HIGHWAY -80

Section 8: Dimitrovgrad bypass

DIMITROVGRAD (toll gate) DIMITROVGRAD (border of the Republic of Bulgaria)
FINAL DESIGN MODIFICATIONS
km. 95+525 - km. 97+980,69

FINAL DESIGN

TECHNICAL INFRASTRUCTURE
BOOK : Design of cable telecommunications conduits

Designer in charge KOSOVOPROJEKT P L U S d...

Director
__________________________ _____________________________
Saa Dunji, M.Sc.E.E. Ruica Raji-teri, M.Sc.E.E.

KOSOVOPROJEKT P L U S d...
Belgrade, June 2013.
 C O N T E N TS

I GENERAL DOCUMENTATION IV GRAPHICAL DOCUMENTATION

1. Company certificate of registration 1. Legend

2. List of participants in design 2. Situation plan
3. Designer in charge appointment 3. Cable ducts schematic
4. Designer in charge licence 4. Manhole 800x2000x1000 (DO-3)
5. Confirmation of the use of regulations, standards and norms 5. Manhole mounting detail
6. Declaration on coordination of design documentation 6. Small diameter PE pipes joints
7. Trench detail
8. Bridge passing detail
II BASE OF THE DESIGN 9. Cross sections

1. Terms of reference
2. Overview of laws, regulations and norms
V STUDY OF SAFETY AND HEALTH AT WORK AND ENVIRONMENTAL PROTECTION

III TEXTUAL DOCUMENTATION

1. Technical description
2. Technical conditions
3. Bill of quantity
 2. OVERVIEW OF LAWS, REGULATIONS AND NORMS USED IN DESIGN

1. Zakon o planiranju i izgradnji (Sl. Glasnik RS br.47 /2003)

2. Zakon o bezbednosti i zdravlu na radu (Sl. Glasnik RS br. 101/2005)
3. Zakon o zatiti od poara (Sl. Glasnik SR Srbije br. 37/88 i Sl. Glasnik RS br. 48/94)
4. Pravilnik o tehnikim normativima za stabilne instalacije za dojavu poara (Slubeni list
SRJ 87/93)
5. Zakon o telekomunikacijama (Sl. Glasnik RS br. 44/03 i 36/06)
6. Uputstvo o graenju mesnih i kablovskih mrea (Zajednica JPTT, 1988)
7. Uputstvo o izradi telefonskih instalacija i uvoda (Zajednica JPTT, 1977)
8. Tehniki uslovi Zajednice JPTT za razvodne i uvodne ormane
9. Zbirka elektrotehnikih propisa u izdanju Sl. Lista SFRJ 1989. god.
10. Zakon o sistemima veza (Sl. List SFRJ br.44/88)
11. Jugoslovenski standard JUS N.N6.170-179 i JUS N.N6 501-504
12. Tehnika dokumentacija i uputstva proizvoaa opreme.
13. Evropski standard EN 124

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 1. TECHNICAL DESCRIPTION

1.1. Introduction
1.2. Route description

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1.1 INTRODUCTION
Corridor 10 is one of the pan-European traffic corridors defined after a conference in Helsinki
in 1997. It stretches from Austria to Greece, and in addition to the main route there are 4
branches.
The corridor main route: Salzburg (Austria) - Ljubljana (Slovenia) - Zagreb (Croatia) -
Belgrade - Nis (Serbia) - Skopje - Veles (Macedonia) - Thessaloniki (Greece).
Corridor 10 brances are:
A: Graz (Austria) - Maribor (Slovenia) - Zagreb (Croatia)
B: Budapest (Hungary) - Novi Sad - Belgrade (Serbia)
C: Nis - Dimitrovgrad (Serbia) - Sofia (Bulgaria) - Istanbul (Turkey)
D: Veles - Prilep - Bitola (Macedonia) - Florina - Igoumenitsa (Greece)
Corridor 10 through Serbia passes following route:
Main route (M1) Batrovci, municipalitiy Sid (border with Croatia) - Belgrade - Tabanovce,
municipalitiy Presevo (border with Macedonia),
and branches in Serbia are:
Branch B (M22) Horgos, Kanjiza (border with Hungary) Belgrade
Branch C (M1.12): Nis - Gradina, Municipality Dimitrovgrad (border with Bulgaria)
The section of the highway E80 at Dimitrovgrad bypass is part of corridor and is one of the
priorities for the construction set by the Government of the Republic of Serbia.
For the implementation of modern traffic management systems as well as for other
information services, telecommunication duct system along the route of the newly designed
highway is planned.
1.2 ROUTE DESCRIPTION
On the section E -80 Nis - Dimitrovgrad, from km 92 +905.55 to km 101 +578.12 for the future
needs of investor and other public and private companies telecommunication duct system is
planned to be build during construction of the road.
Cable duct system is network of underground pipes that serves for cable routing and
protection. It allows quick and easy replacement of cables, simple capacity expansion and
repair of cables in the event of a failure while outer surface are not damaged nor trafic is
interfered.
Cable duct system consists of telecommunication manholes and telecommunication pipes.
Pipes can be made of different materials (concrete, asbestos-cement and the thermoplastic
materials). Through cable duct system cables with metal and thermoplastic coating can be
routed.
The scope of this project is duct system in the area between tunnels Przojna padina and
Progon. Duct system at the rest of the Dimitrovgrad bypass section is in scope of separate
project.
Along the route, laying of 4 PE pipes 50mm is planned and 4 PVC pipes 110mm in the
area between traffic lanes, next to the left lane on section from tunnel Przojna padina to the
technical center. Also, laying of 4 PE pipe 50mm through the bridge No.4 on the right side
of the highway is provided and the connection with tunnel cable duct system. Additionaly, 4
PVC pipes 110mm for connection of cable duct system in front of technical center and left
side of the bridge No4 are provided.
Crossing the bridge is planned by inserting a small diameter polyethylene pipe through the
existing pipes in the bridge (the two PE pipes 50 through protective pipe on the bridge).
Bearing in mind that bridge pipes are at less depth than pipes layed in the soil, two protective
HDPE pipes 110mm are planned for protection of small diameter pipes.
Along the route is planned to install prefabricated distribution manholes DO- 3 (internal
dimensions 200cm x 80cm x 100cm), at a maximum distance of 50m.
Cable duct system in tunnels and the area in front of the tunnels, cable dust system in front of
technical cener and cable duct system on the left side of the bridge between the tunnels, are
in scope of separate projects, as indicated in the graphical part of project documentation.
Designer in charge
Sasa Dunjic, M.Sc.E.E
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 2. TEHNICAL CONDITIONS

2.1 General
2.2 Execution of works

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2.1 GENERAL
The works planned by this project must be carried out in quality according to valid tehnical
regulations by licenced contractors with equipment made and approved in accordance with
technical regulations ZJ PTT for the respective equipment.
The works must be carried out in shortest time.
The Contractor shall comply with the conditions and approvals obtained and embedded in the
project. Any change must be pre-approved and signed by the project designer.
For any non-compliance between project and the works the contractor bears sole liability for
damages that could arise out of it.
The Contractor must comply with the Law on Safety and Health at Work (Republic of Serbia
Official Gazette 101/2005), and is also required to apply protective measures given in
appendix of this project.
The Contractor is responsible to keep construction book and construction log, and it must be
regularly verified by the technical supervisor that oversees the building
The work should be organized in such a way to be carried without delays. It will be completed
within a specified time only with proper organisation of work wich must not start if all the
material has not been previously provided.
Prior to commencement of the works the contractor is obliged to inform all interested parties
who have installations along the route of the commencement of works and to permanently
cooperates with them in order not to damage their installations.
The contractor is required to properly mark the site in order to avoid accidents. Only material
that will be used during the day should be transported the construction site. Vehicles and
equipment shall not be left on the road, nd if it is unavoidable they must be marked with
warning and traffic signs according to Law on Traffic Safety. Trench must be covered with a
surplus land taken away or planned.
If the contractor believes that the traffic could be affected it is necessary to provide traffic
police for public road transport.
The contractor is required to provide space to store the cables in the order of installation and
that the cables can be approached for testing and use.
The Contractor should perform the control of pipes on reels by visual inspection and
accessories by checking the delivered quantity when taking from investors or from the
factory.
The contractor is required during installation and assembly of pipes and materials to comply
with all valid regulations and standards as well as technical requirements and details from the
project.
Upon completion of the installation and assembly of cable sewer contractor has to do
technical documentation, as-built condition on the geodetic plans in scale that should be
1:1000, and 1:500 may be used for settlements, with the analytical elements of the derived
object (object coordinates related to the state trigonometric network) and the measurement
protocol, according to the guidelines of the ZJ PTT.
The newly designed solution predicts the laying of cable-protective PE pipes 50mm in the
ground or in the larger diameter protective pipe.
2.2 EXECUTION OF WORKS
TRACING (ROUTE MARKING)
Tracing of the telecoummunication cable duct system according to the approved project and
building permit should be done first.
Marking of the direction of duct system line in the field is meant by tracing.
Marking the route of the cable duct system is carried out according to the data from the
situation (the project), additional numerical data are used if there are any.
The route is transferred to the land from the plan through the settlement by means of
permanent (persistent) reference, and out settlements using the geodetic instruments.
EARTHWORKS (TRENCHING)
Earthworks are carried out in accordance with the general requirements of the construction
standards and other regulations for this type of work.
The trench in which the pipes will be laid is always digged as open trench, and is also digged
on pre-marked route.
The depth of the trench mainly depends on the category of land, type of cable and the place
where the cable is laying. The designed depth of the trench is 1 m, except at crossing points
where the depth varies depending on the elements of the road which is crossed (drainage
pipes, etc..).
Trench width at the top (level after the field) must be 0.40 m, and width of the trench at the
bottom can vary up to 5 cm from the trench width at the top.
Trench should be digged manually on sections to which is expensive or impossible to use
machinery. These are eg. sections of the route through the dettlements, on the slopes,
through a very rocky landscapes, etc.. During the excavation of the trench, excavated soil is
disposed to one side at a distance of at least 0.30 m from the edge of the trench. The soil
must not be disposed on the road surface.
The bottom of the trench must be leveled and cleaned of larger pieces of hardened material.
Special attention is drawn during the execution of works to the places where there are other
installations when is needed to do the excavation of test trenches and thus determine the
exact location of these installations
Along the slopes, gullies (the ups and downs), where the slope is 30 to 60 degrees trench
should be digged curved as a sinusoid with amplitude (deviation from a straight line) of 1.5 m.
Deflection length should be 5 m.
At the place of joint the trench should be expanded, size of expansion depends on the type of
juncture.
LAYING THE PIPES IN THE GROUND
The pipes are laid in the open trench only after cleaning and alignment of the soil, and if the
ground is rocky a layer of sand sohuld be placed in the trench below the pipes.
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The pipes are laid directly from drums or manually when its needed to provide a sufficient
number of workers. The default length of PE pipes to be installed should not be less than 500
m, and the ambient temperature when laying should not be lower than 5C due to reduced
flexibility of pipes at lower temperatures.
On the point of juncture PE pipes should have enough overlap to allow easier making of joint.
Laying of the pipies should continue untill it reach shaft or some obsticles that will be crossed
by drilling. In that case PE pipes with same diameter are used wich will be directly embedded
in the borehole.
Continuation of pipes is performed with joints which are appropriate dimensions, wherein the
pipes are shortened to an appropriate extent. Joints and place of juncture must be such that
they can sustain overpressure of 6 bar. Place a juncture of two adjacent factory length PE
pipes must allow smooth blowing of future telecommunication cables through them.
After installment and continuation of PE pipe between two shafts, quality check of sealing of
pipies and their joint is needed. Testing should be done by pumping compressed air
overpressured to 6 bar. Prior to this pneumatic testing it is necessary to check the
permeability of the PE pipe with the calibrator.
In the shafts the ends of the pipes should be closed on both sides with rubber caps that are
slanted from their center, with additional protection with heat shrinkable tapes.
After final testing of the PE pipes trench should be backfilled in layers. First layer must be
sand and fine soil, warning tape should be put after compacting 30cm layer above the pipe.
Tape is 4cm wide and the upper side is marked PANJA TK KABL (CAUTION TK CABLE),
bottom side has built-in metal strip (10x0,1mm) for the detection of fiber optic cables
(instructions from PTT Vesnik No. 37/11/93). After that, the trench is backfilled to the end.
The newly designed solution predicts the laying of four PE pipes 50mm in the ground,
while at the crossing points and points of changes in the depth of the trench PE pipes will be
swiped throug the protective pipes of larger diameter.
Protective pipes are also laid in the trench and are made of materials of appropriate
mechanical characteristics corresponding the appropriate JUS (PE). Diameter of pipes fits the
outer diameter which is 110 mm.
CABLE DUCTS CROSSINGS OVER THE ROADS
At the intersections of the cable duct system route with roads, electric cables, waterways,
pipelines, telecommunication cables should be mandatory set up in the protective pipes, ie.
Contruction of a pass through these objects.
By digging the road
In our case, a telecommunications cable sewage will be made during the construction of the
highway and it is not necessary to perform the crossing with drilling so all the crossings will
be performed by digging the (future) road.
At the crossing points planned minimum depth of trench is 1m, but never on the depth less
than 0,8m from lover point of elements of future road (drainage pipes, fence walls,
foundations or similar).
It is planned that all the crossings are performed by laying 2 pipes with outer dimater od
110mm.
PREFABRICATED MANHOLES
It is planned to set up prefabricated manholes DO-3 in the land along the route at the
maximum distance of 50m between them. Internal dimensions of the DO-3 shafts are 200 x
80 x 100 cm.
Prefabricated manholes consist of a bottom plate, sides and the cover lid of cast iron and
modular cast.
They are made of reinforced concrete and fitted with a lid, need to withstand without
deformation load of 250KN with point of attack in the middle of the lid (Class C 250). It should
be produced according to the technical manual for access shafts of cable sewage PTT
Vesnik No.10/83.
Reinforced concrete manholes are constructed of at least MB30 concrete, and reinforcement
can be made with MA500/560, GA RA400/500 or 240/360 armature. Also all other materials
used for construction of manholes must correspond to JUS standards.
Manhole cover is installed above the upper opening and consists the frame and metal lids.
Frame size depends on the size and number of panels that enclose the shaft and in our case
is 200 cm x 80 cm. Since the cover consists of several plates T profiles that are placed
between the lids are an integral parts. Lids should be in all manufactured according to
European standard EN-124 and Technical requirements for making and delivery of light and
heavy lids for cable manholes PTT Vesnik No. 7/64 and Technical requirements for the dual
covers for cable safts PTT Vesnik No.19/75. In our case with selected DO-3 manhole it is
necessary to use a four-part cover which has 80x50cm elements.
Between the prefabricated manholes and ground, and under the shaft, layer of gravel 20cm
deep should be placed. All the manholes are closed using four lids. In order to protect the
installation (as well as the covers themselves) from stealing manhole covers should have a
locking mechanism.
Picture 1. Appearance of the prefabircated manhole DO-3
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It is planned that manholes are positioned between traffic lanes along the left traffic lane.

Picture 4. Pipe protection on the bridge approach

Picture 2. Prefabrcated manhole installation detail

PIPE INSTALATION ON BRIDGES

Installation of telecommunication cables on bridges is typiccaly done in separate ducts or

pipes that are provided for this purpose in the the sidewalk or under the roadway on the
bridge.
In our case there are four 110mm diameter pipes allready in the bridge of which two will be
used for identation of 50mm protective PE pipes (two 50mm diameter pipes in each 110mm
diameter pipe)

Designer in charge
Picture 3. Installation of pipes through the bridge structure
Sasa Dunjic, M.Sc.E.E

Since the pipelines that run through the bridge are at a lower depth than the designed depths
of telecommunication pipes on the approach to the bridge - from the very beginning of the
change of depth to the entrance of pipes in the bridge, and in a lenght of 3m we have planned
instaltion of 2 protective PEHD pipes 110mm diameter and indenting two PE pipes 50 mm
in each of them.

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 V SUPPORTING STUDY

Study of safety and health at work and environmental protection

Highway -80
Dimitrovrgad bypass

1
 CONTENTS

1. GENERAL CONDITIONS

2. MECHANICAL RISKS AND MEASURES OF PROTECTION

3. ELECTRICAL RISKS AND MEASURES OF PROTECTION

4. EXPLOSIVE AND FIRE RISKS AND MEASURES OF PROTECTION

5. RISKS ASSOSIATED TO USE AND MAINTANANCE OF EQUIPMENT

6. STATEMENT

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1. GENERAL CONDITIONS
Safety at work implies obligation of companies to provide working conditions that will not have
adverse effects on health and work ability of workers in order to protect them from injuries,
and also obligation of every employee to comply with the prescribed measures and standards
for safety.
Occupational safety includes measures and resources necessary to achieve safe working
conditions.
The investor is required to provide approval on main design by certified company for safety at
work and that opinion to attach to the request to competent authority for a permit to build.
Employee (worker) has right protection in accordance with law, regulations and measures of
safety at work, general rules and collective agreements.
The company is obliged to provide supervision of inspector in charge, to provide him
requested information about health and safety and to comply with his order to correct any
deficiencies.
Commission for technical inspection, is obliged to determine whether the measures for the
safety at work from technical documentation are satisfied.
The company that performed work can use:
working and auxiliary facilities,
the work equipment and tools
auxiliary constructions and structures (scaffolds , working platforms) ,
tools and personal protection equipment (clothing, footwear and other items and equipment
that are used for the prevention of injury, professional diseases and other adverse
consequences)
only if they comply with the regulations on safety at work, standards and technical regulations,
and if regularly maintained (which is kept permanent records).
Motor drive tools, which is used at work, must have attached the following documents:
user guide;
prescribed public documentation and
report on the results of testing which proves that all measures of safety and that the
equipment is safe for operation.
General measures of the company determine the personal safety conditions regarding use
and quality of protective equipment, which is not prescribed by appropriate standards.
General measures define protective equipment and other safety measures for working tools
to ensure the safety of workers. The measures also include the safety of workers at work
operations, transport, use of hazardous and harmful substances, as well as protection from
fire at the site, and procedures for providing first aid and rescue services organization.
By special measures the company defines the conditions to be met by an employee working
in jobs with increased risk of injury and disease in terms of health, physical and mental
condition of the workers, performing preliminary and periodical medical examinations.
For works that are done at open space, under adverse climatic, atmospheric or other
influences, the company shall define general safety precautions and make the best use of
appropriate personal protective and other equipment.
Protection measures described in this section refer to the dangers that can arise during
installation of telecommunication and signaling cables and the installation, activation and
maintenance of equipment and could be classified into the following categories:
mechanical risks
electrical risks
explosive and fire risks
risks associated to use and maintenance of equipment
2. MECHANICAL RISKS AND MEASURES OF PROTECTION
For cable laying and cable installation must be used tools and the material which is strictly
intended for a particular type of work. The tools can be used only if it is correct and for the
tools that require periodic checks, certificate of check is necessary. The contractor must take
into account the proper use of tools and the implementation of safety measures.
Staff working on cable laying and installation must be qualified for that type of work. Work
must be organized so that it is carried out without disruption from the other workers.
All cables must be placed in special channels defined by architectural solution or in metal
trays and special plastic channels mounted on the wall or ceiling.
Telecommunications and signaling equipment must be housed in separate rooms intended for
it. Installing and securing equipment must be in accordance with the project requirements and
the manufacturer's instructions to prevent damage to equipment and injury of operator in
regular working conditions.
All devices must be connected properly. The premises in which the equipment is placed must
be sufficient space for free movement. Mechanical construction in which the equipment is
placed must be firmly seated and secured.
Staff working on the installation of the equipment must be qualified for this type of work.
Contractor shall organize the work in phases so that each phase can be performed
separately.
First aid is mandatory on the site and contractor must take care of it.
3. ELECTRICAL RISKS AND MEASURES OF PROTECTION
Electrical installations must not be exposed to mechanical, chemical and thermal stresses. All
electrical wiring and appliances must be protected by fuses.
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All cabinets to house electrical equipment must be grounded in accordance with local 6. STATEMENT
regulations. Equipment connection to the power supply network without grounding is not
allowed. Only qualified personnel may connect the device after verification of its properties. Technical documents includes measures for safety and health at work environmental protection
measures in order to eliminate risks and eliminate or reduce damage to tolerable levels.
All installations designed for the equipment in the project must remain intact under the most
unfavorable conditions.

Risk of short circuit or voltage drop was eliminated by proper dimensioning installation lines.

Protection against contact over-voltage and the static electricity is solved by the whole system
of protective measures. Central grounding of the building must be constructed according to
JUS N.B.741 .

Risk of impact of electromagnetic fields was eliminated by proper choice of the distance
between the electrical, signaling and telecommunication lines as well as the choice of
electrostatic and electromagnetic shielding inside and outside the lines.

4. EXPLOSIVE AND FIRE RISKS AND MEASURES OF PROTECTION

Fire protection measures are related to installation, activation and maintenance of

telecommunications and signaling devices. Devices during installation and after activation
must comply with all regulations relating to fire protection.

During installation and maintenance of equipment is not allowed to use flammable or

explosive materials. If the use of such materials cannot be avoided proper ventilation must be
provided.

Tools that can cause a fire and explosion may be used only by qualified personnel. The chief
of works must take care of the safety tools that are used, which can cause fire or explosion.

The room which houses the telecommunications and signaling equipment must be equipped
with hand-held fire extinguisher and fire hydrant which must be easily accessible.

5. RISKS ASSOSIATED TO USE AND MAINTANANCE OF EQUIPMENT Designer in charge

In areas with telecommunication and signaling equipment, enough space must be provided
Sasa Dunjic, M.Sc.E.E
for free movement in order to avoid the possibility of personal injury and equipment damage.
Professional servicing and maintenance of equipment is necessary. Only authorized
personnel can open cabinets with equipment.

Height of work area should be 3m and if there is no window shall be provided with adequate
ventilation. Preferred temperature is in the range 18-21 and the humidity is around 50-60%.
Standard JUS - C9.100 describes the lighting conditions that should be met while restrictions
on noise levels are given by special regulations. It is necessary to provide interfaces for
additional illumination when the position of the equipment is such that it covers day light, or
standard lighting from the ceiling.