compartments for accommodating the required number of circuit
components, instruments and accessories in accordance with the specified form
of internal separation.

The switchboard shall be supplied complete with foundation bolts and other
installation materials as recommended by the manufacturer. Proper size cable
clamping channels with galvanized steel clamps and brass cable glands
respectively for unarmoured and armoured cables shall be provided. All holes,
cutout shall be tool or jib manufactured and free from burrs and rough edges. An
earth bar of appropriate cross section shall be provided and connected to the
bodies of all sections of the switchboard. Two external earth terminals shall be
provided for main earth connection to the body of switchboard. The doors shall
be earthed by means of flexible copper strip. Means shall be provided to limit the
0
opening angle of doors to about 100 .

The cabling inside the switchboard shall be suitably numbered and harnessed by
means of straps or cords. Colour sleeves shall be provided on each cable lugs,
connected to the bus bars, circuit breakers or terminals etc. for phase
identification. Wiring to door mounted components shall be in flexible PVC

Construction of Bridge at Korangi Causeway 8132-3 Low Tension Switchboards /

LT Outdoor Distribution Boards
 conduit. All indicating, selecting and control equipment shall be suitably arranged
and clearly labelled by means of flame proof material using indelible ink/marking
indicating the rating of fuse, switches, etc. The nameplates provided on the front
of panel shall be of flame retardant material preferably stainless steel. Use of
plastic or any inflammable material shall not be permitted for nameplates.

4.2 Components

The switchboards shall be provided with all components as specified or shown

on the Drawings and as necessary for the satisfactory operation of the
switchboard and of the electrical system. Typical specifications are given here
under.

4.2.1 Bus Bars

The bus bars shall be made of 99.99% pure high conductivity electrolytic
tinned copper and shall be completely insulated by heat shrink colored
sleeves of specified voltage grade. And mechanically braced for the
specified fault level according to relevant IEC standard. The phase
identification of bus bars shall be by providing colours sleeves on bus
bars ends and these shall be red, yellow and blue for phase and black
for neutral. The earth bus bar shall be green. The thickness of tinning on
bus bars shall be adequate enough to ensure perfect protection against
corrosion beside ensuring specified rated ampacity.

The bus bars shall be triple pole, neutral & earth and shall be of
appropriate size to meet the electrical and mechanical requirements of
the system. The temperature rise of bus-bars, at rated current, shall not
0
exceed 30 C above the specified ambient temperature.

Neutral bus bar shall be of the same cross section as phase bus bars.
Earth bus bar shall be of half cross section area as phase bus bars.

Contractor shall submit manufacturer verified bus bar sizing calculations

along with supporting documents considering all applicable de-rating
factors for Engineer’s review and approval.

4.2.2 Circuit Breakers

The circuit breaker shall be triple/four pole, current limiting type,

manually operated or motor operated, spring charged type as shown
on the drawings with front drive grip handle. ON-TRIP-OFF indication
shall be provided on circuit breakers. The Circuit breakers shall have the
following protections and setting range unless otherwise shown on the
drawings:

- Adjustable three pole, manual reset thermal overload release of

setting range 80 to 100% of rated current.

- Magnetic triple pole short circuit release having range according

to manufacturer's standard range.

The incoming circuit breakers of main LT panel (normal and emergency)

shall be either air circuit breakers or moulded case type, whereas
outgoing circuit breakers of main LT panel shall be moulded case type,
unless stated otherwise on the drawings. Wherever Air circuit breaker is
specified on the drawing, these shall be 4-Pole, motorized, withdrawable
type, having LSIG protection.

The incoming circuit breaker shall have two numbers normally open and
two numbers normally closed auxiliary contacts rated for 2 Amp, 230

Construction of Bridge at Korangi Causeway 8132-4 Low Tension Switchboards /

LT Outdoor Distribution Boards
 VAC. The incoming circuit breaker shall also have ON-TRIP-OFF
indicating lamps. Where shown on the drawings indication lamps shall
also be provided for outgoing circuit breakers. Generally, the circuit
breaker shall have specified rupturing capacity without the use of back-
up fuses. However, if required and / or as mentioned on the drawings,
appropriately rated HRC fuses shall be provided as backup protection to
ensure a faster tripping in case of abnormally higher fault currents.
Auxiliary release and trip coils shall be provided for desired operation
and/or interlockings as stated on the drawings and/or as needed per
system operational requirement.

The motor operated, spring charged type circuit breakers shall be

provided with anti-pumping circuit to prevent repeating cycle of TRIP
reset and ON even if the close command is given while the circuit
breaker has tripped due to fault.

Unless specified otherwise by the Engineer, the entire main

LT Switchboard including all Incoming and outgoing circuit breakers shall
be “Withdrawable type” and these switchboards shall also comply with
the following requirements:

- All circuit breakers and / or switch fuse units shall be as shown

on the drawing. Where two or more feeders are contained in the
same cubicle, they are to be separated by barriers of steel or fire
resistant insulating material. If required, the metal surface of the
cubicle shall be protected by fire resistant insulating material.
Each panel shall combine in tier form all respective components
with their incoming and outgoing power feeders.

- The draw out switching units shall be mounted on trucks or slide-

in chassis having adequate guidance by greased sliding rails
and/ or rollers. They shall be connected to the bus bars by
means of a self-aligning plug and socket arrangement and
complete isolation of each circuit shall be attained by drawing
out the switching unit.

- The main contacts shall have safety shutters, which will

automatically cover the line contacts as the circuit breaker is
withdrawn. The withdrawal of circuit breaker shall be
accomplished by means of a crank, with as little effort as
possible.

- The contact surfaces of the plugs and sockets shall be silver-

plated. The contacts shall be of ample size and sufficiently
strong to withstand maximum prevailing short circuits and carry
continuously their normal rated currents without damage or
overheating of any kind. Also, the control circuits shall be
provided with plugs and sockets.

- The withdrawable units shall have clearly marked service, test

and isolated (ready for complete withdrawal) positions. A
mechanical interlock is to be provided to prevent withdrawal of
the unit unless the power circuit has been interrupted. The unit
shall, furthermore, positively be locked in the test position before
it is manually released for complete withdrawal.
- All components required to make a fixed type circuit breaker
withdrawable, such as, chasis, plugin plates, side plates etc,
shall be duly supplied by the Contractor with all necessary
details.
4.2.3 Switch - Fuse Units

Construction of Bridge at Korangi Causeway 8132-5 Low Tension Switchboards /

LT Outdoor Distribution Boards
 The switch-fuse unit shall comprise a triple pole on load isolating switch
with HRC fuses. The fuse shall be supplied complete with the fuse base
and shall conform to BS-88 Class Q1 with a fusing factor of 1.5.

4.2.4 Three Phase Energy Meters (Kilowatt Hour Meters)

Three phase or Single phase energy meters of frequency 50 Hz and

accuracy class of 1.0 with proper meter base, cover, frame, terminal
block, terminal cover, auxiliary circuit etc. shall be provided for use with
instrument transformers.

The construction of meter shall be suitable for its purpose in all respect
and shall give reasonable assurance of permanence in all mechanical,
electrical and magnetic adjustments. The construction shall be such that
the meter is not prone to produce appreciable noise in use.

The meter shall have a dust proof case, which can be sealed in such a
way that the mechanism of the meter is only accessible after breaking
the seal. The case shall be made of metal or toughened glass of a
sufficient strength to ensure adequate protection of the internal parts.

The direction of rotation shall be marked by a clearly visible indelible

arrow.

Electronic meters with same accuracy class can also be provided.

4.2.5 Ammeters and Voltmeters

All meters shall be flush mounting, moving iron, spring controlled. The
front dimensions shall be 96 x 96 mm for meters.

The meters shall be of accuracy class 1.5 according to relevant IEC

standard. The ammeter shall be suitable for connection to 5 Amps
secondary of current transformers or directly through shunt as shown on
drawings. The ammeters and voltmeters shall have measuring range as
indicated on the drawings.

Electronic meters with same accuracy class can also be provided subject
to no additional cost.

4.2.6 Current Transformers

Air-cooled, ring type current transformers shall be provided having

transformation ratio as indicated on the drawings. The current
transformers shall be of suitable burden having accuracy class 1.0
according to IEC 61869-2 or relevant standard. The current transformers
shall have 5 amps secondary.

4.2.7 Selector Switches

Ammeter and voltmeter selector switches shall be complete with front

plate and grip handle. R-Y-B and OFF position for ammeters and
RY-YB-BR-RN-YN-BN and OFF position for voltmeters shall be marked
on the respective selector switches.

The selector switches for controls shall be rotary cam type, having
required number of positions. It shall be provided complete with knob
and front plate showing all positions as required.

Construction of Bridge at Korangi Causeway 8132-6 Low Tension Switchboards /

LT Outdoor Distribution Boards
 4.2.8 Air Break Contactors

The contactors shall be air break, triple pole 400 VAC type and suitable
for the type of duty (at least utilization Category AC3) to be performed
and AC6b when used inside Power Factor Improvement plant to perform
capacitor bank switching. The main contacts shall be silver tipped, butt
type with double break per pole. Each contactor shall be provided with
single phase 230 VAC operating coil and minimum two spare normally
open and one normally closed auxiliary contact. The number of working
auxiliary contacts shall be provided according to the system
requirements.

The Magnetic Contactors when used for Motor Starter circuit shall be
type-2 coordinated with the backup protection. That is under short circuit
conditions; the contactor and starter shall cause no danger to persons or
installation and shall be suitable for further use.

4.2.9 Push Buttons

The push buttons shall be illuminated, momentary make/break contact

type or latch type (push-on/push-off) as required and approved by the
Engineer and suitable for flush mounting. The push button for ON and
OFF switching shall be red and green respectively.

4.2.10 Impulse Relay

Impulse Relay shall be 1 or 2 pole, 250 V rated and be provided with

latching mechanism.

4.2.11 HRC Fuses

HRC fuses shall be provided complete with fuse bases, fuse and trip
indicator etc. The fuses shall have a fusing factor as specified for class
Q1 in accordance with BS 88.

4.2.12 Indicating Lamps

Indicating lamps shall be LED type suitable for flush mounting, complete
with base. They shall be suitable for operation on 230V AC or 60V DC/
110V DC and it shall have rosettes of suitable colours as approved by
the Engineer.
4.2.13 Line up Terminals

Line up terminals wherever provided for control or power circuits shall be

suitable for voltage and size of conductors as indicated on drawing.

The line-up terminals for controls shall be suitable for channel mounting.
All necessary accessories such as end plates, fixing clips, transparent
label holder caps and label sheets with marking shall be provided.

4.2.14 Auxiliary Relays

The auxiliary relays used for control purposes shall generally be provided
with operating coil voltage rating 230 volts AC, 50 Hz. The auxiliary
relays shall have appropriate number of pins/contacts as required for
normal operation of the system. Use of different types and makes shall
be avoided as much as possible.

Construction of Bridge at Korangi Causeway 8132-7 Low Tension Switchboards /

LT Outdoor Distribution Boards
 4.2.15 Programme Selector Switches

Programme selector switches shall be rotary or cam type, 2-position,

2-pole and 3-position, 3-pole as required, complete with knob and front
plate with position indication.

4.2.16 Surge Protection

Surge Arresters shall be provided in L.T. switchboard, wherever

required, as shown on drawing. The Contractor shall submit proper
calculations for the Surge protection device (SPD) rating and the SPDs
shall be adequately sized for 400 Volts and shall have the following
characteristics:

- Voltage Class (highest system voltage): 440 V rms

- Service (rated voltage): 400 / 1.732 kV rms

This equipment will be tested in accordance with the relevant IEC

Standard.

4.2 Warranty

All proposed L.T Switchboards (complete set including all equipment, devices,
components, parts etc.) will include a warranty of at least 2 years from his
proposed Original Equipment Manufacturer (OEM). The warranty period shall
commence upon issuance of the Taking Over Certificate (TOC). Effectiveness of
duration of warranty from Original Equipment Manufacturer (OEM) shall
commence from the effective date of Taking Over Certificate issued by the
Engineer. All warranties are to be endorsed in the name of the Employer and an
undertaking shall be submitted from Original Equipment Manufacturer (OEM)
and local representatives for ensuring compliance of services to the Employer
during Warranty Period. The cost incurred for such warranty shall deem to have
been included in the item rate of relevant BOQ item. No additional payment,
whatsoever, shall be admissible in this regard and for extended warranty, if any.

5 INSTALLATION

The LT Switchboards/ LT Outdoor Distribution Boards shall be installed at location shown

on the drawing or as advised by the Engineer. The concrete pedestal shall be
constructed as per relevant specifications for civil works. The Contractor shall be
responsible to ensure co-ordination with the civil works for providing any openings, holes,
etc., to avoid any breakage to completed works. In case the provisions in civil works for
installation of electrical equipment are not made or made incorrect the same shall be
rectified by the Contractor at his own cost and to the satisfaction of Engineer.

The Contractor shall provide foundation bolts and grout them in cement concrete floor
using non-shrinkable material with the approval of Engineer.

All installation materials for physically erecting the switchboard such as bolts, nuts,
washers, supporting steel, etc., shall be provided and installed by the Contractor.
The Switchboard, Automatic Transfer Switch (ATS) and LT Outdoor Distribution Boards
shall be installed upright and in level and shall be firmly and rigidly bolted to the floor and
concrete supports.

The LT switchboard / LT Outdoor Distribution Boards shall be completely erected as per

manufacturer's instructions and as approved by the Engineer. Loose parts dispatched by
the manufacturer shall be installed and connected as per assembly drawing provided by
the manufacturer. Any safety locking of meter, relays, etc., provided by the manufacturer
for safe transport shall be released only after the switchboard is erected in position. The

Construction of Bridge at Korangi Causeway 8132-8 Low Tension Switchboards /

LT Outdoor Distribution Boards
 incoming and outgoing cables shall be connected as recommended by cable
manufacturer and providing color sleeve on the lugs at both ends of cables the cable
armour shall be connected effectively to ground.

The control system components, devices, and wiring etc. shall be installed as per
manufacturer’s instructions and recommendations. After installation, the equipment shall
be sequentially tested to confirm that the required switching is effective. The tests shall
be carried out in the presence of the Engineer and to his entire satisfaction.

The switchboard body shall be connected to earth as per instructions given in section
"Earthing" of these Specifications. The switchboard shall be tested and commissioned in
the presence of the Engineer.

The LT Switchboards / LT Outdoor Distribution Boards shall be tested before energizing

as per instructions contained in article "Testing" of General Specifications for Electrical
Works, Section-8001 of these Specifications.

No separate payment for supplying, installing the control cables for the complete system
and testing and commissioning of the entire system is admissible and is deemed to have
been included in the BOQ rates for LT Switchboards / LT Outdoor Distribution Boards.

6 MEASUREMENT AND PAYMENT

6.1 General

The Contractor's bid amount against Bill of Quantities items as given below shall
include design, manufacturing, fabrication, supply, installation, testing,
commissioning and completion for all works specified herein and as shown on
the Tender Drawings related to the item.

6.2 LT Switchboards / LT Outdoor Distribution Boards

6.2.1 Measurement

Measurement shall be made for the number of each LT Switchboards /

LT Outdoor Distribution Boards given in BOQ acceptably supplied and
installed by the Contractor as a complete job.

6.2.2 Payment

Payment shall be made for the total number of each type of job
measured, as provided above, at the Contract unit price each and shall
constitute full compensation for design, manufacturing, fabricating,
supplying, installing, connecting, interfacing, testing and commissioning
of the LT Switchboards / LT Outdoor Distribution Boards as per single
line diagram shown on the drawing alongwith Power Factor Improvement
Plant (including main circuit breaker, Multi-stage power factor correction
relay, AC6b magnetic Contactors, HRC Fuses, Detuned Harmonic Filter
Reactors including it design calculations, all controls / indications etc.) ,
all erecting material such as foundations bolts, supporting steel
channels, nuts, washers, cable glands etc., complete with foundation
and all related Civil works.

6.3 Protective Paint on LT Switchboards / LT Outdoor Distribution Boards

No separate payments shall be made for the under mentioned specified work
related to the supply and installation of LT Switchboards / LT Outdoor Distribution
Boards. The cost thereof shall be deemed to have been included in the quoted
rates of above work.

Construction of Bridge at Korangi Causeway 8132-9 Low Tension Switchboards /

LT Outdoor Distribution Boards
 - Protective paint system on metal works of LT Switchboards installed outdoor
/ LT Outdoor Distribution Boards in accordance with ISO 12944 Corrosivity
Category “C5” with Medium Durability.
- Civil works for foundation

***** End of Section 8132 *****

Construction of Bridge at Korangi Causeway 8132-10 Low Tension Switchboards

/
LT Outdoor Distribution Boards
 SECTION - 8150

LIGHT FIXTURES

1. SCOPE OF WORK

The work under this section consists of supplying, installing, testing and commissioning
of all material and accessories of the complete Light fixtures as specified herein and/or
shown on the Tender drawings and given in the Bill of Quantities.

The Contractor shall discuss the electrical layout with the Engineer and co-ordinate at
Site with other services for exact locations and positions of the light fixtures

The lighting fixtures with accessories shall also comply with the General Specifications
for Electrical Works, Section-8001 and with other relevant provisions of the Tender
Document.

2. GENERAL

The description of light fixtures is given in the bill of quantities, and stated on the
drawings, and all relevant material is described in this Section.

The determination of quality and quantity will be established on internationally accredited

rd
3 party laboratory based certified photo-metric data covering the coefficient of
utilisation, light distribution curves, construction material, shape, finish, operation, etc.
The Contractor shall submit the certified photometric data and type test certificates for
each proposed /offered light fixture for the Engineer’s review and approval. The type test
certificates must comply with the requirement laid down in the relevant standard.

The Contractor shall submit at least one sample of each and every light fixture specified
and obtain approval of the Engineer before purchasing. The light fixture, for which the
material sample is not submitted, shall be liable to rejection. The quality and finishes of
the light fixtures shall be as required and specified in the relevant section of this
specification. The accessories such LED drivers, LED Chips, LED opticsetc., for all type
of light fixtures, shall be of approved manufacturer. Approved equivalent against those
specified will be accepted if the specified one is/will not be available. For any substitution
the Engineer's approval is necessary. However, if any approved equivalent light fixture
has any additionalfeatures including lumen output then no extra payment shall be
admissible.

Light fixtures offered by the authorized local distributor / supplier shall only be considered
for review subject to submission of following documents by the Contractor:

- Authorization / conformance certificate from the Original Equipment Manufacturer

(OEM) in favor of the respective authorized local distributor / supplier for the supply
and distribution of light fixtures.
- Detailed company profile of the Original Equipment Manufacturer (OEM) comprising
information regarding Country of origin, reference list of similar works done /
products installed by the OEM indicating the name of customer, description and
quantity of product, year of supply etc.
All fixtures shall be finished in standard color schemes as mentioned in the
manufacturer's catalogue for respective fixtures, unless specifically stated in the
Specifications, Drawings or Bill of Quantities or directed by the Engineer.

All proposed luminaires/Light fixtures and the associated drivers/Controlgears will

include a warranty of at least 2 years from his proposed Original Equipment
Manufacturer (OEM). The warranty period shall commence upon issuance of the Taking
Over Certificate (TOC). Effectiveness of duration of warranty from Original Equipment

Construction of Bridge at Korangi Causeway 8150-1 Light Fixtures

 Manufacturer (OEM) shall commence from the effective date of Taking Over Certificate
issued by the Engineer. All warranties are to be endorsed in the name of the Employer
and an undertaking shall be submitted from Original Equipment Manufacturer (OEM) and
local representatives for ensuring compliance of services to the Employer during
Warranty Period. The cost incurred for such warranty shall deem to have been included
in the item rate of relevant BOQ item. No additional payment, whatsoever, shall be
admissible in this regard and for extended warranty, if any.

3. APPLICABLE STANDARDS/CODES

The latest editions of the following standards/codes shall be applicable to the material
specified within the scope of this section:

IEC 60598-1 - General requirements and tests

IEC 60598-2-1 - Particular requirement- Fixed general purpose luminaire

IEC 60598-2-2 - Particular requirement- Recessed luminaries

IEC 60598-2-3 - Particular requirement- Road and Street lighting

IEC 60598-2-5 - Particular requirement – Flood Lights

IEC 62471 - Photo biological Safety of lamps and lamps system

IEC 62031 - LED modules for general lighting – Safety specifications

IEC 62262 - Degrees of protection provided by enclosures for

electrical equipment against external mechanical
impacts (IK code)

BS EN 55015 - Limits and methods of measurement of radio

disturbance characteristics of electrical lighting and
similar equipment

BS EN 61547 - Equipment for general lighting purposes/ -

EMC immunity requirements.

BS EN 61000-3-2 - Electromagnetic compatibility (EMC) -

Limits for harmonic currents emissions.

BS EN 61000-3-3 - Electromagnetic compatibility (EMC) - Limits for voltage

fluctuation and flicker in public LV systems.

BS EN 62493 - Assessment of lighting equipment related human

exposure to electromagnetic fields

LM79 / LM80 /LM82 - Test Reports for the offered luminaires

BS 5266 - Emergency lighting

ISO 7010 - Signs for the purposes of accident prevention,

Fire protection, health hazard information and
Emergency evacuation.

The LED driver shall fully conform to following standards:

BS-EN 61347-1 - Lamp control gear - General and safety requirements.

Construction of Bridge at Korangi Causeway 8150-2 Light Fixtures

 BS-EN 61347-2-11/13 - Lamp control gear –Part-2-11 / Part 2-13
Particular requirements

BS EN 62384 - DC or AC supplied electronic control gear for LED

modules performance requirements
4. MATERIAL

4.1. LED Batten type Light Fixture

The Contractor shall furnish and install the complete LED Batten luminaire of
proper rating as shown on the drawings, specified in Bill of Quantities and/or as
required by the Engineer.

For the description of luminaire including its IP degree of protection, dimensions,

minimum luminous flux, and minimum luminous efficacy, the “Legend & Light
Fixture Schedule” drawing shall be referred.

The luminaire shall have colour temperature of 4000K Colour rendering index
(CRI) shall be greater than 80. The LED shall have colour consistency preferably
within 5 SDCM (standard deviation of colour matching).

The LED luminaire shall be designed for lumen maintenance of L70B50 at the
end of useful life. The complete luminaire shall have a useful life of at least
50,000 burning hours.The luminaire shall be suitable for operating at an ambient
temperature of upto +40 degree Celsius.

The housing shall be made of SPCC cold rolled steel material suitable for indoor
environment whereas optic shall be made of Polycarbonate material with Opal
finish. Optical cover / lens type shall be of Polymethyle material with polymer
plastic bowl / cover finish and stainless-steel fixation material to achieve the
required beam symmetry.

Appropriate size bushed wire entry holes, fixing holes, and earth terminal shall
be provided to suit the installation requirement. The driver shall be fixed output
type and integrated within the luminaire and must be adequately protected
against heating effect. The internal wiring of LED batten light fixtures shall be
done with heat resistant wires at the manufacturer's factory. The internal wiring
shall be clipped properly and heat resistant sleeves be provided on cables
passing near driver. Connectors suitable for connecting 2.5 sq.mm cable
conductors shall be provided for supply connections. An earth terminal for
connection to 2.5-sq.mm cable conductor shall be provided.

The luminaire shall have provision of surface, wall mounting as well as

suspended arrangement as specified on the drawings or in BOQ and as
approved by the Engineer. All installation accessories including mounting clips
etc. shall be provided as per installation requirement at site.

The light fixture shall be designed to comply the IK03 category’s impact
requirement unless required otherwise.

4.2. Corrosion Resistant LED Street Light Fixture

The Contractor shall furnish and install the complete Corrosion Resistant LED
Street Light Fixturesof proper rating as shown on the drawings, specified in Bill
of Quantities and/or as required by the Engineer.

The Contractor shall submit “Natural Salt Spray Test Report” for the proposed
Flood light fixture for Engineer’s review to ensure its application being suitable

Construction of Bridge at Korangi Causeway 8150-3 Light Fixtures

 for harsh outdoor environment. The street light fixture, for which the required
“Natural Salt Spray Test Report” is not submitted, shall be liable to rejection.

For the description of Light fixture including its IP degree of protection, salt spray
testing hours, minimum luminous flux and minimum luminous efficacy, the
“Legend & Light Fixture Schedule” drawing shall be referred.

The luminaire shall have colour temperature of 4000K, with colour rendering
index (CRI) of greater than 70. The LED shall have colour consistency preferably
within 5 SDCM (standard deviation of colour matching).

The system should be designed in a way that it ensures higher uniformity along
with a smooth light of higher colour consistency & system efficiency.

The LED luminaire shall be designed for lumen maintenance of L70B50 at the
end of useful life. The complete luminaire shall have a useful life of at least
100,000 burning hours.The luminaire shall be suitable for operating at an
ambient temperature of upto +50 degree Celsius.

The housing will include optical system, LED light source, integrated heat sink,
SPD and driver. It shall be made of non-corrosive high pressure aluminium die
cast material, optic made of polycarbonate material with thermally hardened
glass front cover, heat resistant silicon rubber gasket in optical LED
compartment, programmable driver and fixation material made of aluminium. It
shall be salt spray tested as required with required beam light distribution optics,
along with 15 kV built in surge protection. The light fixture should have flexible
optical system to achieve lighting parameters for required class of roads.

The heat sink shall be designed to create better air-flow for better heat transfer.
Appropriate size bushed wire entry holes, fixing holes, and earth terminal shall
be provided to suit the installation requirement. The programmable driver which
can carry control signal through neutral; cable shall be integrated within the
luminaire and must be adequately protected against heating effect.

The luminaire shall have provision of pole mounting arrangement as specified on

the drawings or in BOQ and/or as required/approved by the Engineer. All
installation accessories including mounting supports etc. shall be provided as
per installation requirement at site.

The light fixture shall be designed to comply the IK08 category’s impact
requirement unless required otherwise.

5. INSTALLATION

5.1. General

The mounting heights of light fixtures are indicated on the drawings, and
positions of fixtures are according to the mentioned scale.

The Contractor must ensure that the light fixtures are installed uniformly with
respect to the dimensions of the area. Any modifications due to site conditions
may be made with the approval of Engineer. All fixtures shall be carefully aligned
before fixing in position.

The wiring between ceiling rose or terminal box and the fixture shall be carried
out with 3-core 1.0 sq.mm and 1.5-sq.mm flexible copper conductor PVC/PVC
cable respectively for circuits protected by 10 amps and 15/20 amps MCBs. The
wiring inside light fixture body shall be done with heat resistant cables or PVC
insulated cable in heat resistant sleeves as approved by the Engineer.

Construction of Bridge at Korangi Causeway 8150-4 Light Fixtures

 Glasses, shades, reflectors, diffusers, etc., must be in a clear condition after
installation. All light fixtures shall be earthed by an earth wire connected to the
earth terminal in the fixture.

5.2. Surface Mounted Light fixtures (LED Batten)

Light fixtures on the surface of LT outdoor Distributor shall be installed with the
back of the body flush with the surface, and in a manner so as to facilitate wiring.
Nylon plugs and galvanized steel bolts or screws shall be used for fixing the light
fixture to the ceiling of LT Outdoor Distributor.

5.3. Corrosion Resistant LED Street Light Fixture

LED Street light fixture shall be installed Hot Dipped Galvanized, with ISO-
12944, corrosivity category “C3” medium durability painted, Mild Steel, poles and
arm as described in Contract specification section-8920 finished with high-
performance epoxy paint and arm as specified in B.O.Q, and “General detail”
drawing. The light fixture shall be mounted considering that the pole is fixed type
and light fixtures are not damaged during maintenance.

The lighting fixture shall be properly levelled and the luminaire shall be adjusted
to the appropriate position and all screws, bolts checked for tightness, etc. The
light fixture shall be connected to the supply and earth at the proper terminals in
the fixture.

6. MEASUREMENT AND PAYMENT

6.1. General

The Contractor's bid amount against each Bill of Quantities item as given below
shall include supply, installation, testing, commissioning and completion for all
work specified herein and/or shown on the Bidding Drawings related to the item.

6.2. Corrosion Resistant LED Street Light

The Contractor's bid amount against each Bill of Quantities item as given below
shall include supply, installation, testing, commissioning and completion for all
work specified herein and/or shown on the Bidding Drawings related to the item.

6.2.1 Measurement

Measurement shall be made for each type of light fixture including all
accessories acceptably supplied and installed by the Contractor as
complete unit.

6.2.2 Payment:

Payment shall be made for the number of units measured as provided

above at the contract unit price each and constitute full compensation for
supplying, installing, connecting, testing and completion ofCorrosion
Resistant LED Flood Light / Corrosion Resistant LED Street Light
including all accessories such as LED drivers, LED Chips, LED
optics,connecting cables & connectors, suspension rods and pendent
arrangement, GI pipe bracket, ceiling supports, internal wiring, nuts,
bolts, screws, etc., as required and complete in all respects.

***** End of Section – 8150 *****

Construction of Bridge at Korangi Causeway 8150-5 Light Fixtures

 SECTION - 8212

LOW TENSION CABLES

1 SCOPE OF WORK

The work under this section consists of supplying, installing, testing and commissioning
of all material and services of low tension (LT) cables and the accessories as specified
herein or as shown on the Tender Drawings and in the Bill of Quantities.

The Contractor shall discuss the electrical layout with the Engineer and coordinate at
site with other services for exact route, location and position of the L.T. cables.

The LT cables with accessories shall also comply with the General Specifications for
Electrical Works, Section-8001 and with other relevant provisions of the
TenderDocument.

2 GENERAL

- All multi-core and single core PVC insulated and sheathed cables for light
circuits, socket outlets and circuits operating upto 250 volts shall be 300/500
volts grade.

- All single core PVC insulated, non-sheathed cables shall be of 450/750-volt

grade.

- Power cables for main feeders, main to sub main feeders, power equipment,
etc., armoured or unarmoured shall be of 600/1000 volt grade.

- Armouring of multi-core/ single core cables shall be done with appropriate size
galvanized steel/aluminium wire as per relevant codes.

The conductors shall be stranded high conductivity, soft annealed copper. Conductors of
single core cables shall be circular, whereas of multi-core cables may be circular or
shaped according to standard practices and codes. The PVC insulation, bedding and
overall sheath shall be of extruded PVC compound having good flexibility, resistance to
ageing and ability to withstand deformation at high temperatures. Non-hygroscopic filler
shall be provided in multicore cable to fill empty gaps between the cores to make the
cable a smooth round finish. In all shaped cables a non-hygroscopic high strength
binding tape shall be provided on the core assembly. All cables shall be treated for
vermin proofing and be protected against rodents during storage, laying and all
protective pipe/sleeves shall be plugged to attain the same after installation.

Embossed marking on the oversheath at 3 meters intervals shall give the following
information:

- Name of Manufacturer
- Yearof Manufacture
- No. of cores and size of cable in sq.mm.
- Voltage grade
- Type of cable i.e., Cu./PVC/SWA/PVC

3 APPLICABLE STANDARDS/CODES

The latest editions of the following standards and codes shall be applicable for the
materials specified within the scope of this section:

Construction of Bridge at Korangi Causeway 8212-1 Low Tension Cables

 BS 6004 - Electric cables PVC insulated, non armoured cables for
voltages upto and including 450/750 volts for electric power,
lighting and internal wiring

BS 6346 - Electric cables PVC insulated, armoured cables for voltages of

600/1000 V and 1900/3300 V

BS 7846 - Electric cables 600/1000V armoured fire resistant cables having

thermosetting insulation and low emission of smoke and
corrosive gases when affected by fire

BS 7889 - Electric cables. Thermosetting insulated, unarmoured cables for

a voltage of 600/1000 V, for fixed installations

IEC 60227 - Polyvinyl chloride insulated cables of rated voltages upto and
including 450/750V

IEC 60332 - Tests on electric and optical fibrecables under fire conditions

BS 6746 - PVC insulation and sheath for electric cables

BS EN 60228 - Conductors of insulated cables

BS EN 50525 - Electric cables - Low voltage energy cables of rated voltages up

to and including 450/750 V

BS EN 61386 - Conduit systems for cable management

BS EN 50618 - Electric cables for photovoltaic systems

4 MATERIAL

4.1 General

The power, lighting and control cables shall be furnished and installed in
accordance with most appropriate routes, well-coordinated with other services,
for interconnection of electrical and mechanical equipment, fixtures etc., shown
on the drawings.

All cables shall have phase identification colours on insulation of each core. The
colour code for three phase circuits shall be red, yellow and blue for phase
conductors and black for neutral conductor. Where insulated earth conductor is
installed, it shall have green or green-yellow colour insulation.

Single-phase circuits shall have insulation of red colour for phase/line, black
colour for neutral and green or green-yellow colour for earth conductor.

All DC circuits shall have insulation of white colour for positive, black colour for
negative and green or green-yellow colour for earth conductor.

The ends of each length of multi-core armoured or unarmoured cables shall be

properly marked for clock-wise and anti-clock-wise sequence of core colours.

4.2 Cables for Conduit or Channel Wiring

All cables/wiring in concealed PVC or surface mounted GI conduits or in

covered channel shall be single core PVC insulated of specified grade and size,
unless specifically shown on the drawings or given in BOQ.

Construction of Bridge at Korangi Causeway 8212-2 Low Tension Cables

 4.3 Cables on surface/concrete trenches / trays

Cables for distribution system to be installed on surface, in cable ducts, in

concrete trenches or on trays shall be single or multi-core PVC insulated and
PVC sheathed of specified voltage grade and size, unless specifically shown on
the drawings or given in BOQ.

4.4 Cables inside solid bottom surface M.S Trunking / Under Floor Metal Trunking

All cables/wiring inside solid bottom surface M.S Trunking / Under Floor Metal
Trunking shall be 3 core PVC insulated PVC sheathed, high temperature
resistant of specified grade and size, unless specifically shown on the drawing
or given in the BOQ having insulation of red colour for phase/line, black colour
for neutral and green or green-yellow colour for earth conductor.

4.5 Cable/ Wiring Inside Lighting Column

All cables/wiring inside lighting column from cable connection box to light
fixtures / lanterns shall be 3 core PVC insulated PVC sheathed, high
temperature resistant of specified grade and size, unless specifically shown on
the drawing or given in the BOQ having insulation of red colour for phase/line,
black colour for neutral and green or green-yellow colour for earth conductor.

4.6 Underground Cables

Cables for laying directly underground shall be PVC insulated, PVC sheathed
and armoured with galvanized steel/ aluminum wire. Cables fully installed in
underground ducts/pipes and mechanically protected from end to end shall be
PVC insulated and PVC sheathed unless specifically shown on the drawings or
given in BOQ.

4.7 Cable Markers

Above ground cable markers made of Grade-25 reinforced concrete shall be

erected at a maximum interval of 100 meters along the straight trench, at each
bend and joint box for indicating the presence of underground cables. Where the
trench changes its direction two number of markers shall be installed one in
each direction to indicate the two directions of the trench. At the joint box,
additionally a symbol shall be engraved just beneath the letters LV to indicate
the presence of the joint box. The cable markers shall be finished in grey paint.
The letters and symbols for indication shall be engraved in concrete on both
sides. Letters shall be LV for low voltage cable. The colour of the engraved
letters and symbol shall be red. The dimensions of the markers shall be as
shown on the drawing and shall be installed on the ground.

4.8 Cable Accessories

All cable accessories shall be provided for the complete cabling and wiring
system without any additional cost unless specifically mentioned in BOQ. These
shall include but not limited to the items such as saddles, clamps, fixing
channels, connectors, cable joints (where necessary and as approved by the
Engineer), clips, lugs, colour sleeves, identification tags, bushes, glands, etc. All
cable accessories should be standard products of reputable manufacturers.

Construction of Bridge at Korangi Causeway 8212-3 Low Tension Cables

5 INSTALLATION

5.1 General

All installation material, labour, tools, cable rollers and accessories for cable
installation shall be furnished by the Contractor. The cable and accessories shall
be installed as described in accordance with these Specifications, drawings and
manufacturer's instructions.

The Contractor shall confirm the exact cut lengths for cable by actual
measurements at site prior to the ordering. The cable lengths where shown on
the drawings or in BOQ are tentative and only for general guidance. The
Contractor shall be solely responsible for furnishing correct lengths of cable to
avoid joints in cable length except where necessary, after obtaining approval of
the Engineer.

No separate payment for such joints is admissible.

Necessary precautions for safety of cables shall be taken during the laying of
cables to avoid scratches/ cuts to the cable surface. Pulling force on cable at all
times shall remain well within the manufacturer’s recommended limits.

Prior to installation of jointing and termination kits, the cable lengths shall be
checked and tested to ensure that the cables are in sound condition, and no
damage has been done during handling and installation. After installation, these
shall again be tested prior to commissioning as per recommendations of the
standards according to which the cable is manufactured.

5.2 Conduit or Channel Wiring

The wiring through conduit shall be started only after the conduit and channel
system is completely installed and all outlet boxes, junction boxes, etc., are fixed
in position.

The wires shall be pulled in conduit or channel with care, preferably without the
use of any lubricant. Where necessary and if approved by the Engineer, the
cable manufacturer's recommended lubricant may be used. Where several wires
are to be installed in the same conduit, they shall be pulled together along with
the earth conductor. All wires of same circuit shall be run in one conduit.

The wires shall not be bent to a radius less than ten times the overall diameter
of the wire, or more if otherwise recommended by the manufacturer.

The wiring shall be continuous between terminations and looping-in system shall
be followed throughout. Any joint in wires shall not be allowed. The use of
connectors shall only be allowed at locations where looping-in is rendered
difficult. The consent of the Engineer shall be required for using connectors. The
connector shall be of suitable rating having porcelain body with sunk-in screw
terminals. The connector shall be wrapped with PVC insulation tape after its
installation. A minimum of 150 mm extra length of cable/wire shall be provided at
each termination to facilitate repairs in future.

5.3 Cables on Surface/Trenches/Trays/Ladders

All cables for installation on surface of wall, column, ceiling, trenches, trays etc.,
shall be fixed to the surface by means of galvanized steel clips secured to a
steel channel using suitable stud plate, nuts and washers. The distance between
each cable clip shall be such so as to support the entire weight of the cable and
that distance between the cable & surface and also the vertical clearance
between two adjacent cables at any point is 50mm minimum. Common
mounting channels are to be furnished for cable along the same route. The

Construction of Bridge at Korangi Causeway 8212-4 Low Tension Cables

 Contractor can offer alternate cable fixing arrangement, which shall be approved
by the Engineer before commencement of installation.

Cables shall be laid on cable trays/Cable ladders wherever marked and as

shown in the drawing. All cables shall be properly fixed with cable tray/ladders
by means of suitable saddles or other approved means. A minimum distance
between cables equal to the diameter of the cable shall be maintained between
cables.

5.4 Underground cables

The cables to be installed directly underground shall be laid in trenches in single

tiers. Unless shown specifically on the drawing the depth of cable below finished
ground level shall be 900 mm minimum measured from the top of the largest
cable to the general ground level. The burial depth may be increased as
required due to site conditions or when crossing other service pipes and roads.
Burial depth less than 900mm and more than 1500mm shall require Engineer's
approval.

When cables cross road, paved area, other services or other cables, they shall
be laid in protective pipes of required size as shown on the drawings. Cables
entering the buildings shall also be laid in protective pipes. The protective pipe
ends, after installation of cables, shall be plugged watertight be means of
bituminizedhessian or equivalent method as approved by the Engineer. A
minimum clearance of 250mm vertically and 500mm horizontally shall be
maintained between cables and other services.

The cable trench shall be excavated as per route and location shown on the
drawings. Before laying of cables in the trench, the bed of the trench shall be
leveled and filled with a 100mm thick layer of fine sand (as per specification
section 1100). The sand layer shall be leveled and the cables placed thereon.
The cables shall be covered with a layer of fine sand 100mm thick measured
above the top of the cable. Cable protective bricks shall be placed over the sand
cover which shall be of class-C cement concrete, minimum 50mm thick and
300mm (W) X 300mm (L) dimensions. Good quality bricks of proper strength
and shape, well-formed can also be used for the purpose of protection. The
bricks shall be placed over the sand layer and end-to-end to cover the entire
length and breadth of the cable trench. After the concrete bricks are placed, the
remainder of the trench shall be backfilled with earth in layer of loose thickness
of200mm. Each layer shall be thoroughly tamped and compacted. Backfill/ earth
fill shall be compacted to 95% for traffic / paved area and 90% for non-traffic
area of the maximum density of soil / sand when checked as per ASTM D 1557.

A PVC warning tape shall be provided 300 mm below normal ground level
covering the entire length and breadth of the trench. The warning tape shall be
yellow in colour with marking of danger and voltage of the cable printed in black
and as approved by the Engineer.

Cable identification tags of corrosion resistant material shall be tied to cables

with PVC cable tie at a maximum of 20 metersinterval along the cable length for
identification of cable and circuit. The earth continuity conductor shall be laid in
the trench with the cables.

Sufficient slack shall be left in cables for this purpose the cut lengths of cables
shall allow about 3% more in the measured lengths between terminations. At
underground joint box, ample slack shall be left to prevent straining of cable
joints due to settlement of earth. Payment shall be done as per actual lengths
measured at site after installation.

Construction of Bridge at Korangi Causeway 8212-5 Low Tension Cables

 The cut lengths of cables wherever stated are only as a guide. The Contractor
shall measure lengths between terminations of each circuit and if the
discrepancy between measured lengths at site and the one given on the drawing
differ, the Contractor shall report to Engineer and act as directed. Cables,
whether installed underground or in concrete trenches, shall not be bent to a
radius less than 12 times the diameter of the cable or as recommended by the
cable manufacturer, whichever is higher.

If existing services / culverts / drain etc. are present, LV Cables shall be laid
using thrust boring or the support as approved by the Engineer. No payment
shall be made and its cost is deemed to be included in the item else wherein
BOQ.

5.5 Cable Marker

Above ground, cable markers shall be erected at a100 meter interval along the
straight trench, and at each bend and joint box for indication of presence of
underground cable. For more than 3 feet wide trenches, cable markers shall be
provided at both edges of the trench. The cable marker shall bear the necessary
instructions indicated in approved colours.
The Contractor shall submit to the Engineer for approval, schedule of cable
markers showing location of marker and instructions on each marker.

6 MEASUREMENT AND PAYMENT

6.1 General

The Contractor's bid amount against each Bill of Quantities item as given below
shall include supply, installation, testing, commissioning and completion for all
work specified herein and/or as shown on the Drawing related to the item.

6.2 Light Circuit Wiring inside Street light Pole

6.2.1 Measurement

Measurement shall be made for the total number of light circuit wiring
from connections box to light fixture through hollow of the column,
including all accessories carried out by the Contractor as a complete
unit.

6.2.2 Payment

Payment shall be made for the total number of units measured, as

provided above, at the Contract unit price each and shall constitute full
compensation for supplying, installing, connecting, testing,
commissioning and completion of the circuit wiring from connections box
to light fixture with required number of specified size multi core PVC
insulated cable, earth continuity conductor complete with all accessories
complete in all respects.

6.3 LT Cables

6.3.1 Measurement

Measurement shall be made for the total running meter for each size
and type of LTacceptably supplied and installed by the Contractor. If
existing services / culverts / drain etc. are present, LV Cables shall be
laid using thrust boring or the support as approved by the Engineer. No
payment shall be made and its cost is deemed to be included in the item
else wherein BOQ.

Construction of Bridge at Korangi Causeway 8212-6 Low Tension Cables

 6.3.2 Payment

Payment shall be made for the total running meter of each size and type
of LT cable measured, as provided above, at the Contract unit price
each and shall constitute full compensation for supplying, installing,
connecting, testing and commissioning of the LT including all
accessories such as cable joints, lugs, color sleeves, glands, bush, etc.
complete with plugging of protective pipe/ sleeve ends for water
tightening. If existing services / culverts / drain etc. are present, LV
Cables shall be laid using thrust boring or the support as approved by
the Engineer. No payment shall be made and its cost is deemed to be
included in the item else wherein BOQ.

6.4 Excavation / Backfilling

6.4.1 Measurement

Measurement shall be made for the total cubic meter of excavation /

backfilling of trenches acceptably completed by the contractor according
to the specification and as shown on drawings.

6.4.2 Payment

Payment shall be made for the total cubic meter of excavation /

backfilling of cable trench measured as carried out above at the contract
unit price and shall constitute full completion for excavation / backfilling
and all the works related to the item.

No separate payment shall be made for the under mentioned specified

work related to the B.O.Q. item excavation and backfilling. The cost
thereof shall be deemed to have been included in the quoted rates of
above work.

- Dewatering during excavation and backfilling.

- Providing and filling of fine sand in trenches.
- Compacted backfilling of trenches with specified material and
disposal of surplus and rejected material.
- Providing and laying of 300mm x 300mm x 50mm thick concrete
(gade-20) protective tiles in trenches.
- Providing and laying of PVC warning tape.
6.5 Cable Marker

6.5.1 Measurement:

Measurement shall be made for the total number of cable marker

acceptably supplied and installed by the Contractor as a complete unit.

6.5.2 Payment:

Payment shall be made for the total number of cable marker as provided
above at the contract unit price and shall constitute full compensation for
supplying & installing reinforced concrete cable markers, excavation,
backfilling, concrete curing, and painting etc.

***** End of Section – 8212 *****

Construction of Bridge at Korangi Causeway 8212-7 Low Tension Cables

 SECTION - 8230

CONDUITS AND PIPES

1. SCOPE OF WORK

The work under this section consists of supplying, installing and commissioning of all
material and services of the complete Conduits and Pipes as specified herein and/or
shown on Tender Drawings and stated in the Bill of Quantities.

The Contractor shall discuss the electrical layout with the Engineer and co-ordinate at
Site with other services for exact route, location and position of the conduits and pipes.

The conduits and pipes with accessories shall also comply with the General
Specifications for Electrical Works, Section-8001 and with other relevant provisions of
the Tender Document.

2. GENERAL

The extent of works shown on the drawing does not indicate the exact position of
conduits and pipes. The Contractor shall ensure exact location and route of conduit and
pipes in coordination with other services drawings and actual equipment layout plan as
per site requirements and as directed by the Engineer.

The conduit system shall be continuous with manufacturer’s recommended accessories.

The quality and material for the accessories of conduits and pipes such as sockets, end
cap, elbows, bushings, bends, inspection/pull boxes, round boxes, etc., necessary for
the complete installation shall be similar to that of conduits or pipes. All the accessories
shall be supplied by the Contractor without any extra cost and deemed to have been
included in the price of conduits/pipes.

Pull wire shall be laid in all empty conduits.

Appropriate size flexible conduits and pipes shall be used at expansion joints of the
buildings and structures.

Normal and emergency circuits shall run in separate conduits.

3. APPLICABLE STANDARD/CODES

The latest edition of the following standards and codes shall be applicable for the
materials specified within the scope of this section:

BS 61386 - Conduit Systems for Cable Management.

BS 6099 - Conduit for Electrical Installation
BS 4607 - Non-mettalic conduits and fittings for electrical
Installations.

BS EN ISO - Plastics piping systems for water supply and for buried & above
1452-1:2009 – ground drainage and sewerage under pressure. Unplasticized
poly(vinyl chloride) UPVC. General

BS EN 10255 - Non-alloy steel tubes for welding & threading. Technical delivery
conditions

Construction of Bridge at Korangi Causeway 8230-1 Conduits and Pipes

 BS 3505 - Specification for Unplasticized Polyvinyl Chloride (PVC-U)
Pressure Pipes for Cold Potable Water

PS 3051 - Specification for Unplasticized Polyvinyl Chloride (PVC-U)

Pressure Pipes for Cold Potable Water

4. MATERIAL

4.1 Galvanized Iron (G.I.) Conduits and Accessories

G.I. conduits shall be used on surface for lighting and power circuits wherever
specified and required, as shown on drawings or given in BOQ.

The G.I. conduits shall be made of medium gauge mild steel, galvanized inside
and outside by hot dip galvanized process. The conduit shall be free from stains,
burrs or any other defects. The accessories for G.I. conduit such as sockets,
bends etc. shall also be galvanized inside and outside and of the same quality
and specification as the conduit. Each length of conduit shall be furnished with
threaded ends.

The round junction boxes for ceiling light points shall have minimum dimensions
of 64mm diameter and 64mm depth. The junction boxes for wall light points shall
have minimum dimensions of 64mm diameter and 40mm deep. Round junction
boxes shall be provided with one piece cover plate fixed to the box by means of
brass screws. All junction boxes and other accessories shall also be hot dip
galvanized to ensure protection against corrosion.

4.2 PVC Conduits and Accessories

The PVC conduits and accessories for lighting and power circuits shall be
furnished by the Contractor as shown on the drawings or given in BOQ. The
PVC bends shall have enlarged ends to receive conduit without any reduction in
the internal diameter at joint. Manufactured smooth bends shall be used where
conduit changes direction. Bending of conduits by heating or otherwise will be
allowed in special situations only for which the consent of the Engineer shall be
required. The use of sharp 90 degree bends and tees will not be allowed for
concealed wiring.

The round PVC junction boxes for ceiling light or fan points shall have minimum
dimensions of 63 mm diameter and depth. The junction boxes for wall light
points shall have minimum dimensions of 63 mm diameter and 38 mm deep.
Round junction boxes shall be provided with one piece PVC cover plate fixed to
the box by means of brass screws.

4.3 Inspection/Pull and Adaptable Boxes

Inspection/Pull boxes and adaptable boxes shall be provided in GI / PVC/ uPVC

conduit runs wherever required to facilitate pulling operation and/or change in
directions of conduit installation.

The drawings are diagrammatic and do not indicate the position and spacing of
inspection/pull boxes or adaptable boxes. However, these shall be as per
Engineer's approval.

4.3.1 Inspection/Pull Boxes

The rectangular inspection/pull boxes shall be made of 16 SWG heavy

Construction of Bridge at Korangi Causeway 8230-2 Conduits and Pipes

 gauge hot dipped galvanized iron with anticorrosive coating of suitable
design to receive conduits. The box shall be painted inside and outside
with black enamel paint over a base coat of red oxide primer paint. The
minimum length of the box shall not be less than four times the cable
manufacturer recommended bending radius of the cable.

All surface type boxes shall have cover of same gauge sheet steel of
appropriate size. The covers shall be fixed to the box by means of
counter sunk galvanized screws.

4.3.2 Adaptable Boxes

Adaptable boxes shall also be made of 16 SWG sheet steel and painted
and finished to the same quality as the Lighting distribution boards.

4.4 uPVC Pipes and fittings

Un-plasticized PVC pressure pipes and fittings shall conform to BS 3505 and
PS 3051 and shall be of Class D(working pressure - 12 bars) and class-B
(working pressure - 6 bars). The buried uPVC pipes should be able to withstand
the external load acting upon it by continuous movements of heavy duty vehicles
such as trucks, cranes, forklift etc. where pipe changes direction; manufacturer
smooth bend shall be used.

Fittings and accessories for use with uPVC pressure pipes shall be of the same
class and manufacture as the pipe and shall have the required shapes and
dimensions of turned ends to fit the uPVC pressure pipes. uPVC pipes and
accessories shall be suitable for jointing with rubber rings or solvent.

Bending of pipes by heating or otherwise will not be allowed. The use of sharp
90 degree bends and tees will not be allowed. The bends shall conform to same
specifications as given for PVC conduits. For joining of pipe all precautions and
procedures recommended by manufacturer shall be allowed.

Hard PVC pipe range spacers with locking arrangements shall be used if there is
more than one pipe running in parallel. The distance between range spacers
shall not be more than 2 meters. Range spacers shall be prefabricated/precast
and decay resistant.

Flexible pipes shall be used as deemed essential or as approved by the

Engineer.

4.5 Pipe End Marker

Wherever the underground pipe ends do not terminate into any airfield light
fixture, transformer housing or a concrete pit, pipe end markers shall be installed
to indicate the location of the pipe ends underground. The pipe end markers
shall be a concrete slab marker in the vicinity of Runway, Taxiway and Apron.
The size, thickness and concrete grade of the flat pipe end markers shall be as
shown on the drawing. Each marker shall have following information impressed
upon its top surface.

a) The word ‘PIPE’

b) Number of layers X number of pipes in each layer (diameter of pipes)

Construction of Bridge at Korangi Causeway 8230-3 Conduits and Pipes

5. INSTALLATION

5.1 Galvanized Iron (G.I) Conduits and Accessories

The G.I. conduits on surface shall be installed where shown on drawings/

mentioned in BOQ. The conduits shall be installed parallel or perpendicular to
the surface of walls, structural members, ceiling, etc., by means of C.I. saddles
and clamps of approved design. The conduits shall be kept at least 150 mm
away from any other services pipes.

The saddles shall be installed on surface by means of nylon or wooden plugs

and galvanized screws. Appropriate size of holes in structure shall be made by
drilling, the thickness of saddles shall not be less than 6mm and clamps shall be
of 16 SWG G.I. The surface conduits shall be supported at a maximum of one
meter spacing along horizontal and vertical runs. All accessories for complete
installation of conduit system shall be provided by the Contractor. The pull boxes
etc. if required shall be used for surface conduit system. The entire conduit
system alongwith the accessories shall be galvanized.

5.2 PVC Conduits and Accessories

5.2.1 Concealed PVC Conduit

Where concealed PVC conduit system is shown on drawings/ mentioned

in BOQ, the conduit shall be installed concealed in roof, wall, column,
etc. Conduits shall be laid under floor only where specifically stated. The
entire conduit system shall be installed and checked before wiring is
carried out. Any obstruction found shall be cleared before the installation
of cable.
When concealed, the conduit shall have a minimum of 32mm cover of
concrete measured from the top of conduit to finished surface. In the
reinforced cement concrete (RCC) work the conduit shall be laid before
pouring of concrete. Under no circumstances shall chases be made in
the RCC structure for concealing conduit and accessories after pouring
of concrete. The conduit shall be supported on top of bottom
reinforcement of slab. All outlet boxes to be firmly supported and
installed such that they finish flush with the soffit of slab or beam.
Where conduits have to be concealed in cement concrete (CC) work
after concreting or in block masonry, chase shall be made with
appropriate tools and shall not be made deeper than required. The
conduit shall then be fixed firmly in the recess and covered with cement
concrete mixture. The work of cutting in the cement concrete work or
block masonry work shall be coordinated with the civil work. The
Contractor shall obtain approval from the Engineer before starting
chasing and cutting.
The termination of conduits at or near the equipment / switchboard is
shown diagrammatically on the drawings. The exact locations of the
termination shall be coordinated with the equipment/ switchboard to be
installed. Any extension of conduit to suit the site condition shall be
made without any extra cost. Conduit ends pointing upwards or
downwards shall be properly plugged in order to present the entry of
foreign materials. All openings through which concrete may leak shall be
carefully plugged in order to prevent the entry of foreign materials. All
opening through which concrete may leak shall be carefully plugged and
boxes shall be suitably protected against filling with concrete. At all
terminations of conduit, sharp edges of conduit ends shall be prevented

Construction of Bridge at Korangi Causeway 8230-4 Conduits and Pipes

 to avoid the cutting or damaging of wires or cables during pulling
through the conduits.
Under floor conduit shall be installed at a minimum depth of 50 mm from
the finished floor level or as shown on the drawings. The conduits shall
be installed empty, before finishing of floor or in RCC work, with an 18
SWG steel wire drawn through the conduit for pulling cable. No conduits
shall be laid under floor in bathroom.

5.2.2 Surface PVC Conduits

The surface PVC conduits shall be installed where shown on drawings /

mentioned in BOQ. The conduits shall be installed parallel or
perpendicular to the surface of walls, structural members, ceiling, etc.,
by means of PVC saddles and clamps of approved design. The conduits
shall be kept at least 150 mm away from parallel runs of flues, steam
pipes and hot water pipes.

The saddles shall be installed on surface by means of nylon or wooden

plugs and galvanized screws. Appropriate size of holes in structure shall
made by drilling, the thickness of saddles and clamps shall be at
appropriate thickness and prime quality.

The surface conduits shall be supported at maximum of 1000mm

spacing along horizontal and vertical runs. The Contractor shall provide
all accessories for complete installing of conduit system. The pull boxes,
etc. as stated for concealed conduits shall also be applicable for surface
conduit system.

5.3 Inspection / Pull and Adaptable Box

Inspection/Pull boxes and adaptable boxes shall be provided in conduit runs

wherever required to facilitate pulling operation, and/or change in directions of
conduit installation.

Inspection/Pull Boxes

The inspection/pull boxes shall be installed inside the edge barrier /new jersey
barrier under each street lighting column for facilitating the bending &
termination of incoming and outgoing cables in the connection block in the
street lighting column.

The covers shall be fixed to the box by means of counter sunk galvanized
screws.

Adaptable Boxes

The adaptable box shall preferably be fixed adjacent to the DB and have
suitable dimensions to match the installation with DB. However, in any case,
the depth of adaptable box shall be according to number & size of cables &
conduits and shall not be less than the following:

- Conduits upto 25 mm dia. : Min. depth = 50mm

- Conduits upto 32 mm dia. : Min. depth = 65mm
- Conduits upto 50 mm dia. : Min. depth = 90mm
- Conduits more than 50 mm dia. : Min. depth = 2x dia.

Construction of Bridge at Korangi Causeway 8230-5 Conduits and Pipes

 5.4 uPVC Pipes and Fittings

uPVC pipes shall be installed as shown on the drawings. The depth of the pipe
shall vary according to the conditions at site, and approval of Engineer shall be
obtained prior to installation. In general the pipes shall be installed underground
at the following depths measured from the top of the pipe.

- Under roads/pavements : 900 mm below finished surface.

- Under drain / culvert : 1000 mm below bottom slab.
- When crossing other services : 250/500 mm vertical/horizontal.

The trench of required dimensions shall be excavated and the bottom of trench
cleaned and leveled. A 100 mm bed of fine sand shall be provided over which
the PVC pipes installed after proper alignment. Where two or more pipes are
installed in the same trench the clearance between pipes shall not be less than
50 mm. This shall be done by the provision of pipe range spacers as shown in
the drawings & as per Engineers approval. After laying of pipe the trench shall
be backfilled with clean screened sand at least 100 mm above the top most
pipes. The remaining portion of trench shall be backfilled with selected earth in
layers well compacted. Warning tape shall be laid all along the pipe trench at a
depth of 300 mm from finished ground level.

After installation, the ends of the pipe shall be plugged with manufactured end
cap impervious to water and chemicals. All joints shall be sealed adequately not
only to prevent entry of foreign elements but water tightness shall be ensured as
well.

The installation of pipes shall be completed in all respects including its fixing at
terminations, before cabling work is started. All sharp edges and burrs shall be
removed by using reamer or any approved device. The pipe shall be through
cleaned of dirt and dust from inside whereas the pipes shall be installed in
proper co-ordination with other works.

The protective PVC pipe for cable entering building shall be installed so as to
lead cable into the cable trench. The required number of pipes shall be fixed
before completing the work in the plinth. If an opening is provided to the cable
trench or electrical pit from outside, the required number of pipes shall be
installed and part of the opening remained unutilized and annular space after
laying of cable shall be properly packed and sealed using polyurethane sealant
which should be impervious to water and chemical to make it completely water-
tight.

Empty/Spare pipes shall be provided with 5 mm dia rope pulled from end to end
and plugged with manufactured end cap.

Flexible pipes of compatible material and size shall be used wherever deemed
essential.

5.5 Pipe End Markers

The pipe end markers shall be installed flat in the ground with top approximately
2.5 cm. above the finished grade. After the concrete marker has set a minimum
of 24 hours, the top surface shall be painted bright orange with paint suitable for
uncured exterior concrete.

Markers shall be installed after the laying of cables through the pipes is
completed in all respects and cable trenches are finally covered and compacted.

Construction of Bridge at Korangi Causeway 8230-6 Conduits and Pipes

6. MEASUREMENT AND PAYMENT

6.1 General

The Contractors bid amount against each item of Bill of Quantities as given
below shall include supply, installation, testing, commissioning and completion
for all work specified herein and/or as shown on the Tender Drawings related to
the item.

6.2 uPVC Pipes and Accessories

6.2.1 Measurement:

Measurement shall be made for the total running meter of each type and
size of pipes and accessories acceptably supplied and installed by the
Contractor according to specification and as shown on drawings.

6.2.2 Payment:

Payment shall be made for the total running meter of each type and size
of pipes measured as provided above at the contract unit price each and
shall constitute full compensation for supplying, installing and completion
of the laying of the pipes including all accessories related to the item.

No separate payments shall be made for the under mentioned specified

work related to the supply and installation of pipe. The cost thereof shall
be deemed to have been included in the quoted rates of above work.

− Excavation and backfilling.

− Dewatering during excavation and backfilling.

− Providing and filling of fine sand in trenches.

− Providing pipe range spacers.

− Providing flexible pipes and accessories, jointing material/

compound, saddles, sockets, elbows, bend, junction boxes, pull
box ,reducers, 5 mm dia. rope for empty pipe, soft metal bush,
making threads and plugging of pipe with manufactured end cap
etc. whether used or left spare.

− Compacted backfilling of trenches with specified material and

disposal of surplus and rejected material.

− Watertight/fire and heat resistant polyurethane sealants for

sealing all unutilized opening/pipes after laying of cables.

6.3 Conduits (G.I. and PVC) and Accessories

6.3.1 Measurement:

Measurement shall be made for the total running meter of each type and
size of conduits and accessories acceptably supplied and installed by
the Contractor according to specification and as shown on drawings.

Construction of Bridge at Korangi Causeway 8230-7 Conduits and Pipes

 6.3.2 Payment:

Payment shall be made for the total running meter of each type and size
of conduits measured as provided above at the contract unit price each
and shall constitute full compensation for supplying, installing and
completion of the laying of the conduits including all accessories related
to the item.

No separate payments shall be made for the under mentioned specified

work related to the supply and installation of undermentioned items.

− Providing flexible pipes and accessories, jointing material/

compound, saddles, sockets, elbows, bend, junction boxes, pull
box ,reducers, 16SWG GI pull wire for empty conduit, and 5 mm
dia. rope for empty pipe, soft metal bush, making threads and
plugging of pipe with manufactured end cap etc. whether used
or left spare.

The cost thereof shall be deemed to have been included in the quoted
rates of above work.

6.4 Pipe End Markers

6.4.1 Measurement

Measurement shall be made for the total number of markers acceptably

supplied and installed by the contractor as a complete unit.

6.4.2 Payment

Payment shall be made for the total number of units measured, as

provided above, at the contract unit price and shall constitute full
payment compensation for supplying, installing, reinforced concrete pipe
end markers, excavation, backfilling concrete curing and painting etc.

***** End of Section – 8230 *****

Construction of Bridge at Korangi Causeway 8230-8 Conduits and Pipes

 SECTION - 8240

EARTHING / GROUNDING SYSTEM

1. SCOPE OF WORK

The work under this section consists of supplying, installing, testing and commissioning
of all material and services of the complete Earthing system as specified herein, as
shown on the Tender Drawings and given in the Bill of Quantities.

The Contractor shall discuss the electrical layout with the Engineer and co-ordinate at
Site with other services for exact route, location and position of the earth electrode,
counterpoise conductor and ECC etc.

The Earthing/ Grounding system shall also comply with the General Specifications for
Electrical Works Section - 8001 and with other relevant provisions of the Tender
Documents.

2. GENERAL

The earthing/ Grounding system consists of earth electrodes, earthing leads, earth
connecting points, earth continuity conductors, counter poise conductor, equipment
ground lead and all accessories necessary for the satisfactory operation of the
associated electrical system.

A dedicated earthing grid shall be installed underground in the vicinity of the

buildings/structures as shown on the drawings. All mechanical and electrical systems
shall be solidly connected to this earthing grid. The earthing grid shall be of bare tinned
copper conductor strip laid at the same depth as that of the earth pits connected to it.
The main distribution, connection pit, earth connecting point etc. and the lightning
protection system must be integrated to assure an extensive integrated ground-grid.

The electrical contractor has to supervise the installation in order to guarantee the proper
execution of the works ensuring overall earthing resistance within permissible limits of
applicable standards.

3. APPLICABLE STANDARDS/CODES

The latest editions of following standards / codes shall be applicable for the materials
specified within the scope of this section:

BS 7430 - Code of practice for protective earthing of electrical installations

BS 951 - Electrical earthing - Clamps for earthing and bonding
Specifications

BS EN 12163 - Copper and Copper Alloys –Rods for general purposes

BS EN 50522 - Earthing of power installations exceeding 1 kV a.c

IEEE Std.80 - IEEE Guide for Safety in AC Substation Grounding

BS EN 13601 - Copper and Copper Alloys - Copper rod, bar and wire for
General electrical purposes

BS EN 13602 - Copper and Copper Alloys - Drawn round, copper wire for the
Manufacture of electrical conductors

Construction of Bridge at Korangi Causeway 8240-1 Earthing/ Grounding System

 BS EN 60228 - Conductors of insulated cables

BS 6346 - PVC insulated cables

BS EN 12164 - Copper and Copper Alloys – Rod for free machining purposes

BS EN 12167 - Copper and Copper Alloys – Profiles and bars for general
Purposes

BS 6004 - Electric cables, PVC insulated, non-armoured cables for

voltages upto& including 450/750Volts for electric power,
lighting & internal wiring

BS EN 62561-5 - Lightning protection system components (LPSC). Requirements

for earth electrode inspection housings and earth electrode
seals

4. MATERIAL

4.1 Earth Electrodes

4.1.1 Plate Type

The plate type earth electrode shall comprise a 600 x 600 x 3mm 99.9%
pure high conductivity electrolytic copper plate. The surface of the plate
shall be tinned for protection. The plate shall have four terminals for
connecting the earthing leads. Nuts bolts and washers shall be either of
brass or tinned copper. A 50mm dia. G.I. pipe shall be provided from
inspection chamber to earth plate for watering purpose. This pipe shall
have 10mm dia. holes at 500mm center to center all along the length.

At the ground level a medium / heavy weight concrete inspection

chamber with cast iron cover shall be constructed having dimensions as
shown on the drawings. The inspection chamber shall have a cover
supported on angle iron frame. The cover shall be hinged type, as
approved by the Engineer and shall finish flush with the ground level.

4.1.2 Copper Clad Steel Rod Type

This type of earth electrode shall comprise a 3 meter long, 19 mm dia.

copper clad steel rod having flat head at drive end and pointed conical
tip at the driven end. The tip shall be hardened to facilitate driving. At
the top of the rod, a brass clamp for bolted connections shall be
provided suitable for connection to the down conductor or earthing lead
as required.

The inspection chamber with heavy/ medium duty C.I. cover shall be
provided as instructed by the Engineer.

4.2 Earthing Leads

The earthing leads shall connect the earth electrode to earth connecting point
(ECP) inside the inspection chamber unless required otherwise. It shall be of
stranded electrolytic copper. It can be bare tinned copper or PVC insulated
(green or green/yellow) of sizes shown on the drawings. The cost of earthing
leads deemed to have been included in the price of earth electrode and no
separate payment shall be made for it.

Construction of Bridge at Korangi Causeway 8240-2 Earthing/ Grounding System

 4.3 Earth Continuity Conductors

Earth continuity conductors (ECC) shall be stranded bare tinned copper

conductor or single core PVC insulated, copper conductor cable of sizes
indicated on the drawings. All thimbles, lugs, sockets, nuts, washers & other
accessories necessary for the complete installation of ECC shall be provided by
the Contractor without any extra cost.

The specifications for single core PVC insulated cables used as ECC shall be
same as those given in section "LT Cables" of the technical specifications. PVC
insulated cables when used as ECC shall be green or green/yellow.

4.4 Earth Connecting Points (ECPs)

Earth connecting points shall comprise tinned copper bar, rectangular in shape,
having dimensions of at least 50 x 6 mm and 300 mm long. At least six terminals
for connection shall be arranged on the bar, which can be increased or
decreased as required by the Engineer. The length of earth connecting points
shall be suitably increased, if more than six earth wires are required to be
terminated on the same ECP.

The terminals shall have brass or tinned copper bolts, nuts and washers for
protection against corrosion. Two holes shall be provided off center of the
copper bar for fixing to the wall by means of 10 mm dia. nut and bolt and shall
be insulated by means of rubber gaskets/washers, porcelain insulators, etc.

5. INSTALLATION

5.1 General

Complete earthing/ grounding systems as shown on the drawing shall be

installed by the Contractor. The earthing system shall give earth resistance,
including the resistance of soil, earth leads and ECC equal to or less than one
ohm.

At all connections of earth continuity conductors to LT Switch Boards, LT

Distribution Boards, poles or any other metallic body, proper size copper or
brass sockets, thimbles or lugs shall be used to which the copper wire shall be
connected by copper brazing. The soldering of copper wire at joints or
terminations shall not be allowed. All tee-off connections shall be by copper
brazing using suitable socket and clamps. After brazing, the jointed surface shall
be protected by oxide inhibiting compound of low electrical resistance. For
connections to metallic body, the surface shall be thoroughly cleaned before
bolting the lug or socket.

Lead sheaths or steel tape armours are not permitted as grounding conductors.
At any joint or terminations, the ECC shall be connected using proper
accessories. No connection shall be made by twisting of earth conductors.

The earthing system shall be designed and installed to ensure that when any
part of the earthing system is disconnected for the purpose of carrying out
periodic testing an alternative path to earth is available.

The earth continuity conductor shall in general run in cable trench or in

conduits/pipes as shown on the drawings. For under floor runs, these shall be
installed in pipe/conduit of appropriate sizes. Where laid along underground
cables, these shall be laid directly underground in unpaved areas and in pipes
under paved areas.

Construction of Bridge at Korangi Causeway 8240-3 Earthing/ Grounding System

 The earthing system shall be tested after complete installation of earth
electrodes.

5.2 Earth Electrodes

5.2.1 Plate Type

The electrode plate shall be installed at a minimum depth of 16.5 feet

(5meters)from finished ground level or 4 inches (100mm) below
permanent water level whichever is less. The minimum horizontal
distance between earth electrodes shall be 10 feet (3metres). Proper
mixture of lime and charcoal shall be made and buried alongwith the
copper plate in the ground to increase the soil conductivity. The
electrode shall be installed as per details shown on the drawings. The
inspection chambers shall be constructed at locations approved by the
Engineer. Suitable treatment on covers to protect against harsh
atmospheric conditions shall be made as per instruction of Engineer.

5.2.2 Copper Clad Steel Rod Type

In case the soil conditions at site is permitted and approved by the

Engineer, this type of earth electrode may be installed by hammering
the electrode in soil, until the top of the rod is about 12 inches (300 mm)
below the proposed finished ground level. If hammering down of rod is
not possible due to site conditions, a pit shall be first excavated in bare
ground up to the required depth and electrode shall be installed upright
in the pit. The excavated pit shall be backfilled in layers of 20 inches
(500 mm), each layer tamped and compacted. The inspection chambers
shall be constructed at locations approved by the Engineer. Suitable
treatment on covers to protect against harsh atmospheric conditions
shall be made as per instruction of Engineer.

5.3 Earth Continuity Conductors(ECCs)

The earth continuity conductors of sizes shown on the drawings shall be

installed all along the cable runs and connected to the earthing bar/terminals
provided in equipment. The bodies of equipment and all switchboards shall also
be connected to earth by specified size of ECC. All other metal work shall also
be connected to earth by specified size of ECC. Appropriate size and numbers
clamp/saddles shall be utilized to ensure smooth and safe installation of all type
of ECCs.

At any joint or terminations, the ECC shall be connected using proper

accessories. No connection shall be made by twisting of earth conductors.

5.4 Earth Connecting Points

The earth connecting points shall be installed at locations shown on the

drawings. These shall be fixed on wall surface by means of brass screws with
nuts, washers, porcelain insulators and other insulating material as instructed by
the Engineer.

6. MEASUREMENT AND PAYMENT

6.1 General

The Contractor's bid amount against each Bill of Quantities item as given below
shall include supplying, installation, testing, and commissioning of all work
specified herein, as shown on the Tender drawing related to the item.

Construction of Bridge at Korangi Causeway 8240-4 Earthing/ Grounding System

 6.2 Earth Electrode

6.2.1 Measurement:

Measurement shall be made for the total no. of each type of earth
electrode acceptably supplied and installed by the Contractor as a
complete unit.

6.2.2 Payment:

Payment shall be made for the number of units measured, as provided

above, at the Contract unit price each, and shall constitute full
compensation for supplying, installing, testing, commissioning and
completion of earth electrodes including copper plate or copper clad
steel rod, earthing lead, excavation, backfilling, Ground enhancing
material, inspection chamber with cast iron cover, GI pipes for earthing
leads/watering, nuts, bolts, washers, lugs, brazing and all related civil
works, complete with suitable treatment of cover.

6.3 Earth Continuity Conductor (ECC)/ Earthing Leads

6.3.1 Measurement:

Measurement shall be made for the total running feet of each size and
type of earth continuity conductor (ECC) / Earthing Leads acceptably
supplied and installed by the Contractor.

6.3.2 Payment:

Payment shall be made for the total running feet of each size and type
of ECC/ Earthing Leads measured, as provided above, at the Contract
unit price and shall constitute full compensation for supplying, installing,
connecting, testing and completing of ECC/ Earthing Leads/
Counterpoise Conductor/ Equipment Ground Lead including all
accessories such as sockets, clamps/saddles, thimbles, lugs, bolts,
nuts, washers, brazing, etc.

6.4 Earth Connecting Point

6.4.1 Measurement:

Measurement shall be made for the total no. of earth connecting points
acceptably supplied and installed by the Contractor as a complete unit.

6.4.2 Payment:

Payment shall be made for the total number of units measured, as

provided above, at the Contract unit price each and shall constitute full
compensation for supplying, installing and completion of earth
connecting point and all other associated accessories such as nuts,
bolts, washers, lugs, etc.

***** End of Section – 8240 *****

Construction of Bridge at Korangi Causeway 8240-5 Earthing/ Grounding System

 SECTION - 8290

MISCELLANEOUS ITEMS

1. SCOPE OF WORK

The work under this section consists of supplying, installing, testing and commissioning
of all material and accessories for Miscellaneous Items as specified herein and/or shown
on the drawings and given in the Bill of Quantities.

The Contractor shall discuss the electrical layout with the Engineer and coordinate at site
with all other services for exact locations, installation height and positions of the
Miscellaneous Items.

The Miscellaneous Items with accessories shall also comply with the General
Specifications for Electrical Works Section - 8001 and with other relevant provisions of
the Contract Document.

2. GENERAL

The Miscellaneous Items as described in this section shall comply with other sections of
these specifications as applicable. The Contractor shall ensure that all the miscellaneous
items be supplied/fabricated from the reputable manufacturers, who have already
supplied/fabricated similar items.

Effectiveness of duration of warranty from Original Equipment Manufacturer (OEM) shall

commence from the effective date of Taking Over Certificate issued by the Engineer. All
warranties are to be endorsed in the name of the Employer and an undertaking shall be
submitted from Original Equipment Manufacturer (OEM) and local representatives for
ensuring compliance of services to the Employer during Warranty Period. The cost
incurred for such warranty shall deem to have been included in the item rate of relevant
BOQ item. Additional payment, whatsoever, shall not be admissible in this regard and
for extended warranty, if any

3. APPLICABLE STANDARDS/CODES

The latest editions of the following standards/codes shall be applicable to the material
specified within the scope of this section:

IEC 60947-3 - Low Voltage Switch Gear and Control Gear -

Switches, disconnectors, switch-disconnectors and
fuse-combination units
BS EN ISO 1461 - Hot dip galvanized coatings on fabricated iron and steel
articles. Specifications and test methods.

BS EN 15630 - Safety requirements for electric fans and regulators.

BS EN 50085 - Cable trunking and cable ducting systems for electrical
installations.
BS EN 61537 - Cable management. Cable tray systems and cable
ladder systems

BS 4678-2 - Specification for Cable Trunking - Part 2:

Steel Underfloor (Duct) Trunking

BS EN 10346 - Continuously hot-dip coated steel flat products for

Cold forming — Technical delivery conditions

IEC 61084-2-2 - Cable trunking systems and cable ducting systems for

Construction of Bridge at Korangi Causeway 8290-1 Miscellaneous Items

 electrical installations - Part 2-2: Particular requirements

BS EN 60335-2-80 - Household and similar electrical appliances. Safety.

Particular requirements for fans.
BS EN-124 - Gully tops and manhole tops for vehicular and
pedestrian areas - Definitions, classification, general
principles of design, performance requirements and test
methods
ISO-12944-2 - Corrosion Protection of Steel Structures by Protective
Paint Systems
BS 5733 - Specification for general requirements for electrical
accessories.

IEC 60884-1 - Plugs & socket-outlets for household & similar purposes

CEE 7 - standard AC plugs and sockets

BS EN 60529 - Degrees of protection provided by enclosures (IP Code)

4. MATERIAL

4.1. Hot dipped galvanized M.S. Cable Trays / Trunking / Ladders with protective
paint system

The hot dipped galvanized M.S. cable tray / trunking (with cover) shall be 14
SWG M.S. sheets. Suitable trunking design shall be provided for bends,
crossings, etc., keeping in view allowable bending radius of cables.

After cutting/perforation and fabrication of each tray / trunking and cover section,
the metalwork shall be galvanized and coated as specified in 4.4.1.

Arrangement shall be provided to secure the cables in position on the trunking.

Cables laid on tray / trunking shall be properly fixed or clamped, with smooth
finished split pieces with bore diameter to suit the cable. Supports shall be
arranged as far as practicable for easy removal of any cable without disturbing
other cables.

Copper braid connections shall be provided at every joint, fixing accessories of

cable tray to ensure continuity.

Cable trays shall be earthed with flexible copper braid/ strip.

Where specified, the cables shall run on cable trays/trunking supported to the
wall and/or ceiling. The tray shall be of appropriate dimensions to ensure
minimum clearance of one dia spacing between the cables. Tray and trunking
shall be provided with complete accessories such as straight through joint,
flexible expansion coupler, tee, cross, internal and external bend, cover etc.
complete with proper support and fixing accessories, GI nuts, bolts washer etc.

The cable tray/ trunking length shall be fabricated in sections not exceeding 3
meters.

The arrangements shall be provided for manufactured bends, crossing,

connection piece etc. keeping in view the allowable bending radii of the cables.
The design of such trays shall include a factor of safety to guard against
permanent distortion when supporting the load of the erection staff during cable
installation. Arrangement shall be provided to secure the cable in position on the
trays. At every building expansion joint flexible expansion couplers shall be

Construction of Bridge at Korangi Causeway 8290-2 Miscellaneous Items

 provided, All auxiliary material not particularly specified but necessary for proper
execution shall be coated as the cable tray/ trunking/ ladder and shall be
included in the offer.

4.1.1 Protective paint system

All indoor cable trays/ trunking/ ladders shall be coated with protective
paint system in accordance with ISO 12944 Corrosivity Category “C3”
with Medium Durability. The Priming coat(s) shall be Epoxy based and
top coat shall be polyurethane based with color shade not other than
RAL 7032 or 7035.

All outdoor cable trays/ trunking/ ladders shall be coated with protective
paint system in accordance with ISO 12944 Corrosivity Category “C4”
with Medium Durability. The Priming coat(s) shall be Epoxy based and
top coat shall be polyurethane based with color shade not other than
RAL 7032 or 7035.

Appropriate bonding / adhesion material such as Etch Primer is

recommended for use with Galvanized Surfaces before application of
above mentioned protective paint system.

The Contractor shall submit following documents pertaining to protective

paint system for approval of the Engineer,

- Paint manufacturer’s confirmation that proposed paint system is

compatible with the intended surface to be coated
- Paint manufacturer’s confirmation that proposed paint products are
compatible with each other
- Paint products catalogues
- OEM’s recommended surface preparation methodology
- No. of coats
- DFT per coat

4.2 16 A Schuko Socket Outlets (Weather proof)

16 Amp Socket Outlets shall be 2 pin + earth German type (Schuko) socket
outlets with faceplate of colour as approved by the Engineer.

The outlets shall be heavy-duty type suitable for mounting on LT outdoor

Distributor. The 16 Amp Schuko Socket Outlets shall be designed such that the
earth pin of plug is engaged to socket earth prior to making contact to the live
contacts.

Weather proof socket outlet shall be designed for outdoor use or in areas heavily
exposed to dust and / or splashing water. The socket outlet shall be constructed
from extremely robust polycarbonate that provides minimum degree of ingress
protection of IP55. If the specified degree of IP protection cannot be achieved
then the socket outlet shall be supplied with suitable weather proof enclosure.

4.3. Street Lighting Column

For street lighting, lightning columns shall be supplied in total construction

heights of pole as shown on Drawings.

On top of each lighting columns there shall be either one or two bracket mounted
lanterns with suitable adapters provided. Ratings of the lanterns shall be as
specified in the contract drawings and specification section 8150. The street light

Construction of Bridge at Korangi Causeway 8290-3 Miscellaneous Items

 arrangement and conduits shall be as per “Electrical Details”.

All lighting columns shall be of steel (conforming to BS EN 40-5) tubular tapered/

octagonal above the anchor plate with construction heights as specified in the
drawings and longitudinally welded. The welding shall be complying with
BS EN 1011; no circumferential weld shall be accepted. The size of base plate
and bolts will be as per manufacturer’s recommendation or relevant structural
drawing. The steel used for fabrication shall have minimum yield strength as
recommended by the Manufacturer. The lighting columns shall be suitable for
UBC 97 exposure”C” and at the basic, wind speed specified in clause 3.0 of
specification section 8001.

All columns and accessories such as anchor bolts, doors, adaptors, shim plates
etc., shall be galvanized in full bath process and coated as specified in 4.6.1.
After galvanizing the threads of the anchor bolts shall be re-cut and greased.

The Contractor shall submit a civil drawing regarding the foundation of the
Lighting Pole in consultation with the Pole Manufacturer and as shown in
‘electrical details’ drawing. The parameters required for pole foundation are
dimension and weight of the selected light fixture, dimension and weight of Pole,
design wind velocity as mentioned in Contract specification section-8001 along
with seismic calculation for the zone mentioned in the specification

The Contractor shall submit a pole design drawing in consultation with the Pole
Manufacturer in accordance with the project requirement and as shown in
‘Electrical details’ drawing for engineer review and approval.

Lighting columns shall be welded to anchor plates by means of appropriate

gusset plates. For cable access to the light pole a hole of at least 150 mm
diameter shall be provided in the middle section of the anchor plate.
Approximately 800 mm above the anchor plate a lockable door shall be
provided. The door shall have a minimum size of 120 mm x 350 mm or as
approved by the Engineer. Inside the door there shall be a baseboard arranged
with a channel for mounting the cable termination and circuit breaker / MCB
block as shown in “Electrical Details” drawing An earth connection terminal
screw of at least M8 mm shall be provided on the baseboard. The doors shall be
fitted with tamper proof locks.

Cable connection – circuit breaker / MCB blocks (as per number of lights) shall
be provided in every light pole and shall have cable supports and terminals for at
least 2 cables 5 x 25 sq.mm. Screw in sufficient number and size shall be
provided. The design of the cable connection, circuit breaker / MCB block shall
be as required. Each light fixture on pole shall have separate circuit breaker /
MCB.

The arm/bracket length shall vary as per site condition. In all cases the length of
bracket shall be such that overhang (the distance from center of light fixture to
the kerb) shall not be less than 0.5 meters.

4.3.1 Protective paint system

All street lighting poles/ columns shall be coated with protective paint
system in accordance with ISO 12944 Corrosivity Category “C4” with
Medium Durability. The Priming coat(s) shall be Epoxy based and top
coat shall be polyurethane based with color shade not other than RAL
7032 or 7035.

Appropriate bonding / adhesion material such as Etch Primer is

recommended for use with Galvanized Surfaces before application of
above mentioned protective paint system.

Construction of Bridge at Korangi Causeway 8290-4 Miscellaneous Items

 The Contractor shall submit following documents pertaining to protective
paint system for approval of the Engineer,

- Paint manufacturer’s confirmation that proposed paint system is

compatible with the intended surface to be coated
- Paint manufacturer’s confirmation that proposed paint products are
compatible with each other
- Paint products catalogues
- OEM’s recommended surface preparation methodology
- No. of coats
- DFT per coat
5 INSTALLATION

5.1. General

The mounting heights, depths and other dimensions of all the Miscellaneous
Items are stated on the drawings or in general notes. In case of any
discrepancy, the instructions of the Engineer shall be obtained before fixing the
item.

5.2. Hot dipped galvanized M.S. Cable Trays / Trunking / Ladders with protective
paint system

The cable trays / trunking shall be installed on supports fixed to the wall and/or
ceilings/trusses. The supports shall be fixed to civil works by means of Rawl
bolts. The additional hangers and other metalwork required for the installation of
the trays / trunking shall be galvanized and finished by method as specified for
the cable tray / trunking.

The distance between alternate supports (span) in straight runs shall be finalized
as per loading and in no case shall exceed 2 metres. In addition to these,
supports shall be provided near each bend or change in direction, end of
trunking/ tray.

The straight jointing, bends and other accessories shall be fixed with cable tray/
trunking in such a manner that they are in one line with no sharp edges/
protruded surfaces. Rivet head nuts shall be installed on inner side of tray/
trunking.

On straight lengths over 65’-8” (20 meter) and at every building expansion joint
suitable flexible expansion couplers shall be provided.

At each joint, bend earth continuity shall be ensured by using copper earth braid
and copper lugs in electro-tinned finish.

5.3. 16A Schuko socket outlets (weatherproof)

The wiring accessories shall be mounted as stated on the drawings. In case the
mounting height is not mentioned, the instructions of the Engineer at site shall be
obtained before fixing.

5.4. Street Lighting Column

Foundation blocks shall be generally in reinforced concrete, Class ‘B’ (grade 25)
type and in accordance with approved structural calculation. Construction of
foundation blocks shall be according to the relevant drawings or as
recommended by the manufacturer. The foundation designed shall be able to
bear the wind velocity as mentioned in specification section-8001.

Construction of Bridge at Korangi Causeway 8290-5 Miscellaneous Items

 The Contractor shall submit civil works drawings in consultation with the pole
manufacturer for engineer review and approval.

Lighting column and necessary accessories shall be delivered free at location of

use and be unloaded and set up ready for service and operation.

In addition, at least 10 pieces of setting templates for each size light poles shall
be included in the scope of supply.

Expenses for auxiliary tools and equipment, such as crane and operator shall
incorporated in the tender bids. The cable opening and all gaps shall be filled
with approved watertight material.

The transport of the poles to site shall be carried out in a neat and clean manner.
Steel/wood racks with grooves shall be supplied for stacking of poles to prevent
any direct contact with ground. Any pole damaged during transportation or
storage shall be replaced and any damage to paint work shall be made good by
the Contractor at his own cost.

6 MEASUREMENT AND PAYMENT

6.1. General

The Contractor’s bid amount against each Bill of Quantities item as given below
shall include supply, installation, testing, commissioning and completion for all
work specified herein, as shown on the Tender Drawings and given in the Bill of
Quantities related to the item.

6.2. Hot dipped galvanized M.S. Cable Trays / Trunking / Ladders with protective
paint system

6.2.1 Measurement:

Measurement shall be made for the total running meters of each size of
M.S. cable tray/cable trunking with all accessories acceptably supplied
and installed by the contractor.

6.2.2 Payment:

Payment shall be made for the total running meters as provided above
at the contract unit price and shall constitute full compensation for
supplying, installing, and completion of each size of M.S cable tray/cable
trunking for cables complete with all installation material and accessories
such as covers, mounting brackets, bend, elbow, nuts and bolts etc.

6.3. Street Lighting Column

6.3.1 Measurement:

Measurement shall be made for the total number of each type of lighting
column including civil works, foundation as per ambient condition, Load
requirements and with all accessories acceptably supplied and installed
by the contractor as complete unit.

6.3.2 Payment:

Payment shall be made for the total number of units measured as

provided above at the contract unit price each and shall constitute full
compensation for supplying, installing, and commissioning of security

Construction of Bridge at Korangi Causeway 8290-6 Miscellaneous Items

 flood lighting column including civil works, foundation as per ambient
condition and Load requirements, complete with all installation material
and accessories.

No separate payments shall be made for the under mentioned specified

work related to the supply and installation of Street Lighting Column.
The cost thereof shall be deemed to have been included in the quoted
rates of above work.

- Protective paint system on all metal works in accordance with

ISO 12944 Corrosivity Category “C4” with Medium Durability.

- Civil works for foundation

*** End of Section 8290 ***

Construction of Bridge at Korangi Causeway 8290-7 Miscellaneous Items