Part 4.4 - Civil

BOOK III
PART 4.4 Civil Works
TABLE OF CONTENTS
PART 4.4 CIVIL WORKS ................................................................................................... 7

4.4.1 GENERAL CIVIL AND ARCHITECTURAL DESIGN REQUIREMENT .................. 7
4.4.1.1 BUILDING AND STRUCTURAL DESCRIPTIONS .............................................. 7
4.4.1.2 SITE DEVELOPMENT .................................................................................. 17
4.4.1.3 TEMPORARY SITE FACILITIES ..................................................................... 17
4.4.1.4 SITE INVESTIGATION ................................................................................. 17
4.4.1.5 EXISTING SERVICES .................................................................................... 18
4.4.1.6 GROUND RISK ............................................................................................ 18
4.4.1.7 PROVISION OF INFORMATION .................................................................. 18
4.4.1.8 FIRE, SAFE MEANS OF ESCAPE .................................................................. 18
4.4.2 TECHNICAL SPECIFICATION ....................................................................... 19
4.4.2.1 SOIL INVESTIGATION AND LABORATORY TESTING ................................... 19
4.4.2.1.1 SCOPE OF WORKS ..................................................................................... 19
4.4.2.1.2 CODES AND STANDARDS ........................................................................... 20
4.4.2.1.3 WORKS EXECUTION ................................................................................... 20
4.4.2.1.4 CORE DRILLING .......................................................................................... 20
4.4.2.1.5 STANDARD PENETRATION TEST (SPT) ....................................................... 22
4.4.2.1.6 VANE TEST ................................................................................................. 23
4.4.2.1.7 PERMEABILITY TEST .................................................................................. 23
4.4.2.1.8 SAMPLING ................................................................................................. 24
4.4.2.1.9 CONE PENETRATION TEST (CPT) ............................................................... 25
4.4.2.1.10 LABORATORY TESTING .............................................................................. 25
4.4.2.1.11 REPORTS .................................................................................................... 26
4.4.2.2 FIELD AND LABORATORY TEST .................................................................. 28
4.4.2.2.1 GENERAL.................................................................................................... 28
4.4.2.2.3 QUALITY ASSURANCE / QUALITY CONTROL .............................................. 30
4.4.2.2.4 SAMPLE TYPES ........................................................................................... 31
4.4.2.2.5 PACKING, HANDLING, TRANSPORTING AND PRESERVING SAMPLES ....... 31
4.4.2.2.6 LABORATORY TESTING PROGRAMS .......................................................... 32
4.4.2.2.7 LABORATORY TESTING PROCEDURES ....................................................... 33
4.4.2.2.8 DOCUMENTATION AND SUBMITTALS ....................................................... 48
4.4.2.3 EARTH WORK ............................................................................................ 56
4.4.2.3.1 CLEARING, GRUBBING AND STRIPPING .................................................... 56
4.4.2.3.2 EXCAVATION ............................................................................................. 58
4.4.2.3.3 FILL............................................................................................................. 63
4.4.2.4 SURVEYING AND SETTING OUT ................................................................. 70
4.4.2.4.1 SCOPE OF WORK ....................................................................................... 70
4.4.2.4.2 SERVICES TO BE PROVIDED BY THE CONTRACTOR ................................... 70
4.4.2.4.3 ACCURACY OF SURVEYING ........................................................................ 71
4.4.2.4.4 VERIFICATION OF WORKS ......................................................................... 72
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4.4.2.5 CONCRETE WORKS .................................................................................... 73

4.4.2.5.1 SCOPE OF WORKS ..................................................................................... 73
4.4.2.5.3 QUALITY ASSURANCE/QUALITY CONTROL (QA/QC ) ................................ 74
4.4.2.5.4 SUBMITTALS .............................................................................................. 74
4.4.2.5.5 STORAGE OF MATERIALS .......................................................................... 75
4.4.2.5.6 MATERIALS ................................................................................................ 76
4.4.2.5.7 STRENGTH, LIMITING, PROPORTIONING AND MIXING REQUIREMENTS . 83
4.4.2.5.8 FORMWORK .............................................................................................. 88
4.4.2.5.9 CONSTRUCTION DETAILS .......................................................................... 90
4.4.2.6 DETAILING FABRICATION AND PLACING OF REINFORCEMENT ................ 94
4.4.2.6.1 COMPLIANCE WITH STRENGTH REQUIREMENTS ..................................... 97
4.4.2.6.2 BATCHING, MEASURING AND MIXING CONCRETE ................................... 97
4.4.2.6.3 CONVEYING, PLACING AND CONSOLIDATING THE CONCRETE............... 100
4.4.2.6.4 SURFACE TREAMENT OF STRUCTURAL CONCRETE ................................. 103
4.4.2.6.5 PROTECTION OF CONCRETE .................................................................... 106
4.4.2.6.6 CURING .................................................................................................... 107
4.4.2.6.7 TREMIE CONCRETE .................................................................................. 108
4.4.2.6.8 CONCRETE FILLS FOR EQUIPMENT BASES............................................... 109
4.4.2.6.9 REPAIR OF CONCRETE ............................................................................. 109
4.4.2.6.10 CAST-IN-PLACE ELECTRICAL DUCTRUNS ................................................. 109
4.4.2.6.11 INSPECTION AND FIELD CONTROL TESTING ........................................... 109
4.4.2.7 GROUT WORK ......................................................................................... 113
4.4.2.7.1 SCOPE ...................................................................................................... 113
4.4.2.7.2 CODES AND STANDARDS ......................................................................... 113
4.4.2.7.3 QUALITY ASSURANCE/QUALITY CONTROL (QA/Q .................................. 114
4.4.2.7.4 SUBMITTALS ............................................................................................ 114
4.4.2.7.5 STORAGE ................................................................................................. 114
4.4.2.7.6 TYPES AND USES ...................................................................................... 114
4.4.2.7.7 MATERIAL ................................................................................................ 115
4.4.2.7.8 PREPARATION AND MIXING .................................................................... 116
4.4.2.7.9 PLACING AND CURING ............................................................................ 118
4.4.2.7.10 INSPECTION ............................................................................................. 120
4.4.2.8 JETTY (Not Applicable) ............................................................................ 120
4.4.2.9 STABILIZATION FOR RECLAMATION WORKS ( Not Applicable ) ............. 122
4.4.2.9.1 DEFLECTOR WALL .................................................................................... 122
4.4.2.10 TEMPORARY ROAD WORK ...................................................................... 122
4.4.2.11 ASH POND LINING WORKS ...................................................................... 123
4.4.2.11.1 SCOPE ...................................................................................................... 123
4.4.2.11.2 MATERIALS .............................................................................................. 123
4.4.2.12 PILING ...................................................................................................... 123
4.4.2.12.1 GENERAL.................................................................................................. 123
4.4.2.12.3 SOIL DATA................................................................................................ 124
4.4.2.12.4 STEEL PIPE PILE ........................................................................................ 124
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4.4.2.12.5 BORED PILES OR SPUN PILES ........................ Error! Bookmark not defined.
4.4.2.12.6 CONCRETE PILE........................................................................................ 128
4.4.2.12.7 LINES AND GRADES ................................................................................. 129
4.4.2.12.8 PILE TO PILE CAP CONNECTION .............................................................. 130
4.4.2.12.9 RECORDS OF PILE CONSTRUCTION ......................................................... 130
4.4.2.12.10 PILE LOAD TESTING ................................................................................. 131
4.4.2.12.11 NUMBER OF TESTS .................................................................................. 134
4.4.2.12.12 QUALITY ASSURANCE / QUALITY CONTROL (QA/QC) ............................. 134
4.4.2.13 PC CORRUGATED SHEET PILE ( NOT APPLICABLE ) ................................. 134
4.4.2.14 DESIGN AND FABRICATION OF STRUCTURAL STEEL ............................... 134
4.4.2.14.1 SCOPE OF WORK ..................................................................................... 134
4.4.2.14.3 REPORTS AND CERTIFICATES .................................................................. 135
4.4.2.14.4 MATERIALS .............................................................................................. 135
4.4.2.14.5 DESIGN .................................................................................................... 141
4.4.2.14.6 FABRICATION........................................................................................... 142
4.4.2.14.7 QUALITY ASSURANCE/QUALITY CONTROL (QA/QC) ............................... 148
4.4.2.14.8 INSPECTION AND TEST AT SHOP ............................................................. 149
4.4.2.15 ERECTION OF STRUCTURAL STEEL .......................................................... 150
4.4.2.15.1 SCOPE OF WORKS ................................................................................... 150
4.4.2.15.3 SUBMITTALS ............................................................................................ 150
4.4.2.15.4 FIELD REPRESENTATIVE ........................................................................... 151
4.4.2.15.5 MATERIALS .............................................................................................. 151
4.4.2.15.6 PERFORMANCE ....................................................................................... 151
4.4.2.15.7 INSPECTIONS AND EXAMINATION .......................................................... 155
4.4.2.16 GALLERY WORK ....................................................................................... 157
4.4.2.16.1 SCOPE OF WORK ..................................................................................... 157
4.4.2.16.3 WORKMANSHIP, SEQUENCE AND FINISH ............................................... 158
4.4.2.16.4 MATERIAL ................................................................................................ 158
4.4.2.16.5 DESIGN REQUIREMENTS ......................................................................... 159
4.4.2.16.6 DETAILED REQUIREMENTS ...................................................................... 160
4.4.2.16.7 FABRICATIONS AND ERECTION ............................................................... 164
4.4.2.16.8 CLEANING AND PAINTING ....................................................................... 165
4.4.2.16.9 GALVANIZING .......................................................................................... 165
4.4.2.17 ANCHOR BOLT ......................................................................................... 166
4.4.2.17.1 SCOPE OF WORKS ................................................................................... 166
4.4.2.17.4 SUBMITTALS ............................................................................................ 166
4.4.2.17.5 MATERIAL FOR ANCHOR BOLTS, NUTS AND WASHERS .......................... 167
4.4.2.17.6 ANCHOR BOLT SLEEVES ........................................................................... 167
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4.4.2.17.7 SETTING ................................................................................................... 167

4.4.2.17.8 COATING AND PROTECTION ................................................................... 168
4.4.2.18 CONCRETE EXPANSION ANCHOR WORKS ............................................... 169
4.4.2.18.1 SCOPE OF WORKS ................................................................................... 169
4.4.2.18.3 SUBMITTALS ............................................................................................ 169
4.4.2.18.4 DEFINITIONS ............................................................................................ 169
4.4.2.18.5 MATERIAL ................................................................................................ 170
4.4.2.18.6 INSTALLATION ......................................................................................... 170
4.4.2.19 METAL DECKING WORK .......................................................................... 171
4.4.2.19.1 GENERAL.................................................................................................. 171
4.4.2.19.4 SUBMITTALS ............................................................................................ 172
4.4.2.19.5 DESIGN .................................................................................................... 173
4.4.2.19.6 STORAGE ................................................................................................. 173
4.4.2.19.7 MATERIAL ................................................................................................ 173
4.4.2.19.8 FABRICATION AND INSTALLATION .......................................................... 173
4.4.2.20 WELDING IN STEEL STRUCTURES ............................................................ 176
4.4.2.20.1 SCOPE OF WORK ..................................................................................... 176
4.4.2.20.3 MATERIALS .............................................................................................. 176
4.4.2.20.4 DETAILED REQUIREMENTS ...................................................................... 177
4.4.2.20.5 PERFORMANCE ....................................................................................... 177
4.4.2.20.6 INSPECTION AND EXAMINATION ............................................................ 178
4.4.2.20.7 QUALITY ASSURANCE PROGRAM ............................................................ 185
4.4.2.20.8 WELDS IMPRACTICAL TO RADIOGRAPH.................................................. 186
4.4.2.21 PRIME COAT AND SHOP FINISH PAINTING ............................................. 186
4.4.2.21.1 SCOPE OF WORKS ................................................................................... 186
4.4.2.22 SUBMITTALS ............................................................................................ 188
4.4.2.22.1 GENERAL REQUIREMENT ........................................................................ 188
4.4.2.22.2 MATERIALS .............................................................................................. 190
4.4.2.22.3 DETAILED REQUIREMENTS FOR PAINTING OF STRUCTURES: ................. 191
4.4.2.22.4 CLEANING AND PAINTING OF EQUIPMENT AND PIPING ........................ 193
4.4.2.22.5 PERFORMANCE ....................................................................................... 194
4.4.2.22.6 INSPECTION ............................................................................................. 197
4.4.2.23 FIELD FINISH PAINTING ........................................................................... 208
4.4.2.23.1 SCOPE OF WORK ..................................................................................... 208
4.4.2.23.4 SUBMITTALS ............................................................................................ 209
4.4.2.23.5 GENERAL REQUIREMENTS ...................................................................... 210
4.4.2.23.6 SPECIFIED SURFACE CLASSES .................................................................. 214
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4.4.2.23.7 PAINTING WORK SYSTEM ....................................................................... 225

4.4.2.23.8 DETAILS OF PAINTING WORK SYSTEMS .................................................. 225
4.4.2.23.9 COLOR CODING AND/OR IDENTIFICATION AND MARKING .................... 227
4.4.2.23.10 RESTRICTIONS DURING PAINTING .......................................................... 227
4.4.2.23.11 METHOD OF APPLICATION ...................................................................... 228
4.4.2.23.12 INSPECTION ............................................................................................. 228
4.4.2.23.13 SAMPLES .................................................................................................. 229
4.4.2.24 METAL SIDING, ROOF AND INTERIOR WALLS ......................................... 233
4.4.2.24.1 SCOPE ...................................................................................................... 233
4.4.2.24.4 SUBMITTALS ............................................................................................ 234
4.4.2.24.5 DEFINITIONS ............................................................................................ 234
4.4.2.24.6 DESIGN REQUIREMENTS ......................................................................... 235
4.4.2.24.7 STORAGE ................................................................................................. 236
4.4.2.24.8 MATERIALS AND DETAILS ........................................................................ 236
4.4.2.24.9 ERECTION ................................................................................................ 240
4.4.2.24.10 PROTECTION OF INSULATION DURING ERECTION .................................. 241
4.4.2.24.11 CLEANING OF SIDING, ROOFS AND INTERIOR WALLS ............................. 241
4.4.2.24.12 REMEDY OF DEFECTS IN APPEARANCE ................................................... 241
4.4.2.24.13 INSPECTION AND TESTING ...................................................................... 241
4.4.2.25 MISCELLANEOUS ARCHITECTURAL WORK .............................................. 244
4.4.2.25.1 SCOPE OF WORK ..................................................................................... 244
4.4.2.25.3 DOORS ..................................................................................................... 245
4.4.2.25.4 WINDOWS ............................................................................................... 252
4.4.2.25.5 LOUVERS .................................................................................................. 254
4.4.2.26 MISCELLANEOUS AND EMBEDDED METAL WORKS ................................ 290
4.4.2.26.1 SCOPE ...................................................................................................... 290
4.4.2.26.3 SUBMITTALS ............................................................................................ 291
4.4.2.27 DRAINAGE AND DUCT WORKS ................................................................ 293
4.4.2.27.1 SCOPE OF WORKS ................................................................................... 293
4.4.2.27.3 CONCRETE PAVED DITCHES .................................................................... 294
4.4.2.27.4 STORM SEWERS AND CULVERTS ............................................................. 294
4.4.2.27.5 CABLE DUCT, TUNNEL AND PIPE TRENCH ............................................... 296
4.4.2.28 ROAD WORK, PARKING WORKS .............................................................. 297
4.4.2.28.1 SCOPE OF WORKS ................................................................................... 297
4.4.2.28.2 CODES AND STANDARD .......................................................................... 297
4.4.2.28.3 SUBGRADE PREPARATION FOR ROADS AND PARKING ........................... 298
4.4.2.28.4 ROAD WORKS .......................................................................................... 298
4.4.2.28.5 CONCRETE WALKS, DRIVES AND INCIDENTAL PAVING ........................... 301
4.4.2.28.6 CURBS AND GUTTERS .............................................................................. 302
4.4.2.28.7 WHEEL STOPS .......................................................................................... 304
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4.4.2.29 FENCE WORKS, GATES, GUARD RAIL....................................................... 304

4.4.2.29.1 SCOPE OF WORKS ................................................................................... 304
4.4.2.29.2 FENCE TYPE ............................................................................................. 304
4.4.2.29.3 MATERIALS .............................................................................................. 305
4.4.2.29.4 FENCING DETAILS .................................................................................... 306
4.4.2.29.5 GATES ...................................................................................................... 306
4.4.2.29.6 FENCE CONSTRUCTION ........................................................................... 306
4.4.2.29.7 GUARD RAIL ............................................................................................. 307
4.4.2.30 FINISHED GRADING AND ENVIRONMENTAL PROTECTION ..................... 308
4.4.2.30.1 SCOPE OF WORKS ................................................................................... 308
4.4.2.30.2 FINISHED GRADING ................................................................................. 308
4.4.2.30.3 ENVIRONMENTAL PROTECTION .............................................................. 309
4.4.2.31 CHIMNEYS ............................................................................................... 315
4.4.2.32 POND LINING ........................................................................................... 316
4.4.2.32.1 SCOPE ...................................................................................................... 316
4.4.2.32.2 MATERIALS .............................................................................................. 317
4.4.3 DESIGN PHILOSOPHY AND BASIC REQUIREMENTS ................................. 319
4.4.3.1 CODES AND STANDARD .......................................................................... 319
4.4.3.2 STRUCTURE DESIGN REQUIREMENTS ..................................................... 320
4.4.3.3 DESIGN LOADINGS .................................................................................. 322
4.4.3.3.1 DETAIL DESIGN REQUIREMENT ............................................................... 325
4.4.3.4 ARCHITECTURAL DESIGN REQUIREMENT ............................................... 327
4.4.3.5 OTHER CIVIL DESIGN REQUIREMENT ...................................................... 330
4.4.4 SUPPORT DATA ....................................................................................... 332
4.4.4.1 SOIL INVESTIGATION ............................................................................... 332
4.4.4.2 TOPOGRAPHY .......................................................................................... 333
4.4.4.3 BATHYMETRI ........................................................................................... 334
PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.vi

BOOK III
PART.4.4. Civil Works
PART 4.4 CIVIL WORKS
4.4.1 GENERAL CIVIL AND ARCHITECTURAL DESIGN REQUIREMENT
4.4.1.1 BUILDING AND STRUCTURAL DESCRIPTIONS
The Bidder shall provide all necessary permanent civil works for overall scope
of works. For clarification, additional notes about certain civil buildings and
structures are given below.
The Bidder shall propose the architectural views of the buildings in his bid
proposal.
Contractor may provided spun pile for all building foundation and proposes
the vibration study influence to existing CCPP if using spun pile to owner.
4.4.1.1.1 STEAM TURBINE BUILDING
The size and arrangement of this building shall be designed to house a steam
turbine and all associated mechanical and electrical equipment specified in
the applicable mechanical and electrical technical specifications and shall also
consider space for maintenance.
The Steam Turbine Building composes of Turbine Hall, Deaerator Bay and
Condenser. The Steam Turbine Building shall be of structural steel framing,
enclosed with double skin insulated metal sidings and slope double skin
insulated metal roofing.
The ground floor shall be of reinforced concrete slab finished with floor
hardener conforming to ASTM D 1308. The elevated floors shall be also of
reinforced concrete and shall be provided with galvanized steel grating for
any floor openings as approved by the Owner. All side opening shall be
completed with galvanized hand rail. Galvanized metal decking shall be used
for forming the elevated concrete floors.
Windows and louvers shall be provided for ventilation purposes, and smoke
heat vents shall be provided at the roof for air circulation. The frame windows
and louvers shall be anodized aluminum. Turbine cyclone ventilator shall be
installed on the roof of the building.
The Steam Turbine and generator shall be mounted on a turbine table top
reinforced concrete foundation supported by bored piles or spun piles
separate with building foundation.
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BOOK III
The Steam Turbine Building shall be mounted on a monolithic slab/mat

reinforced concrete foundation supported by bored pile.
4.4.1.1.2 BOILER HOUSE AND AUXILIARY
The size and arrangement of this structure shall be designed for boiler and all
associated mechanical and electrical equipment specified in the applicable
mechanical and electrical technical specification; and also shall consider an
ample space for maintenance requirement and access equipment for
operator.
The Boiler House shall be of structural steel framing enclosed with slope
metal roofing and siding as necessary. The Boiler House shall consist of local
control room and chemical storage for chemical feed system.
The floor shall be reinforced concrete slab finished with floor hardener
conform to ASTM D 1308. Steel grating shall be provided for any floor
openings as approved by the Owner. All side opening shall be completed with
galvanize hand rail. Galvanized metal decking shall be used for forming the
elevated concrete floors.
The Boiler House shall be mounted on a monolithic slab/mat reinforced

concrete foundation supported by bored piles or spun piles.
4.4.1.1.3 CENTRAL CONTROL BUILDING
The Central Control Building shall be designed as a concrete framing structure

and shall be approved by The Owner.
The Central Control Building shall consist of central control room, cable
spreading and main floors for housing control board, computers, electrical
equipment, cable, batteries, laboratory equipment, sanitary, pray room,
library, pantry, locker room, chief room, space to accomodate elevator,
emergency exit (stair and ladder) and air conditioning. Proposed layout of
Central Control Room shall be approved by The Owner.
Windows shall be anodized aluminum frames and insulated glazing. Air

conditioning system shall be provided in the majority of rooms in the Central
Control Room such as control room, computer room, office room, conference
room and others as approved by the Owner. The central control room shall be
installed with raised floor and ceiling grid system. All windows shall be fully
weather stripped and sealed thoroughly to prevent sand/dust penetration.
Central Control Room will use Emergency lock door steel pin with anti panic
bar and also will be completed with smoke detector.

BOOK III
4.4.1.1.4 ADMINISTRATION BUILDING (Not Applicable)
4.4.1.1.5 CHIMNEY
The Chimney arrangement drawings shall be included in the Bidder’s proposal

to show an intended arrangement of the chimney for this project.
The Chimney’s windshield shall be of reinforcement concrete of approx 150
meter height. To ensure the minimum maintenance over the operational life
of the power plant, the chimney shall include low viscosity corrosion inhibitor
protection which accept chloride testing in accordance with ASTM 1152 to be
lower than 0.007.
The foundation system for the Chimney shall be circular shape, supported by
bored pile. The foundation shall be proportioned in such a way that the
bearing and allowable settlement criteria shall not exceed, with no uplift
permitted and no increase in allowable in bearing for wind load. The
reinforcing shall be designed using a radial concept.
4.4.1.1.6 ACCESS ROAD AND BRIDGES
The access is from the main road from Jakarta Priok Harbour, Cigading Port
and Merak Harbour to Cilegon which is available for heavy transportation. If
the Bidder wish to use the road for equipment transportation he is
responsible for reinforcing and prepare the road and bridges in any certain
area, if necessary.
The Bidder shall provided Access Road and Bridge at KDL CFSPP 1 x 150 MW
site. (Refer to General Layout)
4.4.1.1.7 COOLING WATER INTAKE AND DISCHARGE
Cooling water for the Turbine Condenser and Power Station Auxiliary Plant
shall be drawn from and discharged to the sea.
The Bidder shall indicate in their layout drawing showing locations of cooling
water facilities (sea water intake pipe / cannal , pond, filter screen in intake,
Cooling Water pump house, pump pit, pipe to condenser, discharge, etc.) in
his bid proposal.
Optimization of the cooling water system and associated intake and outfall
positions shall be the responsibility of the Bidder.

BOOK III
Sea cooling water will be pumped from Pump House to Condenser by using
underground pipe. From condenser, cooling water will be discharged through
underground pipe ended in a seal pit and will continue its flow back to the
sea using open discharge canal.
The capacity of Intake line, pump pit, seal pit and discharge canal shall cover
for ultimate capacity i.e. for three (3) units of 150 MW each.
The Bidder shall undertake survey works to provide sufficient hydrographic

data (e.g. currents, bathymetry, tidal levels, sea water temperatures, etc) for
mathematical modeling of tidal, currents and thermal dispersion to verify the
location of intake and outfall structures and sedimentation study.
The cooling water discharge canal shall be either reinforced concrete
structure or reinforced concrete panel. The cooling water intake pipe shall be
of reinforced steel cylinder concrete pipe and Steel structure founded on
steel pipe piles. Design, manufacturing,and testing shall be refer to
requirement of EN 639 dan EN 641 standard
4.4.1.1.8 COOLING WATER INTAKE PUMP HOUSE
The Cooling Water Pump House is placed on offshore which shall be of

reinforced steel cylinder concrete pipe and Steel structure founded on steel
pipe piles. Design, manufacturing, and testing shall be refer to requirement
of EN 639 dan EN 641 standard
This structure shall be provided with auxiliary facilities such as sluice gate,
Trash rack rake, traveling screen, gantry crane rail beam and over head crane.
4.4.1.1.9 DEFLECTOR WALL (If Needed)

To avoid the wave resonance inside the outfall basin deflector wall structure
is required.
The common type of this structure is rubble mound deflector having high
porosity.
The Bidder shall design it accordingly and approved by owner.
4.4.1.1.10 ELECTRO CHEMICAL BUILDING
Electro Chemical Building shall be erected on shallow Foundation or bored

piles or spun piles (if necessary, based on soil condition).
The inside surface of concrete wall and floor shall be protected from acid and
alkali by the chemical resistant proof coating.

BOOK III
4.4.1.1.11 WASTE WATER TREATMENT FACILITIES
The Waste Water Treatment facilities building shall be of steel frame and
reinforced concrete for Control Building founded in shallow foundation or
bored piles or spun piles (if necessary, based on soil condition).
4.4.1.1.12 WATER TREATMENT PLANT
Water Treatment Plant structure shall be reinforced concrete founded on

shallow foundation or bored piles or spun piles (if necessary, based on soil
condition).
4.4.1.1.13 HSD OIL TANK FARM FOUNDATION
The fuel oil storage tanks foundations are reinforced concrete slab founded
on bored piles or spun piles ( if necessary, based on soil condition )
4.4.1.1.14 PIPE WORK SUPPORT STRUCTURE
The design and construction shall take into account the anticipated
movement, static, dynamic and seismic force where applicable and the need
to restrict differential settlements and movements between pipe supports
and adjacent plant and buildings.
Pipe work support structures shall sit on reinforced concrete sleeper

supported by bored piles or spun piles if necessary, based on soil condition (
onshore ) and steel pipe piles ( offshore area )
4.4.1.1.15 COAL STORAGE AND COAL HANDLING FACILITIES STRUCTURE
The Coal Storage facilities shall consist of transfer tower, coal shelter, reclaim
hopper coal conveying. All structures including Coal Control Building and Coal
Shelter shall be supported on shallow foundation if necessary supported by
bored piles or spun piles based on soil condition.
4.4.1.1.16 ASH HANDLING FACILITIES AND BOTTOM & FLY ASH SILO
The Slug hopper and fly ash silo shall be used to dispose off the station
surplus ash by products. It is envisaged that the Slug hopper and fly ash silo
will be used for disposal of furnace bottom ash (FBA) and pulverized fly ash
(PFA).

BOOK III
Ash handling facilities (slug hopper and fly ash silo) shall be founded on
shallow foundation or bored piles or spun piles, subject to soil condition.
Preliminary design for ash handling facilities (slug hopper and fly ash silo)
shall be submitted in the bid proposal for owner approval.
4.4.1.1.17 CABLE DUCTS AND UNDERGROUND CABLE DUCT
The underground cable duct shall consist of reinforced concrete around PVC
cable pipes. Concrete of cable duct shall be placed so as not to damage the
pipes and the spaces between each pipe shall be completely filled with
concrete.
The Cable ducts shall consist of box culverts of reinforced concrete structure
completed with drainage system including submerged pump and pump pit
facilities shall be founded on shallow foundation or bored pile (if necessary,
based on soil condition).
4.4.1.1.18 CABLE TRENCH
The cable trench shall consist of reinforced concrete, covered with removable
trench covers and shall be well drained.
Cable trench shall be founded on shallow foundation or bored pile (if

necessary, based on soil condition).
4.4.1.1.19 150 kV SUBSTATION BUILDING
The 150 kV substation building shall be designed as reinforced concrete

structure.
The foundations for the substation building shall be shallow foundation. If

necessary shall be supported on bored piles or spun piles based on soil
condition and shall be approved by the Owner.
4.4.1.1.20 DREDGING
The Bidder shall be responsible to conduct dredging work for the purpose of
installing the cooling water intake. The necessity of dredging work shall be
based on Bathymetry survey data which shall be subjected to the Owner’s
approval.

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4.4.1.1.21 AUXILIARY/MISCELLANEOUS BUILDINGS AND STRUCTURE
The other auxiliary/miscellaneous building and structure shall include but not
limited to:
 BOP plant and facilities
 Emergency diesel generator building
 Reverse Osmosis Structure (N/A)
 Support structure for conveyors
 Laboratory
 Fire fighting pump house
 Transformer foundation and facilities
 Firewall for transformer area
 Workshop
 Warehouse
 Guardhouse
 Local control room (stockyard and coal handling)
 Switchyard Building
The foundation of auxiliary/miscellaneous building and structures shall be

either shallow foundation or bored piles or spun piles if necessary, based on
soil condition and shall be approved by the Owner.
4.4.1.1.22 SITE DRAINAGE
The Power Station complex shall be provided with an integrated and

comprehensive drainage system which minimizes the influence of total site
discharges to the environment and complies with the local authority’s
requirements.
The drainage shall be either pre-cast or cast in-situ reinforced concrete.

Drainage crossing the road shall be designed as concrete box/pipe culvert.
The design of the drainage system of the Project, shall adopt the same design
concept with the existing drainage system as stated below:
The existing KDL Power Plant has four (4) kinds of water drainage system, i.e.:
i) storm water drainage,
ii) sanitary water drainage,
iii) oily water drainage
iv) waste water drainage.
Storm water at the roof of the building is collected by box gutter and drained
to the downspout and discharged to the drainage ditch located around the
building. Storm water from on-site road is drained to the side ditch and
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discharged to the drainage ditch. Storm water at the open yard is drained to
the nearest drainage ditch. Storm water at the switchyard is drained and
discharged to the drainage ditch through underground piping. All storm water
is finally collected and discharged to the existing outfall channel which is
located at east side of the Plant.
Meanwhile, sanitary drainage from toilet and waste water from kitchen is
drained to the septic tank provided around the building and its effluent water
from the septic tank is drained to the drainage ditch and finally discharged to
the outside of the Plant.
Oily water is drained to the oil separator at first. And its effluent is then
drained to the drainage ditch and finally discharged outside of the Plant.
Drainage from the plant equipment such as the chemical water is drained to
the waste water treatment plant and after duly treated it is discharged to the
existing outfall channel which is located at east side of the Plant.
Following is the proposed design concept for each drainage system;
a). Storm Water Drainage

The storm water drainage system’s ditches shall be adequate to discharge
surface run-off due to a 10-year recurrence interval storm as applied on the
existing drainage. The rational formula will be used for determining rainfall
runoff.
The minimum requirement of drainage ditch shall be of reinforced concrete

with 300mm wide, taking into account a maximum water velocity of
3.0m/sec.
The underground storm water drainage shall be provided with adequate

number of manholes with heavy frames and covers.
The manhole shall be 600mm as minimum size and be installed at all changes
in grade, size or alignment, at all intersections, and at intervals in accordance
with the following table.
RELATIONSHIP OF MANHOLE INTERVALS AND PIPE DIAMETER
DIAMETER OF PIPE Under Under Under Under Under

(mm) 300 600 1000 1500 1650
MAXIMUM INTERVALS
OF MANHOLE (m) 50 75 100 150 200
Wherever necessary, sewage pump shall be provided to the sewage system
due to the insufficient gradient condition of drainage root .

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b). Sanitary Water Drainage
The sanitary water drainage system shall consist of manhole, cleanout, piping,
grease trap and septic tank as well as absorption field where required.
All sewers will be designed to allow half full at normal flow with a minimum of
0.75 and maximum of 3.0 meters per second water velocity.
Cleanouts shall be provided at the junction of the building sewer and at each
change in direction of the sewer.
If the sewer length from the building to the septic tank is more than 15m, a
cleanout shall be provided at minimum of 15m intervals. If the sewer line
crosses any potable water line, 5 meters of both sides of the water line shall
be of cast iron. If the sewer line is within 3 meter distance from any potable
water line, the sewer line shall be of cast iron pipe with leaded joints. Grease
traps shall be provided in the waste line from kitchen.
Septic tank shall have sufficient capacity to accommodate the possible

number of people. Tanks shall be of reinforced concrete with manhole and
rungs and shall be of such construction permitting easy operation, inspection
and cleaning. The structure shall have sufficient strength against soil pressure,
water pressure, load, etc. The inside surface of tank and baffle walls shall be
coated with bituminous coating. The piping from the building to the septic
tank may be cast iron or PVC with the minimum inside diameter of 150mm.
Mechanical sewage system shall be provided, consisting of blower unit, pre-

treatment tank and main tank, and the following equipment which might be
required :
 Blower Motor
 Air Diffuser
 Flow Control Float
 Surface Skimmer
 Sludge Re-Circulation
 Raw Sewage Pump
 Effluent Pump
 Defoaming Pump
 Control Panel and Piping
Allowable BOD (Biological Oxygen Demand) concentration for discharge will

be planned to be 50 ppm.
For further construction stage, the EPC Contractor will be requested to

perform percolation tests to determine the absorption rate and field.

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c). Oily Water Drainage (Transformer Area Drainage & Oil Separator)
To contain oil spills, all drainage from the transformer area shall be routed
through WWTP to be processed futhermore.
The design of transformer pit and piping from transformer pit to oil separator
will be based on the largest flow expected from the following conditions:
 Surface runoff from the transformer area.
 Accidental oil spill should be drainage from the transformer area and shall
be routed through oil separator.
 Deluge system flow required for the largest transformer fire protection
system and will be based on estimated flow rate of 30 liters/s.
 Accidental oil spill from the largest transformer and shall be based on
estimated spilled oil volume of 3,000 liters.
 The main line connecting to the oil separator will be sized to be capable to
handle additional flow from other areas as required.
d). Waste Water Drainage System
To contain the chemical water such as acidic or alkaline water, all drainage
from the chemical equipment area will be routed through waste water
treatment plant. Waste Water Drainage System shall not contaminated with
Rain and Rain Water.
4.4.1.1.23 ROAD WORK
The Bidder shall be responsible to design and construct 8 meter width of main
road; 6 meter width of secondary and 4 meter width of tertiary roads
including guardrails and associated road markings and signs, necessary
parking areas and road lighting. All roads shall be rigid pavement provided
with 1 meter width of pedestrian on each side.
All roads arrangement shall be shown on the Bidder’s drawing proposal and
subject to Owner’s approval.
4.4.1.1.24 FENCE WORK
The Bidder shall be responsible to provide perimeter and security fencing and
gates. The perimeter fence required only for south and west side of site.
The perimeter fencing shall be concrete slab including post for stiffener and
gates. The height of perimeter fencing shall be 2.5 m.

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The perimeter wall shall have five strands of barbed wire mounted on 45º
extension arms.
Hazardous area shall be concrete slab fenced including post. The height of
security fencing shall be 2.5 m.
All of fencing and gates arrangement shall be shown on the Bidder’s drawing
proposal and subject to Owner’s approval.
4.4.1.2 SITE DEVELOPMENT
The Bidder shall be responsible to design and construct all site development
works in the power plant area.
The works shall consist of but not limited to clearing, grubbing, stripping,
excavation of unsuitable material, disposed off unused material, demolish
some existing building, backfilling and compacting under building and heavy
structure, soil improvement, reclamation, sea protection also filling and
compacting to grade level including demolition any substructure founded on
the project area.
The Bidder shall describe the material and arrangement of this soil
improvement method in his proposal. All material and arrangement shall be
subject to approval of the Owner.
4.4.1.3 TEMPORARY SITE FACILITIES
The Bidder shall be responsible for providing temporary site construction

facilities i.e. site office and fully furnish facilities including furniture and
facilities such as water, electricity, telephone, air conditioning system, sewage
treatment, sewerage, car park shelter for both Owner and Bidder.
The Contractor’s establishments shall following all Indonesian laws and local
regulations in respect of building standards, fire safety and hygiene as
applicable.
4.4.1.4 SITE INVESTIGATION
A limited site geotechnical data is provided by the Owner for reference only
to the Bidder relating to ground conditions and other site specific data which
are purely factual descriptions of findings at discrete locations around the
project site. The Owner will not accept any responsibility for the integrity of
the data nor any interpretation placed upon it. Accordingly the Bidder shall
satisfy himself on the ground conditions and other site specific issues in

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preparing his bid proposal. Except otherwise noted in the bid document, no
subsequent cost extensions will be entertained.
The Bidder shall undertake site investigations and site survey prior to
design/construction of the civil work at his cost. The Site investigation
required by Bidder and proposed after contract signing will be the Bidder’s
responsibility at no additional cost to the Owner.
Any hazards or constraints to construction likely to be encountered shall be

identified and addressed in the report.
All geo-technical reports and information shall be submitted to the Owner

prior to design work.
4.4.1.5 EXISTING SERVICES
The Bidder shall satisfy himself of the nature and location of any services
which may affect, or be affected by the design, construction or operation of
the permanent and temporary works and shall make due allowances of the
protection or diversion of such services required for and during the
construction of the works.
All costs arising out of disruption of existing services by the Bidder shall be
borne by the Bidder.
The Owner accepts no liability for additional costs nor delays which may be
incurred due to the discovery, disruption or damages to any existing services
occurred during the construction of the works.
4.4.1.6 GROUND RISK
The Bidder is required to make due allowances for and include in his bid
proposal for ground risk (unforeseen condition) appertaining to existing sub-
surface conditions and those pertaining to the completed (handed over) site.
4.4.1.7 PROVISION OF INFORMATION
The Bidder shall provide full and detail architect's and structure’s drawings of
all buildings and structures including structure and foundation calculation to
the Owner for approval. The Bidder shall not proceed with working
drawings/construction without such approval from Owner.
4.4.1.8 FIRE, SAFE MEANS OF ESCAPE

BOOK III
Plant and buildings provided by the Bidder constituting "the Works" shall
comply with the applicable fire authority requirements regarding safe means
of escape in the event of fire or other emergency hazard.
The buildings shall be designed and constructed so that there are safe means
of escape from fire to a place of safety at all the time.
4.4.2 TECHNICAL SPECIFICATION
4.4.2.1 SOIL INVESTIGATION AND LABORATORY TESTING
4.4.2.1.1 SCOPE OF WORKS
The scope of Soil investigation including all tests shall be performed to clarify
the soil conditions in order such satisfactory and economical foundations can
be designed and proposed recommendations for suitable types of foundation
and establishing the reliable soil parameter based on the analysis of the
geotechnical data.
These investigations should be performed immediately after the Contract

Award. The Contractor should submit the investigations program to the Owner
for approval. The program approval does not relieve the Contractor from his
obligation to undertake additional investigations of the soil based on the
Owner’s request, and that may be the result of the soil investigation first report
evaluation.
Investigation and elaboration of reports on investigation results and structures

foundations conditions should be entrusted to an institution specialized for soil
mechanics and foundation. Such an institution and the Report should be
approved of by the Owner.
The work shall include but not limited to the mobilization and demobilization,
transports and furnishing of all machines, equipment and installations
necessary to perform the works specified hereafter, such as drilling rigs, rods,
bits, casings, CPT, power generators, compressors, pumps, vehicles, cisterns
and all other matters deemed necessary by the Contractor to perform the
foreseen.
The soil condition is described briefly in section 4.1.4.2 GEOLOGICAL AND

GEOTECHNICAL CONDITION in book II.

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4.4.2.1.2 CODES AND STANDARDS
The Contractor shall comply with the requirements of this book section
4.4.3.1, "CODES AND STANDARD".
The Codes and standards of the following organizations extracted from this
book section 4.4.3.1, "Codes and Standards" are specifically applicable to
the design, manufacture and testing of the work included in this
specification.
ASTM American Society for Testing and Materials
BS British Standard
AASHTO American Association of State Highway and Transportation

Officials.
4.4.2.1.3 WORKS EXECUTION
SCOPE OF INVESTIGATION
The following minimum of the investigations program is compulsory:
a. 22 bore-holes on the new site with total depth of 1100 m.
b. 15 static cone penetrations test on shore to the depth of 30 m in

average.
c. In each of the bore-holes, undisturbed samples of soil shall be taken in 5.00

m interval and minimum 1 (one) at each different layer, vane test and SPT
test shall be performed in 1.00 m interval.
d. Testing laboratory for undisturbed and disturbed samples of soil properties.
4.4.2.1.4 CORE DRILLING
PROCEDURE
Core drilling shall be carried out by rotational method with clear water flush or
on the request of the Owner without any flush at all.
Core recovery is required on the entire length of all drillings. A minimum core
recovery of 90% is requested. Only material not altered or damaged by the
drilling process will be considered as “core“. Zones where SPT, vane tests or

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undisturbed sampling was performed are considered as zones with recovered

core.
Cores have to be handled carefully, in order to prevent deformation or
breakage.
DEPTH
Drilling equipment must be able to perform bore holes to a depth of at least 50
m.
The final depth of the bore hole, as well as the depth achieved with every core
run shall be measured with the drill rods in 5 cm accuracy.
If a boring does not reach the required depth, an additional hole(s) shall be
drilled and no compensation will be given for the abandoned hole(s).
The Owner is entitled to change the length of borings based on geological

features.
DIAMETERS
The initial diameter shall be chosen by the Contractor. The final core diameter
shall not be less than 54 mm.
In order to allow for proper telescoping, core barrels, bits and casing for several
diameters shall be already on the site.
OTHER OBLIGATIONS TO THE CONTRACTOR

The Contractor shall assist the Owner during core logging and all other works
related to the preparation and supervision of the Contractor's work.
The Contractor shall take colored picture of all cores. Two copies of 9 x 13 cm
pictures including the respective negatives/soft copies shall be handed over to
the Owner.
Each finished bore holes shall be marked by a concrete block cast in place, with
a minimum base dimension of 40 x 40 cm and a minimum height above ground
surface of 10 cm. The number marks of the bore holes shall be engraved on the
concrete.
EQUIPMENT
Rigs employed shall meet the following specifications:
 Hydraulic or mechanical feed

 Transmission gear to adjust spindle speed (e.g. 60 to 300 rpm).

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The core barrels shall be in perfect, which guarantees the request core
recovery. The use of single - tube core barrels is not allowed.
Diamond bits and hardened steel bits in perfect condition from a well-known
manufacturer shall be used.
The Contractor shall supply all necessary flush water for the execution of boring
and pertinent tests. Facilities for sedimentation and water reservoir of
adequate capacity might be necessary. Only clear water shall be used.
The Contractor shall establish the sequence of drilling and testing based on the
frequent requirements for the different bore holes tests to guarantee testing
and sampling in natural soil conditions and to allow for a reasonable drilling
progress. The sequence shall be approved by the Owner.
Core boxes shall be made of good and durable material; and each box shall be
covered by a lid with hinges.
The inner length of a core box shall be 1 m and for each meter of bore holes
one meter of core box shall be foreseen. At the end of each drilling, markings as
well as other pertinent information (e.g. core loss, extracted sample, etc) shall
be made immediately in the core boxes with indication of actual depth.
Inscriptions on the boxes have to be punched into aluminum or plastic straps.
The boxes must have the following indications on the inside of the lid:
 Job site
 Mark number of bore hole
 Date of finishing the bore hole
 Number of the box
 Depth interval
The boxes must also have the following indications on the outer small side:
 Job site
 Number of bore holes
 Number of the boxes
Core boxes have to be stored in such a way that they are protected against rain
and sun.
4.4.2.1.5 STANDARD PENETRATION TEST (SPT)
The test shall be made according to the following standards:

ASTM Designation D 1586 or BS 1377.

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Each extracted sample shall be packed and sealed in a plastic bag and placed in
the core box. It shall be labeled for identification with date, bore holes number,
depth and number of blows.
With the sampler resting on the bottom of the hole, drive the sampler with
blows from the 140 pound hammer falling 75 cm until either 45 cm have been
penetrated or refusal (defined as 100 blows per 15 cm or less of penetration)
has been reached.
Standard reporting shall give the number of blows for the first, second and
third penetration of 15 cm. Should the number of blows for the first 15 cm
exceed 20, the penetration depth for the first, second and third 20 blows shall
be reported. Furthermore, it shall be reported whether the hammer is free
chopping or fixed by a rope.
4.4.2.1.6 VANE TEST
The test shall be done according to the standard ASTM D 2573, AASHTO T223,
BS 1377, T18 or other standards as approved by the Owner.
To allow for calibration it shall be performed just below the location of a SPT
test.
The test shall be performed in such a way that the rods are isolated from the
soil, i.e. no friction occurs between the rods and the soil.
The maximum and residual value of torque and corresponding shear strength
shall be reported.
4.4.2.1.7 PERMEABILITY TEST
Should there be any sandy layers of the subsoil, the permeability shall be
measured with the falling head test method.
The test shall be performed where such a layer is encountered or as directed by

the Owner.
In general, not more than 2 tests shall be performed in one sand layer and no
test shall be closer than 3 m to the next one.
Prior to performing the test, the bottom of the bore hole shall be cleaned and
the water within the casing shall be clear. The ground-water level at the time of
the test shall be registered.

BOOK III
For the test, the casing shall be filled with clear water and the falling of the
head as function of time shall be measured. Registering time may be up to 20
minutes.
After the test, the depth of the bore holes shall be controlled.
If the casing is telescoped, special measures are needed to avoid water loss at
the level of diameter change.
The record of tests shall include:
 depth of boring
 depth of ground-water level
 duration of test
 diameter of casing at depth of casing and water level measurements
 array of data with time and fall of water level during test.
The Contractor shall interpret the data obtained and shall give the permeability
of the measured soil layer.
Data and interpretation shall be handed over to the Owner on approved forms
within 48 hours.
The compensation for the test is independent on the diameter or the depth
below surface where the tests were performed.
The supply of the required water volume for flushing the hole and testing is
understood to be part of the test and the Contractor is not entitled to any
additional payment irrespective of the volume of water lost in preparation and
performance of the test.
4.4.2.1.8 SAMPLING
In the course of the field investigations, 3 types of samples shall be

distinguished:
 Undisturbed soil samples

 Disturbed samples
 SPT-samples
All samples shall be taken from the drillings. Within counting the SPT- samples,
one sample shall be taken in every 1 m interval.
Undisturbed soil samples are extracted from bore holes with a special
instrument, as defined in ASTM D 1587, in fine-grained or cohesive soils.
The instrumentation is subject to the Owner's approval.

BOOK III
Undisturbed soil samples shall be taken in appropriate soils every 2 m interval

or at regular intervals, as directed by the Owner.
Disturbed samples shall be of soil, taken from cores and packed and sealed in
plastic bags or plastic tubes. Number, type and size of these samples will be
directed by the Owner.
All samples shall be labeled. The label shall indicate the project site, bore hole
location, depth and date of extraction.
On the site, the samples shall be stored in a special place sheltered from sun
and rain.
4.4.2.1.9 CONE PENETRATION TEST (CPT)
CPT equipment and testing procedure shall be in accordance with the

recommended standard ASTM D 3441-05
Deviations from such standard shall be indicated in the test report and need to
be approved by the Owner.
Based on the actual geological knowledge, depth which are envisaged for
testing is 30 m.
The test results shall be presented in a plot of cone resistance and-total side
friction versus depth.
Additionally but not alternatively, the Contractor may offer the measurement
of the pore water pressure versus depth. In this case the Contractor shall
submit a description of the equipment employed and shall indicate the price for
such readings per linear meter as an offered item to the price of CPT.
The test records shall be handed over to the Owner within 48 hours after test
performance.
They shall also be integrated in the Final Report.
Such payment includes also the set up of the test equipment at each location.
4.4.2.1.10 LABORATORY TESTING
The samples taken from the field shall be transported to the laboratory at least
every fortnight.

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The Contractor shall be responsible for adequate storage, extraction,

description and preparation of each sample.
All the works shall be included in the unit prices of tests and no extra
compensation will be given for such work.
The Contractor will receive, from the Owner, a test list indicating the tests to be
performed for each sample. If, for any reason, such test program could not be
followed, the Contractor shall immediately inform the Owner and furnish the
necessary reasons accordingly.
The number of each test given is the minimum required.
Variations from the given quantities might be directed by the Owner.
For each test, the Contractor shall indicate the standard to be followed.
Deviations from any standard or the use of other standards than the ones
specified hereafter are the subject to approval from the Owner.
The following tests for soil properties shall be performed in accordance with
ASTM and/or AASHTO and/or BS standards. Test and data recording shall
include:
 Particle-size analysis of soil, ASTM D422 or AASHTO T88 or BS1377.

 Liquid limit of soil, ASTM D423 or AASHTO T89 or BS 1377.
 Natural water content, ASTM D2216 or BS 1377.
 Natural (moist) unit weight, BS 1377.
 Specific gravity, ASTM D854 or AASHTO T100 or BS 1377.
 Organic matter, ASTM C40 or ASTM T21 or BS 1377.
 Permeability, ASTM D2434
 Unconfined compression strength, ASTM D2166 or AASHTO T208 or BS
1377.
 Consolidation, ASTM D2435 or AASHTO T216 or BS 1377
 Triaxial shear strength, AASHTO T266 or BS 1377
 Direct shear strength, AASHTO T236
4.4.2.1.11 REPORTS
DAILY REPORTS ON FIELD WORK

The driller shall carry out a daily report, containing:
 Diameter and type of bit
 Diameter and depth of casing
 Rotation speed
 Drilling pressure

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 Total water losses

 Pressure of clear-water flush, color of flush
 Depth and time interval of core runs
 Types of soil
 Water level in hole at beginning and at end of shift, intermediate
measurements.
 Any other pertinent information
The form of the daily report is subject to the Owner's approval.

There is no extra compensation for the daily reports.
FINAL REPORT ON FIELD WORK
The Final Report shall contain the following items:

 Activity time schedule table of investigation program
 Layout of the planned plant area to be constructed, with structures
locations indicated, and the positions of investigations to be carried out.
 List of drilling equipment used by the Contractor on site
 Comments on the performed work.
 Drawings of the bore logs.
 Complete data and interpretation for all field tests as SPT and permeability.
 List of all extracted samples (SPT, disturbed and undisturbed)
 Logs of CPT.
DRAFT REPORT.
A draft of the Final Report is subject to the Owner's approval. It shall be

delivered within 7 days after termination of the field work.
PROGRESS REPORT OF LABORATORY WORK
Fortnightly, the Contractor shall prepare and forward to the Owner one (1)
report with the following features:
 Samples received
 Tests performed
 Deviation from the test program
 Comments on the test program and on the test result
 An annex containing all test results of the given period
No extra compensation is foreseen for such Progress Reports.

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TEST RECORD
All forms for the test readings and interpretations shall be approved in advance
by the Owner. The Owner may also require additional forms or different plots.
FINAL REPORT ON LABORATORY WORK
The final report shall contain the following items:

 A sample list
 A list of performed tests
 Summaries of test results, arranged according to technical, geological or
geotechnical features
 All test results, readings, plots and interpretations.
The Contractor shall prepare the Final Report and submit it to the Owner for
approval. It shall be delivered within 30 days after termination of the field
works.
All forms and reports shall be in English.
The Contractor shall hand over six (6) copies of the Final Reports to the Owner.
Furthermore, the original of all text and data sheets and a transparent copy of
all drawings shall be delivered to the Owner.
The lumpsums for reporting shall include all data collections, typing, copying,
interpretation, calculation, designing, drawings, reproducing, posting, as well as
all paper and other material and work necessary, to provide the required and
approved reports.
The contract work is regarded to be terminated after the Owner has accepted
in writing, the draft of the Final Reports and after the Contractor has delivered
all originals and soft-copies of the Final Reports in correspondence with the
accepted Draft Reports, as specified above.
4.4.2.2 FIELD AND LABORATORY TEST
4.4.2.2.1 GENERAL
GENERAL CONDITIONS AND REQUIREMENTS
The work to be performed consists of furnishing all supervision, labor,

equipment, tools, supplies, materials, and transportation, and the performance
of all work items listed in Book II “Summary of Work”.

BOOK III
The Contractor shall have the sole responsibility of satisfying himself

concerning the nature of the work, and the conditions, particularly with respect
to testing procedures of the required laboratory tests.
The Contractor shall provide a qualified Geotechnical Engineer to present in the

laboratory on all workday to supervise the work. The work is subject to
inspection and observations, and technical direction by the engineer ( see book
I part 2 sect 2.1.17 ). The methods employed for laboratory testing shall be
approved by the engineer.
WORK INCLUDED
Delivering, packing and transporting to Contractor's laboratory soil and/or rock

samples from the exploration site (s) and/or storage sheds near the projects
site area.
Storing, handling and preparing for testing of all soil and/or rock samples at the
Contractor's laboratory.
Preparing and implementing a documented Laboratory Quality

Assurance/Quality Control Program.
Performing laboratory tests in accordance with the requirements described in

this specification and in designated standards. A general list of the laboratory
tests for soil and/or rock samples is provided in Table 4.4.2.2 attached to this
specification. Not all of the tests described in this table may be required. Types
and number of tests and testing priorities will be determined by the engineer.
If and when required by the Engineer, reporting on the preliminary results of all
tests upon their completion, typically on a weekly basis.
Preparing and submitting a draft and final data report on laboratory testing
giving complete results of all the tests, and summarizing the procedures for all
the tests performed in accordance with the procedures and requirements
specified, with appropriate graphs and data plots.
Preserving and temporarily storing the unused portions of all soil and/or rock
samples until further written disposition instructions given by the engineer.
Preserving all the raw data sheets, calculation sheets and graphs until further
written disposition instructions given by the engineer.
Any engineering services related to engineering analysis and design other than
those needed to calculate laboratory test results.

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Tests shall be conducted in conformity with the American Society of Testing

Material (ASTM) standard listed in Table 4.4.2.2 The Contractor may propose
other applicable material or international standards for the Engineer's
evaluation, acceptance and approval.
4.4.2.2.3 QUALITY ASSURANCE / QUALITY CONTROL
QUALITY REQUIREMENTS
This Specification covers services influencing the safety of structures. The

Contractor shall use procedures conforming to referenced standards, unless
otherwise approved by the engineer.
All laboratory testings shall be carried out by qualified personnel under

qualified supervision by the Contractor. All testings shall be carried out using
properly calibrated equipment. The accuracy of calibration shall be
documented and the documentation shall be available for inspection by the
Engineer.
QUALITY CONTROL PROGRAM
A documented quality assurance/control program, applicable to the services to

be performed in the laboratory by the Contractor shall be prepared and shall be
approved by the Engineer prior the implementation.
INSPECTION OF WORK
The Contractor, including any subordinate organizations engaged by him, shall

be subjected to a surveillance inspection and audit by the engineer. Inspection
on laboratory activities in progress might be performed by the Engineer to
provide compliance with specified technical and quality requirements, to
observe the equipment and procedures, and to review the testing program.
Inspection or audit by the engineer shall not relieve the Contractor from the
responsibility to comply with the requirements of the Contract Documents.
SUBCONTRACTS AND ASSIGNMENTS
In the event the Contractor employs any other party to perform any portion of
the work to which the quality assurance program is applicable shall be
approved by the owner. All of the quality assurance requirements of this
Specification shall be bound upon the subordinate organization.

BOOK III
4.4.2.2.4 SAMPLE TYPES
The Contractor shall be required to perform testing on the following types of

samples:
 Moisture content samples in moisture content containers.
 Disturbed bulk samples in plastic bags or lined sacks.
 Disturbed split-barrel samples in jars.
 Undisturbed 75 mm nominal diameter samples in Shelby tubes or in other

types of tubes as approved by the Engineer.
 Undisturbed block samples in containers as approved by the Engineer.
 Rock core, 75 mm nominal diameter, samples in core boxes and/or in other

containers as approved by the Engineer.
 Undisturbed chunk samples of soft rock in container's as approved by the

Engineer.
The Contractor should note that not all of the sample types described in this
specification might be required to be tested in the laboratory.
4.4.2.2.5 PACKING, HANDLING, TRANSPORTING AND PRESERVING SAMPLES
The Contractor shall pack, handle, transport and preserve all core samples in
good condition in accordance with ASTM: D2113, Standard Practice for
Diamond Core Drilling for Site Investigation, and all soil samples in accordance
with ASTM: D4220, Standard Practice for Preserving and Transporting Soil
Samples.
The Contractor may propose for the Engineer’s approval suitable methods to
pack, handle, transport, and to preserve soil and rock samples. All samples
shall be handled, packed, shipped and stored in compliance with the
requirements of applicable standards using procedures that has been proven
adequate for minimizing or preventing disturbances or changes in material
properties.
Undisturbed tube samples, block samples, chunk samples including rock core
boxes shall be treated with extreme care at all times and shall not be dropped,
jarred, vibrated or exposed to extreme temperatures.

BOOK III
On the Contractor's laboratory premises, all of the sample tubes, block

samples, and chunk samples including rock cores shall be kept sealed and shall
be stored in a constant-temperature humid room. Should the seal on any
sample be broken for any reason, such sample shall be resealed.
All moisture contents and disturbed sample containers and/or bags shall be
kept sealed to avoid changes in moisture content until required for testing. All
sacks containing bulk soil and aggregate samples shall be securely tied and
labeled and kept in the storage until disposal as determined and approved by
the Engineer.
Should only a portion of a sample be used for testing, the remainder shall be
resealed immediately, and shall be properly stored in marked containers.
4.4.2.2.6 LABORATORY TESTING PROGRAMS
The work includes performing laboratory tests on disturbed and undisturbed

and remolded soil samples, and on rock cores obtained during the subsurface
investigations. All testing shall be performed as soon as practical after receiving
the samples.
In general, standard test procedures which are followed without deviation and
performed on standard equipment shall be documented by reference only. For
tests where there are no standard procedures available, or where it is
appropriate to use modified or alternative procedures, the details of the test
procedures shall be documented for evaluation and future referencing. The
technical basis for deviating from standard testing procedures shall be included
in the documentation. Use of other than standard equipment, even if it is used
with standard testing procedures, shall also be documented. The Contractor
shall submit testing schedules, subject to approval by the Engineer, before any
testing is commenced. A listing of the number of required tests which are
anticipated at this time, for this Contract, shall be included in Schedule of
Prices.
All testing will be assigned in writing by the Engineer, and shall be performed in
accordance with the requirements of the standards referenced herein and/or
as directed and approved by the Engineer. The Contractor may consider to
perform additional tests which he believes are necessary and appropriate for a
proper evaluation of the characteristics of the materials subject to approval by
the Engineer.

BOOK III
4.4.2.2.7 LABORATORY TESTING PROCEDURES
GENERAL
Except for modifications described in this Specification, the test procedures

shall correspond to those described in the latest editions of the referenced
ASTM standards.
The laboratory testing procedures for the most commonly performed

laboratory tests are described in the following subsections. Details of other test
procedures shall be as determined by the engineer and shall comply with the
applicable standard requirements.
LABORATORY CLASSIFICATION OF SOILS
Laboratory classification of soils shall be carried out in accordance with ASTM:

D2487, Test Method of Classification of Soils for Engineering Purposes.
Laboratory Visual-Manual classification of soils shall be carried out in

accordance with ASTM: 2488, Practice for Description and Identification of Soils
(Visual-Manual Procedures).
Soil classification shall be provided for all samples unless otherwise requested
by the Engineer.
MOISTURE CONTENT
Moisture content shall be determined in accordance with ASTM: D 2216,

Method for Laboratory Determination of Water (Moisture) Content of Soil,
Rock, and Soil-Aggregate Mixtures.
Tests on moisture content samples shall be carried out as soon as the samples
arrived at the laboratory. Moisture content tests on undisturbed samples
required, as part of other specified tests shall be carried out immediately after
the samples are opened for the best performance of the required tests.
If approved by the Engineer, moisture content may also be determined in

accordance with ASTM: D4643, Standard Test Method for Determination of
Water (Moisture) Content for Soil by the Microwave Oven Method.
UNIT WEIGHT OF UNDISTURBED SAMPLE
The wet unit weight shall be obtained by dividing the weight of the sample by
its volume. The volume of the sample shall be determined by measurement or

BOOK III
displacement. The dry unit weight of the sample shall be obtained using the
wet unit weight and the moisture content.
The test report shall include wet and dry unit weights and the moisture
content.
SPECIFIC GRAVITY
Specific gravity tests shall be made in accordance with ASTM: D854, Test
Method for Specific Gravity of Soils.
The test report shall include percentage of soil finer than the No. 4 sieve, and
the specific gravity of the soil solids.
When required, the specific gravity and absorption of aggregates of size coarser
than No. 4 sieve size shall be determined in accordance with ASTM C 127, Test
Method for Specific Gravity and Absorption of Coarse Aggregate. The test
report shall include information on the percentage of aggregates retained on
sieve No. 4, bulk and apparent specific gravities and percentage absorption.
SIEVE ANALYSIS
Sieve analysis of soils shall be made in accordance with ASTM: D422, Standard
Method for Particle-Size Analysis of Soils. Hydrometer test shall not be
conducted.
The test report shall include, for each sample tested, the gradation curve
presented as curve of particle size versus percent passing by dry weight.
SIEVE AND HYDROMETER ANALYSIS
Combined sieve and hydrometer analyses shall be performed on soils in

accordance with ASTM: D422.
The results shall be presented as a curve of particle size versus percent passing
by dry weight.
MATERIAL IN SOILS FINER THAN NO. 200 SIEVES
Determination of the total amount of material in soils finer than the No. 200
sieve shall be performed in accordance with ASTM: D1140, Standard Test
Method for Amount of Material in Soils Finer than the No. 200 sieve.
The test report shall include percentage of soil finer than the No. 200 sieve.

BOOK III
ATTERBERG LIMITS
Atterberg Limits (Liquid Limit and Plastic Limit) shall be determined in

accordance with ASTM: D4318, Standard Test Method for Liquid Limit, Plastic
Limit, and Plasticity Index of Soils.
The test results for each soil sample shall include values of liquid limit
determined from the flow curve, plastic limit and plasticity index.
COMPACTION TESTS
In all required compaction tests, sufficient number of test points shall be

obtained to accurately define the moisture content-dry density curve on both
sides of the optimum moisture content. The minimum numbers of test points
shall be 5, and at least 3 of them shall be at moisture content higher than the
optimum. The zero air voids curve corresponds to the specific gravity of the
tested material shall be included on all figures showing the moisture content-
dry density curves.
Standard Proctor Test shall be performed in accordance with ASTM: D 698,

Standard Test Methods for Moisture-Density Relations of Soil and Soil-
Aggregate Mixtures Using 2 kg Rammer and 30 cm Drop.
Modified Proctor Test shall be performed in accordance with ASTM: D1557,

Standard Test Methods for Moisture-Density Relations of Soils and Soil-
Aggregate Mixtures Using 4.6 kg Rammer and 45 cm Drop.
RELATIVE DENSITY TESTS
Relative density of soils shall be determined on bulk samples in accordance

with ASTM: D4253, Standard Test Methods for Maximum Index Density of Soils
Using a Vibratory Table, and ASTM: D4254, Standard Test Methods of Minimum
Index Density of Soils and Calculation of Relative Density.
The test report shall include the maximum index density, maximum index void
ratio, minimum index density, minimum index void ratio, in-situ soil deposit or
fill dry density, in-site soil deposit or fill void ratio, and the calculated relative
density.
CBR TEST
California Bearing Ratio (CBR), test shall be performed in accordance with

ASTM: D 1883. Standard Test Method for CBR (California Bearing Ratio) of
Laboratory-Compacted Soils.

BOOK III
Test specimen shall be compacted to dry density of 95 percent of the maximum

dry density determined in accordance with (ASTM: D1557).
SHRINKAGE TEST
The shrinkage limit of soils shall be determined in accordance with ASTM: D427,
Standard Test Method for Shrinkage Factors of Soils.
The test report shall include the shrinkage limit, shrinkage ratio, and volumetric
and linear shrinkage of soil.
STABILOMETER, R-VALUE TESTS
Resistance (R-Value) tests of laboratory compacted soils shall be determined

with the stabilometer and expansion pressure devices in accordance with
ASTM: D2844, Standard Test Method for Resistance R-Value and Expansion
Pressure of Compacted Soils.
The test report shall include a graph of R-Value versus exudation pressure.
PINHOLE TEST
Disperse properties of cohesive materials shall be determined by the "Pinhole

Test" in accordance with ASTM: D4647, Standard Test Method for Identification
and Classification of Disperse Clay Soils by the Pinhole Test.
The test report shall include the dispersibility and dispersive classification of
test specimen in accordance with Pinhole Test Method (D).
pH TEST
Determination of soil pH to supplement soil-resistivity measurements shall be

in accordance with ASTM: G51, Standard Test Method for pH of Soil for Use in
Corrosion Testing.
The test report shall include the results of pH measurements and the corrosion
potential of the soil tested.
SULFATE TEST
The sulfate tests on soil samples shall be performed in accordance with the
State of California Department of Transportation, California Test: 417, Method
of Testing Soils and Waters for Sulfate Content.

BOOK III
The test report shall include the result of the water soluble sulfate content of
the soil specimen tested, in percentage.
SAND EQUIVALENT TEST
The sand equivalent test provides a measure of the relative proportions of

detrimental fine dust or clay-like material in soil or fine aggregates.
The sand equivalent test shall be performed in accordance with the State of
California Department of Transportation, California Test: 217, Method of Test
for Sand Equivalent.
EXPANSION INDEX TEST
The expansion index test provides a basic index property of the soil sample
comparable to Atterberg Limits.
The expansion index test shall be performed in accordance with the applicable
requirements of the UBC Standard No. 29-2, Expansion Index Test.
GENERAL MINERAL ANALYSIS OF GROUND WATER
General Mineral Analysis shall include analysis for bicarbonate, carbonate,

hydroxide alkalinity, calcium, chloride, copper, foaming agents (MBAS), iron,
magnesium, manganese, pH, potassium, sodium, sulfate, specific conductance,
total dissolved solids, total hardness, and zinc.
All tests on ground water shall be performed in accordance with "Standard

Methods for the Analysis of Water and Wastewater", APHA-AWWA-WPCF
(American Public Health Association-American Water Works Association-Water
Pollution Control Federation).
PARTIAL CHEMICAL ANALYSIS OF GROUND WATER
Partial Chemical Analysis shall include alkalinity, hardness (Ca, Mg), chloride,
nitrate, iron, manganese, pH, and specific conductance.
UNCONFINED COMPRESSION TEST
Unconfined compression tests shall be performed on undisturbed and

compacted (remolded) cohesive soil samples in accordance with ASTM: D2166,
Standard Test Method for Unconfined Compressive Strength of Cohesive Soil.
The height to diameter ratio shall be at least 2. Tests shall be carried out at in-
site moisture content for undisturbed samples. Compacted (remolded)

BOOK III
specimens shall be tested at the predetermined density and moisture content

prescribed by the Engineer.
Samples shall be subjected to compressive stress at a constant rate of (strain).
Compression shall continue until twenty (20) percent (strain) is reached.
The test report shall include initial moisture content, dry unit weight, a plot of
compression stress versus strain, unconfined compressive strength and shear
strength (cohesion).
UNCONFINED COMPRESSION TEST ON ROCK CORE SPECIMENS
Determination of the unconfined compressive strength of intact cylindrical rock

specimens shall be in accordance with ASTM: D2938, Standard Test Method for
Unconfined Compressive Strength of Intact Rock Core Specimens.
The test report shall include rate of loading and the calculated unconfined
compressive strength of the rock specimen.
TENSILE STRENGTH TEST ON ROCK CORE SPECIMENS
Determination of the direct tensile strength of intact cylindrical rock specimens

shall be in accordance with ASTM: D2936, Standard Test Method for Direct
Tensile Strength of Intact Rock Core Specimens.
The test report shall include rate of loading and the calculated direct tensile
strength of the rock specimen.
CREEP TEST ON ROCK CORE SPECIMENS
Determination of the creep behavior of intact cylindrical and soft rock core
specimens which are subjected to uniaxial compression shall be in accordance
with ASTM: D4341, Standard Test Method for Creep of Cylindrical Hard Rock
Core Specimens in Uniaxial Compression, and ASTM: D4405, Standard Test
Method for Creep of Cylindrical Soft Rock Core Specimens is Uniaxial
Compression, respectively.
The test report shall include stress level and temperature at which test were
performed, and plot of strain versus time curve.
LABORATORY VANE SHEAR TEST
Whenever required by the Engineer, determination of shear strength (cohes-

ion) of saturated fine-grained undisturbed and remolded cohesive soils shall be
in accordance with ASTM: D4648, Standard Test Method for Laboratory
Miniature Vane Shear Test for Saturated Fine Grained Clayey-Soil.

BOOK III
The test report shall include maximum torque reading, type of torque units and
the undrained shear strength (cohesion) of the soil sample.
CONSOLIDATION TEST USING CONTROLLED STRAIN LOADING
The constant-rate-of-strain consolidation test provides a means for studying

strain rate effects. This method is not applicable to soils of high permeability
nor to partially saturated soils.
Determination of the rate and magnitude of consolidation of undisturbed and

remolded soil samples which are restrained laterally and drained axially and
subjected to controlled-strain loading shall be in accordance with ASTM: D4186,
Standard Test Method for one-dimensional Consolidation Properties of Soils
Using Controlled Strain Loading.
The test report shall include : plot of void ratio versus log of average effective
vertical stress or axial strain versus log of average effective vertical stress; plot
of coefficient of consolidation versus log of average effective vertical stress, and
for tests in which secondary compression date were provided, a plot of
deformation versus log of time.
ONE-DIMENSIONAL CONSOLIDATION TEST
Determining the rate and magnitude of consolidation of undisturbed and

remolded soil samples which are restrained laterally and loaded and drained
axially shall be in accordance with ASTM: D4186, Standard Test Method for
One-Dimensional Consolidation Properties of Soils, with modifications as
described below.
For undisturbed samples, the specimen shall be prepared at natural (in-site)

moisture content. The Engineer might require some of the specimens to be
tested at the natural moisture, and other specimens to be inundated prior to
loading. The required test conditions will be indicated by the Engineer for each
test. The specimens shall be loaded in increments doubling the previous stress
commencing at 1.2 t/m2 up to a certain stress specified by the Engineer. Some
of the tests will require a maximum stress of at least 300 t/m2 and preferably
400 t/m2.
Unless approved otherwise by the Engineer, every increment of loading and

unloading shall be maintained for a minimum of 24 hours or until movements
have ceased, whichever period is shorter.
When required by the Engineer, undisturbed samples prepared for

consolidation test at natural moisture content and/or remolded samples

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prepared at predetermined moisture contents and dry densities shall be

inundated prior to application of any load increment. Compression or swell
caused by inundation shall be monitored within 24 hours or until movements
have ceased, whichever period is shorter, before the load increment is applied.
For some tests on undisturbed and compacted (remolded) specimens, the

Engineer may require determination of the amount of heave (swell) pressure or
settlement (collapse) by inundating the specimen at a stress of 1.2 t/m2, or at
in-site stress where the samples were obtained, or at any other stress
specified by the engineer. Observations of any additional settlement (collapse)
or heave (swell) caused by inundation shall be made within 24 hours or until
movements have ceased, whichever period is shorter. Should swelling occurs,
the heave pressure shall be determined by adding small load increments until
the original deformation reading just prior or inundation is restored. Testing
will then be continued under additional load increments, up to the maximum
stress specified by the Engineer and then, unloaded. In all tests, after
completion of consolidation at the maximum stress, the specimen shall be
unloaded in decrements at stresses equal to one-fourth of the previous stress,
with observations of swelling movements.
The time-compression (settlement) curves shall be plotted for each stress

increment in two different ways:
Deformation (settlement) reading versus square root of the time to reach 90

percent consolidation (Taylor Method).
Deformation (settlement) reading versus logarithm of elapsed time

(Casagrande Method).
The test reports shall also include for each specimen a plot of void ratio versus
logarithm of applied stress during loading and unloading. From these plots,
compression index, swell index, where possible the preconsolidation pressure,
coefficient of consolidation for each load increment, and estimates of average
permeability coefficient and coefficient of secondary compression shall be
provided for each sample tested.
ONE-DIMENSIONAL SWELL OR SETTLEMENT TEST
When required by the Engineer, determination of the magnitude of swell or

settlement of undisturbed and/or compacted (remolded) soil samples shall be
performed in accordance with ASTM: D4546, Standard Test Methods for One-
Dimensional Swell or Settlement Potential of Cohesive Soils.
This method will be used to determine either the magnitude of swell or

settlement under known axial stress, or the magnitude of vertical stress needed

BOOK III
to maintain no volume change of laterally constrained, axially loaded

specimens.
The test report shall include the information required in ASTM: D2435, the
percent heave or settlement for the given vertical pressure and swell pressure.
Compression and swell index shall also be reported.
CONSOLIDATED-DRAINED DIRECT SHEAR TEST
General
Determination of the consolidated-drained shear strength (cohesion and angle

of internal friction) of a soil material shall be in accordance with ASTM: D3080,
Standard method for Direct Shear Test of Soils Under Consolidated Drained
Conditions. Direct shear tests shall be performed on undisturbed or compacted
(remolded) fine-grained materials of low permeability and on compacted
granular material of relatively high permeability. The test procedure described
in ASTM: D3080 shall be followed with modifications as described below.
The minimum specimen diameter for circular specimens or minimum width for
rectangular specimens shall be 50 mm for specimens from tube samples and 3
inches for specimens from undisturbed block samples. The normal stress will
be specified by the Engineer. The shearing shall be commenced after the
primary consolidation is completed or within 24 hours after the application of
normal stress, whichever is earlier. Shearing shall be performed at a rate of
shear strain low enough to prevent development of pore pressures, positive or
negative.
The rate of shear shall be subjected to approval by the Engineer. Shearing shall
be continued to a sufficient horizontal strain to permit the determination of
peak shear strength, and wherever required by the Engineer, residual (ultimate)
shear strength for the fine grained materials. If repeated direct shear testing is
required (see ‘Repeated (Rehearsed) Direct Shear Test’ below), the direct shear
testing equipment shall have capability of reversal of the direction of shearing.
Tests on Undisturbed Specimens
Consolidated-drained direct shear tests shall be performed on specimens of

fine-grained material prepared from tube samples, ring samples and
undisturbed block samples as specified by the Engineer. If required by the
Engineer, samples having a preexisting shear plane, shall be placed in such a
way that the orientation of the specimen in the testing apparatus would result
that shearing be induced along that plane.

BOOK III
The test report shall include a plot of normal deformation versus logarithm of
elapsed time and a plot of shear stress and normal deformation during shear
versus the horizontal deformation.
Description of the specimen shall include existence of any weakness plane or

shear plane on which the shear was induced. Plots of normal stress versus peak
(maximum) shear stress and normal stress versus residual (ultimate) shear shall
also be provided.
Tests on Compacted (Remolded) Specimens
For tests on compacted material, three consolidated-drained direct shear tests

shall be conducted on different specimens prepared at different normal stress
levels designated by the Engineer. Consolidated-drained direct shear tests shall
be performed on specimens at dry unit weight and moisture content to be
specified by the Engineer.
The test report shall include a plot of normal deformation versus logarithm of
elapsed time and a plot of shear stress and normal deformation during shear
versus the horizontal deformation.
Description of the nature of the failure surface shall be included. Plot of normal
stress versus peak (maximum) shear stress and normal stress versus residual
(ultimate) shear shall also be provided.
TRIAXIAL COMPRESSION TESTS
Unconsolidated-Undrained Triaxial Compression Tests
Unconsolidated-undrained triaxial compression tests shall be performed on

undisturbed and/or on compacted (remolded) soil samples in accordance with
ASTM: D2850, Standard Test Method for Unconsolidated, Undrained
Compressive Strength of Cohesive Soils in Triaxial Compression, with
modifications as described below.
The diameter of the specimen shall be between 50 mm and 100 mm with

height of 2 to 2.5 times the diameter. Tests shall be conducted on samples at
natural and/or initial moisture contents. Strain-controlled testing equipment
shall be used. The confining pressures at which the triaxial compression tests
are to be conducted shall be designated by the Engineer. Compression shall be
continued until twenty (20) percent axial strain is reached.
For tests on undisturbed soil samples, unless otherwise requested by the

Engineer, three tests specimens shall be prepared from each selected sample.
Using the earlier determined unit weight and moisture content, the Contractor

BOOK III
shall verify that the dry unit weight of the three specimens would not differ by
more than 2 lb/ft3 and the moisture contents would not differ by larger
margins, other samples of similar material from comparable depths shall be
used to select each set of the three test specimens of similar dry unit weight
and water content. However, substitution of samples shall be subjected to
approval by the Engineer.
For tests on compacted (remolded) material, three unconsolidated-undrained

compression tests shall be conducted on different specimens prepared such
that their dry unit weights would not differ by more than 2 lb/ft3 and the initial
moisture content would not differ by more than 1.0 percentage point.
In some of the tests, the Engineer may require that the deviator stress shall be
recycled up to five times so as to obtain hysteresis loops. Such tests shall be
carried out at a strain rate that permits accurate observation and plots of
hysteresis loops.
The deviator stress range for each loop shall be from zero to about two-thirds
of the estimated maximum strength of the specimen. Following the completion
of the last hysteresis loop, the sample shall be stressed to 20 percent of total
axial strain, unless this strain was reached during an earlier loading cycle.
The test report shall include initial moisture content, initial dry unit weight, and
a plot of deviator stress versus axial strain for each confining pressure. The test
report shall also provide plots of deviator stress versus axial strain hysteresis
loops.
Consolidated-Undrained Triaxial Compression Tests
Consolidated-undrained triaxial compression tests with pore pressure

measurement shall be performed on specimens prepared from undisturbed
samples and/or compacted (remolded) samples as specified by the Engineer.
Unless otherwise approved by the Engineer, the test procedure shall generally
follow the one outlined in Part II, Section 3 of "The Measurement of Soil
Properties in the Triaxial Test", Second Edition, 1962 by Bishop, A.W. and
Henkel, D.J., Arnold Publishers, London.
Three test specimens shall be prepared from each sample selected by the
Engineer. Each specimen shall have a height of 2 to 2.5 times the specimen
diameter. The confining pressures shall be specified by the Engineer.
The test specimens shall first be consolidated at natural moisture content for
undisturbed specimens and at initial compaction moisture content specified by
the Engineer for remolded (compacted) specimens. The specimen volume-
change shall be determined by direct measurement against back pressure, as

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well as by measurement of the changes in the volume of the cell fluids. Deader
water shall be used as cell fluid. The pore pressure shall be measured using high
air-entry value ceramic disks at one end of the specimen, while drainage was
allowed from the other end. To accelerate consolidation by radial drainage,
filter strips may be wrapped around the soil specimen. Time versus
consolidation volume change and time versus pore pressure dissipation shall be
recorded.
The specimen which is not originally under saturated conditions shall then be
saturated by back pressure maintaining the effective cell pressure constant
until the Pore Pressure Coefficient "B" reaches a value of at least 0.95. Volume
changes during saturation shall be recorded and the specimen shall be allowed
to reconsolidate under saturated conditions. Pore pressure generated during
saturation shall be noted and the time rate of consolidation shall be recorded.
The specimen shall then be subjected to compressive axial stress at a constant

rate of strain sufficiently low to allow 95 percent equalization of excess pore
pressure. Backpressure shall be maintained throughout the test. The rate of
strain shall be subjected to approval by the Engineer. The test shall be carried
out upto (20) percent axial strain unless the peak deviator stress is clearly
established at a lower strain. Pore pressures shall be measured throughout the
test. Care shall be taken to obtain sufficient frequent observations to define
accurately the stress-strain and pore pressure-strain curves, including at low
strains.
The test report shall include moisture contents and dry unit weights (initial,
after consolidation, and final); plots of volume changes and pore pressure
dissipation versus logarithm of elapsed time during consolidation; and plots of
deviator stress and excess pore pressure versus axial strain during axial
compression. Magnitudes of Kempton’s Pore Pressure Coefficients "B" and "A"
shall also be reported. The Contractor shall report the details of equipment
used and the methods adopted to measure pore pressures, volume changes,
axial deformation and axial stress, and the rate of strain used during
compression. The report shall complete with all consolidation, volume change,
pore pressure and stress/strain data and their appropriate plots together with
total and effective shear strength envelopes for both peak shear strength and
shear strength at (20) percent strain.
Consolidated-Drained Triaxial Compression Tests
Consolidated-drained triaxial compression tests shall be performed on

specimens prepared from undisturbed samples and/or compacted (remolded)
specimens specified by the Engineer, unless otherwise approved by the
Engineer, the test procedure shall follow the one outlined in Section 4, Part III

BOOK III
of "The Measurement of Soil Properties in the Triaxial Test", Second Edition,

1962 by Bishop, A.W. and Henkel D.J., Arnold Publishers, London.
Three test specimens shall be prepared from each sample selected by the
Engineer.
Each specimen shall have height of 2 to 2.5 times the specimen diameter. The
confining pressures shall be specified by the Engineer. Accurate measurement
of volume changes during consolidation, saturation and axial compression are
required. Volume changes shall be determined by measurement of the changes
in the volume of the cell fluids as well as by directly measuring the inflow into
or outflow from the specimen against back pressure. The specimens shall be
consolidated at confining pressures to be determined as part of the test,
specimens shall be wrapped with filter paper with vertical slots to accelerate
consolidation.
Tests shall be required both on partially saturated and on saturated specimens.
For tests under partially saturated conditions, the test specimen shall be
consolidated under confining pressures to be specified by the Engineer, and
shall then be compressed at a constant rate of strain sufficiently low to prevent
any buildup of pore pressures, either positive or negative.
For tests under saturated conditions, the test specimen shall first be
consolidated at the moisture content as for the partially saturated test, by
measuring the volume changes, without the application of back pressure.
After consolidation is completed, back pressure shall be applied in small

increments, with simultaneous rising of the cell pressure, until the Pore
Pressure Coefficient "B" reaches a value of at least 0.95. Saturation shall be
achieved by passing deader water through the specimen. Observations shall be
made to flow quantity and specimen volume change against time, until a
constant rate of flow is achieved and no further volume changes are taken.
For tests in which determination of permeability is required, the coefficient of

permeability shall be determined from the constant flow rate.
The specimen shall then be subjected to compressive axial stress at a constant

rate of strain sufficiently low to prevent any build up of pore pressure, either
positive or negative. The rate of strain shall subject to approval by the Engineer.
Backpressure shall be maintained throughout the test. Compression shall be
continued until (20) percent axial strain is reached, unless the peak deviator
stress is clearly established at a lower strain. Pore pressures shall be measured
throughout the test. Care shall be taken to obtain sufficient frequent

BOOK III
observations to define accurately the stress-strain curves, including at low

strains.
The test report shall include moisture contents and dry unit weights (initial,
after the initial consolidation, after saturation and final); plots of volume
changes and pore pressure dissipation versus logarithm of elapsed time during
consolidation; and plots of deviator stress a volume changes during axial
compression. The Contractor shall give details of equipment used and the
methods adopted for measuring volume changes during consolidation, axial
deformation and excess pore pressure, and the rate of strain used during
compression.
The report shall be completed with all consolidation, volume change, pore-
water pressure and stress/strain data and their appropriate plots together with
total and effective shear strength envelopes for both peak shear strength and
shear strength at twenty (20) percent strain.
Multi-Stage Triaxial Tests
When required or approved by the engineer, some of the consolidated-

undrained and drained triaxial tests described above shall be carried out by a
multi-stage procedure. The deviator stress shall be plotted as the test
progresses, and as soon as it is determined that the maximum deviator stress
has been racked, the compression stage shall be stopped. The specimen shall
then be consolidated at a higher confining pressure, after which it shall be
compressed until the maximum deviator stress is reached.
If the cumulative axial strain for the two combined stages does not exceed
12 percent, the specimen shall then be consolidated at a higher confining
pressure and shall then be compressed until (20) percent axial strain is reached.
The confining pressures for the successive stages shall be the same as if the test
were performed on separate specimens, and the test procedures, rates of
strain and test reports shall be in general as described above for tests on
separate specimens.
Multi-stage tests shall not be carried out, nor continued if a noticeable shear
plane develops during the first or second compression stage, or if the
cumulative strain exceeds 8 percent following the first compression or 12
percent following the second compression.
PERMEABILITY TESTS
When required, permeability tests shall be performed by the methods

described below. In some of the tests, the Engineer may require that the
effluent from the soil sample shall be collected in clean, brown-colored,
sterilized bottles, for performing chemical tests.

BOOK III
Permeability Test as a Part of Triaxial Compression Test
Permeability test as part of the triaxial compression test shall be carried out on
compacted (remolded) granular soils or on low permeability undisturbed and
remolded soil specimens, and shall also comply with the applicable
requirements of the test method ASTM: D2434, Standard Test Method for
Permeability of Granular Soils (Constant Head).
The compacted (remolded) specimens shall be prepared at initial moisture

contents and unit weights specified by the Engineer. Tests on undisturbed
samples shall be carried out at initial natural moisture contents.
The height to diameter ratio of specimens shall be 2 to 2.5. The confining
pressures shall be specified by the Engineer. Test specimens shall be saturated
by the backpressure method prior to carrying out the permeability test.
Observations shall be made to flow quantity until a constant rate of flow is
achieved. The coefficient of permeability shall be determined from the constant
flow rate.
Constant-Head Permeability Test on Granular Soils
Determination of the coefficient of permeability by a constant-head method for

the laminar flow of water through granular soils shall be in accordance with
ASTM: D2434. Permeability tests shall be performed on specimens of coarse-
grained (granular) material prepared from undisturbed tube and/or block
samples, or compacted (remolded) samples as specified by the Engineer. The
undisturbed soil samples shall be tested at initial moisture content and in-situ
densities at which the samples were obtained. The compacted samples shall be
prepared at initial compaction moisture contents and unit weights as specified
by the Engineer.
Before commencement of this test all test specimens shall be fully saturated by
backpressure. For compacted samples, each test shall consist of three separate
determinations of permeability at initial densities specified by the Engineer. The
test shall include determination of the particle size distribution of the tested
specimens by sieve and hydrometer methods.
The test report shall include details of the specimen preparation, saturation
technique, testing procedure, and equipment used for the tests; initial and final
dry unit weights, initial and final moisture contents; gradation curve; plot of
velocity versus hydraulic gradient covering the ranges of soil identifications and
of densities; and values of coefficients of permeability normalized to 200c.

BOOK III
Variable-Head Permeability Test on Cohesive Soils
Determination of the coefficient of permeability by a Variable-Head method for

the laminar flow of water through fine-grained soils shall be carried out in
accordance with procedures described in "Soil Testing for Engineers" by T.
William Lambe, John Wiley and Sons, Inc., and shall also comply with the
applicable requirements of the test method ASTM: D2434 as identified by the
Engineer.
Variable-Head permeability tests shall be performed on specimens of fine-

grained (cohesive) material prepared from undisturbed tube and/or block
samples, or compacted (remolded) samples as specified by the Engineer. The
undisturbed soil samples shall be tested at initial moisture contents and in-site
densities at which the samples were obtained.
The compacted samples shall be prepared at initial compaction moisture
contents and unit weights as specified by the Engineer.
Before permeability test the specimens shall be saturated by back pressure.

Each test on a specimen shall consist of two independent determinations of
coefficients of permeability by using different initial heads of water. The test
shall include determination of the particle size distribution of the tested
specimens by sieve and hydrometer methods.
The test report shall include details of the specimen preparation, saturation
techniques, testing procedure, and equipment used for the test; initial and final
unit weights, initial and final moisture contents; gradation curve; plot of
velocity versus hydraulic gradient covering the ranges of soil identifications and
of densities; and values of coefficients of permeability normalized to 200c.
4.4.2.2.8 DOCUMENTATION AND SUBMITTALS
QUALITY CONTROL PROGRAM
Contractor shall submit documented Quality Control Program. As a minimum,

the Program shall include the followings:
 An organization chart including Project task assignments;
 Qualification and training of personnel;
 Procedures for identification, control and storage of Project documents,

records and storage and shipping of samples;
 Control of measuring and test equipment including calibration procedures

BOOK III
and records of test equipment;
 Use of procedures and test methods conforming to referenced applicable

standards and specifications.
Procedures for providing applicable quality assurance/control requirements to

subordinate organizations performing any portion of this Contract.
PRODUCTION PLAN AND SCHEDULE

Contractor shall submit a Production Plan and Schedule as a minimum; the
Production Plan and Schedule shall include the followings:
 Description of all tasks;
 Descriptions of laboratory procedures, methods and standards proposed to

be used for this contract including all shipping and storage procedures;
 Proposed manpower, geotechnical personnel, and crews on any part of the

Project to satisfactorily perform the work described in this contract;
 Qualifications of all personnel proposed to be assigned to perform the work

described in this contract, including subcontractors;
 List of all proposed testing equipment, accessories and materials including

all supplies;
 Proposed schedule for laboratory testing, including all works to perform the
complete work described in this contract in a timely manner.
Proposed work shifts, if any, and their relations to overall project schedule.
PRESENTATION OF RESULTS AND LABORATORY TESTING DOCUMENTS
The results of the tests shall be transmitted to the Engineer in preliminary form
as soon as they become available, on typically once per week basis. The
Engineer will also require periodic progress reports by telephone. Close
communication between the Contractor and the Engineer will be establised at
all stages of the work. Upon completion of the testing program, the Contractor
shall present a detailed report as described below.
The presentation of results of each test shall include borehole or test

trench/test pit number, sample number and depth, soil classification and such
other information as may be required in the specification for each type of test.

BOOK III
All laboratory testing records and documentation shall be in accordance with

Subsection ‘Reports’.
For test results shown in graphical form, the scale of graph axis shall be
selected to provide as clear and as accurate as possible presentation of the
results. Contractor's standard laboratory test forms shall be modified or
replaced if necessary to achieve this requirement. All test forms shall subject to
approval by the Engineer.
At the end of the contract period, all samples results and laboratory
documentation shall be handed over to the Owner.
REPORTS
The Contractor shall furnish the Engineer with weekly progress reports
including the preliminary test results with a notation verifying that the work
performed complies with the requirements of the quality assurance/control
program. The Engineer may also request intermediate progress results by
telephone.
Within approximately (7) days after completion of the laboratory testing

program, the contractor shall submit to the Engineer two (2) copies of a
reproducible typed draft Data Report. The report shall include but shall not be
limited to the following items:
Complete results of all laboratories testing including data plots and summary
tables.
Reference of procedures used, with full descriptions of those procedures which

differ from ASTM or other specified standards.
Statement certifying that all works were done under qualified supervision using
calibrated equipment, and all the original data sheets and computations are
available in the Contractor's files for review.
The Draft Data Report will be reviewed by the Engineer within 7 calendar days,
and shall be finalized by the Contractor within 13 calendar days after the
Engineer's review. The Contractor shall provide six (6) copies of a reproducible
typed Final Data Report. The final version of the Data Report shall incorporate
Engineer's review comments where appropriate.

BOOK III
RECORD KEEPING
Pertinent records of laboratory activities shall be maintained and reported to

the Engineer as work progresses, and shall be verified as completed. Specific
requirements are noted throughout this Specification.
Any unusual circumstances or nonconformance encountered during laboratory

activities shall be recorded and reported to the Engineer.
The Contractor shall maintain appropriate quality assurance/control records

furnishing the evidence of the quality of services and activities.
The Contractor shall not dispose off any of such nonpermanent records until
the Engineer has given advise in writing which items are to be discarded. The
Contractor will then be advised to discard such item or to ship it to a
permanent storage site as designated by the Engineer.

BOOK III
TABLE 4.4.2.2
LABORATORY TESTS FOR SOIL AND ROCK SAMPLES
ASTM DESCRIPTION
D 421 Practice for Dry Preparation of Soil Samples for Particle-Size Analysis
and Determine of Soil Constants
D 422 Method for Particle-Size Analysis of Soils
D 425 Test Method for Centrifuge Moisture Equivalent of Soils
D 427 Test Method for Shrinkage Factors of Soils
D 558 Test Methods for Moisture-Density Relations of Soil-Cement Mixtures
D 559 Methods for Wetting-and-Drying Tests of Compacted Soil-Cement
Mixtures
D 560 Methods for Freezing-and-Thawing Tests of Compacted Soil-Cement
Mixtures
D 698 Test Methods for Moisture-Density Relations of Soils and Soil-
Aggregate Mixtures Using 5.5-lb Rammer and 12-in. Drop
D 806 Test Method for Cement Content of Soil-Cement Mixtures
D 854 Test Method for Specific Gravity of Soils
D1140 Test Method for Amount of Material in Soils Finer than the No. 200
Sieve
D1557 Test Methods for Moisture-Density Relations of Soils and Soil-
Aggregate Mixtures Using 10-lb Rammer and 18-in. Drop
D1558 Test Method for Moisture Content Penetration Resistance
Relationships of Fine-Grained Soil
D1632 Practice for Making and Curing Soil-Cement Compression and Flexure
Test Specimens in the Laboratory
D1633 Test Method for Compressive Strength of Molded Soil-Cement
Cylinders
D1634 Test Method for Compressive Strength of Soil-Cement Using Portions
of Beams Broken in Flexure (Modified Cube Method)
D1635 Test Method for Flexural Strength of Soil-Cement Using Simple Beam
with Third-Point Loading
D1883 Test Method for CBR (California Bearing Ration) of Laboratory-
Compacted Soils
D2166 Test Method for Unconfined Compressive Strength of Cohesive Soil
D2168 Methods for Calibration of Laboratory Mechanical-Rammer Soil
Compactors
D2216 Method for Laboratory Determination of Water (Moisture) Content
of Soil, Rock, and Soil-Aggregate Mixtures
D2217 Practice for Wet Preparation of Soil Samples for Particle-Size Analysis
and Determination of Soil Constants

BOOK III
TABLE 4.4.2.2
LABORATORY TESTS FOR SOIL AND ROCK SAMPLES (Continued)
ASTM DESCRIPTION
D2434 Test Method for Permeability of Granular Soils (Constant Head)
D2435 Test Method for One-Dimensional Consolidation Properties of Soils
D2487 Test Method for Classification of Soils for Engineering Purpose
D2488 Practice for Description and Identification of Soils (Visual-Manual
Procedure)
D2607 Classification of Peats, Mosses, Humus, and Related Products
D2664 Test Method for Triaxial Compressive Strength of Undrained Rock

Core Specimens Without Pore Pressure Measurements
D2844 Test Method for Resistance R-Value and Expansion Pressure of
Compacted Soils
D2845 Method for Laboratory Determination of Pulse Velocities and
Ultrasonic Elastic Constants of Rock
D2850 Test Method for Unconsolidated, Undrained Compressive Strength of
Cohesive Soils in Triaxial Compression
D2901 Test Method for Cement Content of Freshly Mixed Soil-Cement
D2973 Test Method for Total Nitrogen in Peat Materials
D2974 Test Methods for Moisture, Ash, and Organic Matter of Peat and
Other Organic Soils
D2976 Test Method for pH of Peat Materials
D2977 Test Method for Particle Size Range of Peat Materials for
Horticultural Purposes
D2978 Test Method for Volume of Processed Peat Materials
D2980 Test Method for Volume Weights, Water-Holding Capacity, and Air
Capacity of Water-Saturated Peat Materials
D3080 Method for Direct Shear Test of Soils Under Consolidated Drained
Conditions
D3148 Test Method for Elastic Module of Intact Rock Core
Specimens in Unixial Compression
D3152 Test Method for Capillary-Moisture Relationships for Fine-Textured
Soils by Pressure-Membrane Apparatus
D3155 Test Method for Lime Content of Uncured Soil-Lime Mixtures
D3551 Method for Laboratory Preparation of Soil-Lime Mixtures Using a
Mechanical Mixer
D4015 Test Method for Bearing Ratio of Laboratory-Compacted Soil-Lime
Mixture
D3668 Test Methods for Modulus and Damping of Soils by the Resonant-
Column Method
D4016 Test Methods for for Viscosity of Chemical Grouts by the Brookfield
Viscometer (Laboratory Method)

BOOK III
TABLE 4.4.2.2
ASTM DESCRIPTION
D4083 Practice for Description of Frozen Soils (Visual-Manual Procedure)
D4186 Test Method for One-Dimensional Consolidation Properties of Soils
Using Controlled-Strain Loading
D4219 Test Method for Unconfined Compressive Strength Index Test of
Chemical-Grouted Soils
D4220 Practices for Preserving and Transporting Soil Samples
D4221 Test Method for Dispersive Characteristics of Clay Soil by Double
Hydrometer
D4253 Test Methods for Maximum Index Density of Soils Using a Vibratory
Table
D4254 Test Methods for Minimum Index Density of Soils and Calculation of
Relative Density
D4318 Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils
D4319 Test Method for Distribution Rations by the Short-Term Batch
Method
D4320 Method for Laboratory Preparation of Chemically Grouted Soil
Specimens for Obtaining Design Strength Parameters
D4341 Test Method for Creep of Cylindrical Hard Rock Core Specimens in
Unixial Compression
D4373 Test Method for Calcium Carbonate Content of Soils
D4380 Test Method for Density of Benton tic Slurries
D4381 Test Method for Sand Content by Volume of Benton tic Slurries
D4404 Test Method for Determination of Pore Volume and Pore Volume
Distribution of Soil and Rock by Mercury Intrusion Porosimetry
D4405 Test Method for Creep of Cylindrical Soft Rock Core Specimens in
Unixial Compression
D4406 Test Method for Creep of Cylindrical Rock Core Specimens in Triaxial
Compression
D4427 Classification of Peat Samples by Laboratory Testing
D4452 Methods for X-Ray Radiography of Soil Samples
D4511 Test Method for Hydraulic Conductivity of Essentially Saturated Peat
(Constant Head)
D4525 Test Method for Permeability of Rocks by Flowing Air
D4531 Test Method for Bulk Density of Peat and Peat Products
D4535 Test Methods for Measurement of Thermal Expansion of Rock Using
a Dilatometer
D4542 Test Method for Pore Water Extraction and Determination of the
Soluble Salt Content of Soils by Refractometer
D4543 Practice for Preparing Rock Core Specimens and Determining
Dimensional and Shape Tolerances

BOOK III
TABLE 4.4.2.2
ASTM DESCRIPTION
D4546 Test Methods for One-Dimensional Swell or Settlement Potential of
Cohesive Soils
D4609 Guide for Screening Chemicals for Soil Stabilization
D4611 Test Method for Specific Heat of Rock and Soil
D4612 Practice for Thermal Diffusivity of Rocks
D4633 Test Method for Stress Wave Energy Measurement for Dynamic
Penetrometer Testing Systems
D4643 Test Method for Determination of Water (Moisture) Content of Soil
by the Microwave Oven Method
D4644 Test Method for Slake Durability of Shales and Similar Weak Rocks
D4647 Test Method for Identification and Classification of Dispersive Clay
Soils by the Pinhole Test
D4648 Test Method for Laboratory Miniature Vane Shear Test for Saturated
Fine-Grained Clayey Soil
D4718 Practice for Correction of Unit Weight and Water Content for Soils
Containing Oversize Particles
D4753 Specification for Evaluating, Selecting, and Specifying Balances and
Scales for Use in Soil and Rock Testing
G 51 Test Method or pH of Soil for Use in Corrosion Testing

BOOK III
4.4.2.3 EARTH WORK
4.4.2.3.1 CLEARING, GRUBBING AND STRIPPING
SCOPE OF WORK
This work consists of clearing, grubbing and stripping of areas where
excavation, filling or back filling are to be done, surfaces of quarry sites, as well
as stockpile and waste pile sites, as indicated on the approved drawings or as
directed by the Owner, including transportation and disposal of the unsuitable
and waste materials removed during the clearing, grubbing and stripping
operations.
CLEARING
Clearing includes removal and disposal of trees and downed timber, brush,
hedges, bushes and other vegetation or organic materials; and rubbish, debris
or other foreign or objectionable materials at grade, except the removal of
topsoil.
No trees shall be cut outside the clearing limits without the approval of the
Owner and all trees designated by the Owner to be left intact shall be protected
from damage by the Contractor's operation.
GRUBBING
Grubbing includes removal and disposal of stumps, large roots, buried logs and
other objectionable materials to 1,000 mm below ground surface. Explosives
may be used only if specifically approved by the Owner and their use shall
conform to the regulations of authorities having jurisdiction.
REMOVALS
Trees shall be fallen down in such a manner as not to damage other trees or
other vegetation indicated to remain in place, nor damage existing structures
and facilities, nor constitute a hazard to traffic or life.
In areas to be excavated or stripped the grubbing shall be performed as part of

the excavation.
STRIPPING
Stripping consists of removing of all rubbish, humus, vegetable matter and all or
part of the organic topsoil in the respective areas, which can be removed by
simple excavation methods and to a depth as directed by the Owner.
All borrow and quarry areas shall be stripped to a depth which allows for
suitable construction materials to be produced.

BOOK III
EXECUTION AND DISPOSAL

The Contractor shall perform all work as specified in this section either
manually or using mechanical equipment. If the Contractor removes and
wastes otherwise suitable material required for the works, the amount of
suitable material removed shall be replaced by an equal quantity of approved
material at Contractor's expense.
No grading and earth moving shall start in any area until clearing; grubbing and
stripping have been completed for the area.
Burning of debris on the project site is not allowed If burning of debris is

indicated then the bidder request to the owner.
Burn debris is only in areas indicated or areas designated by the Owner.
Prior to burning any material, secure approval and permits from and
compliance with the regulations of authorities having jurisdiction.
Neatly pile the combustible materials and burn them when they are in a
suitable condition. Do piling in such a manner as shall lessen fire risks.
Burn materials thoroughly and completely into ashes, with no charred pieces,
such as charred logs, remaining. Ashes and charcoal residue need not be
removed. Combustible materials which are difficult to burn, such as tree
stumps and root clumps, may be buried below grade as directed by the Owner,
with depth not less than 300 mm of earth covering over them and shall be
leveled with surrounding grade if grubbing is not required. If grubbing is
required, then unburnable materials shall be disposed off the project site.
Provide fire-fighting facilities, satisfactory to authorities having jurisdiction and

to the Owner and maintain such facilities in first class operating condition
during the course of burning operations.
All materials excavated during clearing, grubbing and stripping operations shall
be wasted in disposal areas as directed by the Owner, except if designated for
reuse. Disposal areas shall be left with neat and acceptable appearance,
graded surfaces and slopes assuring proper drainage. Topsoil in the disposal
area shall be spread and compaction shall be not less than six passes of
bulldozer or similar acceptable equipment.

BOOK III
4.4.2.3.2 EXCAVATION
SCOPE OF WORK
The Contractor shall perform excavation in accordance with this Specification

and as shown on the approved drawings or as directed by the Owner.
Excavation shall include incidental clearing, grading, compacting, leveling,

excavating and disposal of excavated materials, protection, sheeting, shoring,
bracing and cofferdams, dewatering of excavation and work areas and
preparation of bearing areas as required to properly install and complete the
work, regardless of portion of the work for which dewatering is required and
regardless of the nature of materials encountered in excavation, including
construction of temporary diversion ditches, culverts, temporary access road
etc. where required.
GENERAL EXECUTION OF EXCAVATION
The Contractor shall notify the Owner in writing at least three working days
prior to the start of any excavation work in any working area, to enable the
Owner to verify all necessary levels and cross-sections of the original ground
surface. The Contractor shall, prior to starting the excavation in any area,
submit to the Owner a plan of operation with complete details of the method
of excavation, type of equipment to be used, proposed method of diversion of
drainage, safety measures to be used, etc.
The Contractor shall set out Works as shown on the approved drawings,
utilizing the established benchmarks and coordinates.
The Contractor is responsible for the correct setting-out of Work. Any

additional work caused by his negligence in setting-out will be at his expense
and corrective action must be carried out without any delay as directed by the
Owner.
The Contractor is responsible for all necessary safety measures from the
commencement of work until its completion. The Contractor shall strictly
follow safety regulations to prevent accidents.
The Contractor must take every precautions and shall use the most appropriate
methods of excavation and equipment to avoid the loosening of material or the
breaking of rock beyond the lines and grades shown on the drawings or as
directed by the Owner. If for any reason whatsoever excavation is carried out
beyond the lines and grades shown in the approved drawings, the Contractor
shall, at his own expense, restore the required lines and grades with mass
concrete.

BOOK III
Bottoms of all excavations must be trimmed to line and grade, the final 20 cm
of excavation in any loose geological formation where concrete is to be placed
shall be excavated by hand tools to avoid disturbance of the bottom, which will
then be well rammed, all immediately prior to the placing of concrete.
Particular care shall be exercised when excavating in the vicinity of existing and
partially or fully completed structures. The Contractor shall repair or replace, at
his own expense, any structures or equipment damaged by this actions.
It will be the Contractor's responsibility to utilize to the fullest extent all

materials from excavations which are approved and deemed suitable by the
Owner as backfill or other construction. The Contractor shall make his best
efforts to comply with the above requirements.
Where possible, suitable materials shall be excavated separately from materials

to be wasted and shall be placed in the designated final locations directly from
the excavation or shall be stockpiled, if the immediate placement in the
designated location would not possible.
PROTECTION AND SUPPORT
The Contractor shall provide protection and support required to properly

installing work, to protect and support adjacent structures and improvements
as required for the safety of traffic and life.
Protection and support includes temporary sheeting, bracing and shoring and
where indicated, permanent sheeting, bracing and shoring. Temporary
sheeting, bracing and shoring shall be removed by the Contractor when their
use is no longer required, unless otherwise directed by the Owner.
Excavation slopes shall be protected and supported, where required or when

directed by the Owner, so that the slopes and bottom will be maintained for
depth, width and condition indicated and so that adjacent structures or other
construction will be protected from damage caused by any earth movement.
Protection and support shall be arranged for minimum interference with pipe
laying, electrical installation and other similar work.
DEWATERING AND DIVERSION OF WATER
General
The Contractor shall furnish, install and operate necessary incidental

dewatering equipment as required to do all excavation in the dry.

BOOK III
Unless specifically permitted by the Owner, no surface run-off shall be pounded

or restricted to a greater degree than would have occurred naturally either
before the beginning of construction or after completion of the Work.
Diversion of Surface run-off
During the excavation and backfill work, the Contractor shall construct
temporary drainage ditches, culverts and other structures as required and as
directed by the Owner to divert/drain the work areas.
The Contractor's plans for diversion of the surface run-off are subject to review
by the Owner. Before commencement of the Work, the Contractor shall submit
to the Owner for review, drawings and data indicating his proposed plans for
diversion and care of surface run-off.
The Contractor shall not place any fill across routes of natural drainage
channels until the Contractor has made provisions to drain the surface run-off
into a new diversion ditch.
No surface run-off shall be pounded or restricted to a greater degree than

would have occurred naturally either before the beginning of construction or
after construction of the work, unless approved by the Owner. Any damage to
any property, equipment or materials as the result of noncompliance to the
above shall be the sole responsibility of the Contractor.
Dewatering
The excavation shall require installation of a dewatering system consisting of

cofferdam/ cut-off walls, sumps and pumps of adequate capacities and other
associated works. water from dewatering of excavation pits will have to be
pumped into sufficiently sized settlement ponds before being discharged. The
discharged water needs to fulfill all environmental criteria. The Contractor shall
design, furnish and install a complete dewatering system and maintain the
dewatering system in operating condition until the completion of his work.
The Contractor shall submit a design for the dewatering system proposed to be
installed by him prior to carrying out the work.
The Contractor shall be responsible for the safety and functioning of the
dewatering system installed by him.
The pumps, piping and the sumps installed shall have adequate capacity to
keep the excavation dry for the entire construction period.

BOOK III
In the case of any failure of the dewatering system occurs, the Contractor shall
be responsible for correction of all deficiencies and shall repair any damages at
no additional cost to the Owner.
The Contractor shall make available a standby electric supply system, or spare
diesel pumps and spare parts for quick replacement for the continuous service
of such dewatering system.
DISPOSAL OF EXCAVATED MATERIALS
Excavated materials which are not suitable as fill materials shall be hauled and
disposed off to the designated spoil area. The materials which are in excess of
the fill requirements for the Contractor's work shall be hauled to the
designated stockpile area.
The spoil area and the stockpile area shall be leveled, trimmed and graded to
drain as directed by the Owner.
LINES AND GRADES
Excavation shall be performed to the lines and grades shown on the approved
drawings or to the depth where suitable foundation conditions are
encountered.
The Contractor must take all necessary precautions and utilize such methods of
excavation which will prevent the disturbance of material and its possible
displacement beyond the required excavation lines as indicated on the
approved drawings or as directed by the Owner.
No compensation will be allowed in case of any over excavation and an

approved material for back filling shall be obtained at Contractor’s own
expense.
EARTH EXCAVATION
Earth excavation means general excavation, including excavation from stockpile

areas, of material such as clay, silt, sand, gravel, crushed or screened rocks,
boulders of up to a volume of 0.75 m3, cemented or weathered rock which may
be removed by hand tools, power shovels, dozers or other earth-moving
equipment and by ripping without continuous systematic drilling and blasting.
Rippable material shall be defined as such that the materials can be removed
by a properly equipped D8 Caterpillar, or similar, without excessive wear on the
equipment.
Earth excavation may be accomplished by any method and by the use of any
excavation and hauling equipment suitable for the work. Rock or boulders

BOOK III
encountered in the excavation may be drilled and blasted whenever other

methods of loosening such as ripping, crowbarring, or wedging were proved to
be impracticable and it shall be removed as required.
In case that earth excavation shall not be carried out on rock or to a specified
levels as indicated on the drawings and the natural foundation material is
possibly disturbed or loosened, for any reason, the foundation shall be
improved by compaction, or replaced with approved fill and compacted, or by
other means as directed by the Owner.
TRENCH EXCAVATION
Trenches shall be excavated in hard and soft materials to the limit lines and
grades shown on the approved drawings or as directed by the Owner.
The Contractor shall furnish all labor, material and equipment required for the
proper execution of the work. Correct and adequate bracing and supporting of
the excavation shall also be included.
Excavation performed beyond the lines and grades shown on the approved
drawings, without specific instructions from the Owner, shall be back filled to
grade and lines with approved materials. All additional work of this nature shall
be carried out at the Contractor's expense.
Trenches for pipelines, steel pipes, ducts and conduits shall be excavated in
straight sections and provide a minimum of 20 cm between the outside face of
the pipelines, electrical duct or conduit and the side of the trench.
Mechanical excavation shall stop not less than 5 cm above the final bottom
level and also at an approved distance from permanent works so that no
damage occurs to the same.
The work shall include the excavation of the remainder, which shall be done
and graded manually to provide uniform bearing on compacted soil
immediately before the installation or placement of any equipment.
If the characteristic of the material at any location in the bottom of a pipe

trench is as such that it might cause unequal settlement or provide unequal
bearing for the pipe, or is otherwise unsuitable for the pipe’s foundation,
unsatisfactory materials shall be removed and shall then be back-filled with
granular materials and/or concrete and compacted as directed by the Owner at
no extra cost to the Owner.
EXCAVATION FOR THE CONTRACTOR’S CONVENIENCE
This classification shall consist of all excavation performed by the Contractor for
the purpose of executing the Work, but not specifically shown, required or

BOOK III
mentioned in the Contract Documents, such as excavation for haul roads,

camps, shops, sanitary land fills and other similar excavation. Permission shall
be obtained from the Owner for the location of borrow areas and eventual
spoil areas for unsuitable material.
The Contractor shall stabilize any slopes resulted from such excavation in such a
manner that they would not represent any danger to the public or property.
Such excavation shall be performed at the Contractor's own cost and no
separate payment will be made for this work.
PREPARATION OF BEARING AREAS
Bearing areas for foundations shall be inspected and approved by the Owner
before any concrete could be placed thereon. If bearing areas are not suitable,
as determined by the Owner, The contractor has to allow for this his estimate
and design
Before placing any concrete on soil, the bearing soil shall be compacted as
specified herein for type of fill material involved. Surfaces shall be relatively
smooth.
Before placing any concrete on soil which absorbs water, the surface of such
soil shall be thoroughly wetted with clean water prior to concrete pouring.
4.4.2.3.3 FILL
SCOPE OF WORKS
The scope of work under this section covers excavation of materials from the
stockpile area, if required, hauling to the places of fill, spreading, compacting,
finishing, and incidental dewatering where required for the general site fill,
construction of the core for any embankment, structural backfill, trench backfill
and other miscellaneous fill.
The Contractor shall perform filling/backfilling work in accordance with this

Specification and as shown on the approved drawings or as directed by the
Owner.
MATERIAL SOURCES
The sources of material shall be materials previously excavated at the Site by

the Contractor or from off-Site sources.
General fill material shall be well graded, not more than 15% passing No. 200
screen, maximum particle size is 75 mm.

BOOK III
FILL/BACKFILL PLACEMENT
Compacting Equipment
Compacting equipment shall be of such design, weight and quality as is

required to obtain the densities specified herein.
Areas inaccessible to self-propelled compacting equipment shall be compacted

by hand operated mechanical tampers or vibrators.
Self-propelled compacting equipment, i.e., sheep's foot rollers and segmental

pad rollers, and hand operated mechanical tampers and vibrators, shall
efficiently perform compaction in accordance with this specification and as
indicated.
No plea by the Contractor would be accepted by the Owner regarding the
inadequacy of the equipment available at the Project Site to produce the
specified densities. The Contractor shall furnish equipment as specified.
STRUCTURAL & GENERAL SITE FILL
Preparation of Sub grade:
Sub grade to receive Structural Fill material will be inspected by the Owner to
determine its suitability and its sufficient bearing capacity for the material and
loads to be placed on it.
In case of unsuitable sub grade, as determined by the Owner, the Contractor
may be directed to perform additional excavation with compensation thereof
made as specified in the Contract.
Compaction Densities: Material shall be brought up to grade elevation

indicated on the drawings, with suitable moisture control and compaction
throughout placement, to produce the following densities:
a. Type structural fill material: to 90 percent of maximum dry density per

ASTM D1557, Test Method indicated.
b. Type SFG material: to a minimum of 85 percent of relative density per ASTM

D2049, Test Method indicated.
Placing Material:
a. Unless otherwise indicated, structural and general site fill material shall be
placed within two percent of the optimum moisture content as applicable,
in uniform layers not over 150 mm (loose measure).

BOOK III
b. The Contractor shall add water or dry-out material to maintain the optimum
moisture content throughout placing and compacting.
Trench Fill Materials
Materials shall be approved fill materials from the site excavation or the off-site
sources.
Sand material shall be no more than 10% passing No. 200 screen, maximum
particle size No. 4.
Filling in the excavated trenches shall be placed in layers and the method of fill
placement shall be approved by the Owner. Prior to the start of the fill
placement, the Contractor shall submit a statement describing in more detail
his proposed method of fill placement in the excavated trenches area for the
Owner's approval.
The fill shall be placed in layers not exceeding a thickness of 300 mm (loose
measure) and shall be compacted to produce densities to a minimum of 90%
relative density per ASTM D2049, Test Method Indicated.
BACKFILL AROUND STRUCTURES
Backfill shall be placed within the limits of the excavations or to the lines and
grades shown on the approved drawings in 20-cm thick horizontal layers and
compacted carefully. Backfill shall not be placed until the structure has been
inspected and approved, the concrete has cured sufficiently to achieve
specified compressive strength, the forms removed, the excavation cleaned of
trash, debris and water and the concrete has received its bituminous coatings
(if directed or shown on the approved drawings). Where backfill is placed on
more than one side of a structure, it shall be placed and compacted evenly to
maintain similar fill elevations on all sides of the structure at the same time.
Granular material used as structural back fill shall be compacted to a minimum
of 90 percent of relative density per ASTM-D2049, Test Method indicated.
BACKFILLING OF PIPE TRENCHES AND CUTS
General
Backfilling around pipe shall not be performed until pipe runs have been
bedded, inspected and tested.
Care shall be exercised in placing and compacting material around pipes to

maintain the material approximately at the same level, not in excess of a 300

BOOK III
mm differential, on both sides of the pipe, throughout the placing and

compacting of the material.
Placing and compacting of material shall be performed simultaneously on both
sides of pipes in such a manner to prevent injurious side pressures on piping.
Material shall be thoroughly compacted using hand operated power tampers

until compacted material is at least 600 mm above pipe.
Self-propelled compaction equipment shall not be used above pipe until the
compacted material has reached the 600-mm minimum or unless approved by
the Owner.
When a flat bed is required for the bottom of a trench for pipes, granular
material shall be provided for bedding to depths indicated on the approved
drawings. If unsuitable soil, as determined by the Owner, is encountered and it
is directed to be removed, the Contractor shall provide the additional depth of
granular compacted bedding required. Bedding for contour cuts shall be
provided as indicated on the-approved drawing.
Bedding and Backfilling Material Placement
a. For coated pipe, granular bedding and backfill material shall be crushed
stone, coarse sand or gravel or other material approved by the Owner.
Unless otherwise directed by the Owner, bedding and backfilling material
shall conform to ASTM C33, and be not larger than 10 mm in size.
Bedding material, material under haunches and along sides of pipe of a
point 150 mm above the top of the pipe shall be of such material. Care shall
be taken in placing material to prevent damage to pipe coating.
b. For uncoated pipe, granular bedding and backfill material shall be Type
Structural Fill Material. Bedding material and material under haunches and
along sides of pipe to a point 150 mm above the top of pipes shall be this
type of material.
c. Compaction densities for material (both ASTM C33 and Type Structural Fill
Material) shall be per Sub clause ‘Trench Fill Material’.
d. Material from 150 mm above the top of pipe to indicate grade shall be
selected material approved by the Owner. This material shall be placed and
compacted per Sub clause ‘Structural & General Site Fill’ or ‘Trench Fill
Material’ as applicable for the materials to be used.

BOOK III
Backfilling of Fiberglass Reinforced Pipe (FRP)
Plastic FR pipe includes RTRP (Reinforced Thermosetting Resin Pipe) and RPMP
(Reinforced Plastic Mortar Pipe) and may be of any type or grade, lined or
unlined, per ASTM D2310.
The manufacturer of the pipe shall be advised by the Contractor of the soil
conditions expected to be encountered in bedding and backfilling pipe trenches
or cuts. Promptly thereafter the pipe manufacturer shall submit recommended
procedures for cut, slope, bedding material, bedding depth, haunch and fill over
pipe utilizing either available material from the Site, or more appropriate
material obtained off-Site. These procedures will be reviewed and shall be
approved by the Owner prior to placement of the Fiberglass Reinforced Pipe.
Bedding and haunch material (to a minimum height above the top of pipe of
300 mm) shall be Type Structural Fill material. Material above Type SFG
material shall be randomly filled or as directed by the Owner.
Depth of each layer of material placed shall be as directed by the pipe
manufacturer, but not greater than 150 mm (loose fill layer thickness) and shall
be compacted using portable tampers.
Care shall be taken during placement to assure evenness of compaction

densities, especially under joints between pipe sections, as well as to avoid
floatation of the pipe.
BACKFILLING OF ELECTRICAL DUCT-BANKS AND DIRECT BURIAL CABLE
Duct Banks
Material directly above and on both sides of duct banks may be the material
excavated from the trench or cut, unless otherwise indicated on the drawings,
providing that the maximum size of stone in the material is not greater than 50
mm.
Compaction shall conform to the requirements of Sub clause ‘Structural &

General Site Fill’ or ‘Trench Fill Material’, as applicable.
Direct-Burial Cable
Material around direct-burial cable may be the material excavated from the
trench or cut, providing it is free from debris or coarse aggregate. Maximum
size of stone shall not exceed 50 mm in the fill material.

BOOK III
Compaction shall conform to the requirements of Sub clause ‘Structural and

General Site Fill’ or ‘Trench Fill Materials’ paragraphs above as applicable.
SURFACE FILL OF SUBSTATION
Materials
General
Fill material shall be clean, washed gravel or crushed stone and shall be free of
foreign matter. Crushed stone shall be tough, durable, free from excessive
quantity of flat, elongated, soft or disintegrated material.
Fire Protection Fill
Fire protection fill shall have standard size #3 gradation in accordance with
ASTM D448.
General Fill
General fill shall conform to the following gradations:

Nominal Size % by Weight
Square Openings Passing
38 mm 100
25 mm 90- 100
13 mm 60- 90
No. 4 35 - 55
No. 16 10- 40
No. 200 0-12
Performance
Preparation of sub-grades
Sod, vegetation, roots, debris and other organic matter shall be removed from
the fill areas.
Sub grade shall be graded as required and shall be free of pockets and high
spots and shall be approved by the Owner prior to the placement of fill.
The fill area shall have special drainage facilities.

BOOK III
Placing of Fill
Fire protection fill shall be placed in areas designated on the approved drawings
as "Fire Protection Fill Area". General fill shall be placed in the areas designated
on the approved drawing as "General Fill Area".
Fire protection and general fill may be placed prior to electrical installation.
Fire protection fill shall not be rolled, tamped or packed. Finished surface shall
be level and no traffic is permitted on fill during placing operations.
General fill shall be compacted by rolling with a 10 ton or heavier vibratory

roller with a minimum of 2 passes per layer. The maximum lift thickness shall
be 15 cm. Finished surface shall be leveled.
The entire substation area within the fence, excluding the building, roads,
parking lots, trenches and foundations, shall be covered with a minimum 200
mm thick general surface fill.

BOOK III
4.4.2.4 SURVEYING AND SETTING OUT
4.4.2.4.1 SCOPE OF WORK
The scope of work under this section includes furnishing of labor, technicians,
qualified professional surveyors, surveying equipment and materials required
to perform all surveying work, setting out and calculations necessary to
establish the accurate location of all plant facilities.
4.4.2.4.2 SERVICES TO BE PROVIDED BY THE CONTRACTOR
GENERAL
The Contractor shall, as described in this section, perform all surveying and
setting out and calculations necessary to establish the accurate location of all
plant facilities and shall carry out a continuous survey during construction.
The Contractor shall set out, construct and establish bench marks in stable
areas at the Site for his work. The survey for his bench mark grid shall only be
based on approved triangulation points of the national grid. The Contractor
shall submit calculations and drawings for the triangulation work done to
establish the benchmarks.
The Contractor shall submit in sufficient advance, for approval by the Owner,
the methods he intends to apply for the surveying work.
PROTECTION OF BENCH MARKS
The Contractor shall protect, preserve and keep accessible to the benchmarks
of the basic survey. Any damage or removal of benchmarks shall be avoided as
far as possible. Any accidental damage to any benchmark shall immediately be
brought to the attention of the Owner. It is expressly understood that the
Contractor shall held responsible for damage to the benchmarks and the
resulting consequences. He shall thus take preventive measures subject to
approval in order to minimize the possibility of destroying benchmarks.
Benchmarks must be of stainless steel or cast iron.
The steel bolt shall be embedded in an absolutely stable concrete block of

suitable size subject to approval of the Owner. Inscriptions shall be durable and
clearly legible. Intermediate points of the Contractor's triangulation survey
used in establishing bench marks may be marked by steel pipes or other pegs,
subject to the Owner's approval. Every new bench mark shall be double-
checked, as far as possible in relation to points other than those which served
to establish the point in question.

BOOK III
PERSONNEL AND EQUIPMENT
The Contractor shall entrust the surveying only to such persons whom by their
training and experience have sufficient qualification and knowledge to ensure
proper fulfillment of the survey tasks assigned to them. If requested, they shall
give the Owner any information relating to the survey. For the performance of
the survey, the Contractor shall have a sufficient number of reliable, accurate
and well adjusted instruments, the type and quality of which shall be subject to
the approval of the Owner.
AUXILIARY WORK
The auxiliary work of this section shall include, but not be necessarily limited to
the following:
 Performing all necessary survey calculations with clear presentation of the

calculations and results in order to facilitate verifications
 Exposing covered Fix-Points
 Removing machinery and obstructions from the required sight-lines
 Stopping all machinery, drilling and blasting, pile driving and other work
causing ground vibrations, stopping all smoke, dust, gas etc. hindering view
causing refraction.
 Restricting or stopping traffic of persons and vehicles near instruments or in
sightlines during instrument observations
 Providing an adequate number of laborers experienced as surveying aides
and materials as deemed suitable by the Owner for the control and auxiliary
surveys.
 Removing all obstructive accumulation of water
 Taking all necessary safety precautions
 Furnishing and marking materials required in connection with control
surveys
 Providing fix-points in lieu of or in addition to the Owner's or Contractor's
fix-points in accordance with the instruction of the Owner
 Making all necessary topographic works for the verification of lines and
grades and quantity takeoff.
4.4.2.4.3 ACCURACY OF SURVEYING
Horizontal distance shall normally be measured with optic or electronic

distance measuring devices. Chaining with metallic tape shall be restricted to
the measurement of short distances (maximum 30 m) and will be rejected for
use in horizontal distance surveys for traverses.
Angles shall be measured by theodolite.
Elevations shall be determined by differential horizontal leveling.

BOOK III
Table 4.4 2.4.3- 1 STANDARDS OF ACCURACY - TRAVERSE
Traverse for Traverse for setting

additional fixed point out
Number of azimuth courses

between azimuth checks not 25 50
to exceed
Astronomical azimuth
2”0 5”0
Probable error of result
Azimuth closure at azimuth 10 sec (N)1/2 or 3.0 sec 30 sec (N)1/2 or 8.0 sec
check points not to exceed* per station per station
Distance measurements 1 in 15.000 1 in 7.500

accurate within
After azimuth adjustment, 1.67 ft (M)1/2 or 1 in 3.34 ft (M)1/2 or 1 in

closing error in position not 10.000 5.000
to exceed*
N is the number of stations for carrying azimuth

M is the distance in miles
* The expressions for closing errors in traverse surveys are given in two forms.
The expression containing the square root is designed for longer lines where
higher proportional accuracy is required. The formula which gives the smaller
permissible closure shall be used.
Leveling shall be made as forward and backward running, between fixed

elevations of the basic survey loop closure on the same bench mark. The
difference of the two measurements or of the measured and fixed elevation
shall not exceed 12 mm (K) 1/2, where K is the total leveling distance in
kilometers.
4.4.2.4.4 VERIFICATION OF WORKS
All relevant elements of survey and setout may be checked by the Owner. The
Contractor shall notify Owner for this check sufficiently in advance of
performing the work. In addition, the Contractor shall assist, if required, the
Owner at any time in the performance of the verification work. The Contractor
shall keep clear all marks and sightlines required for this purpose.

BOOK III
Checks shall usually be made during work breaks, but in cases of urgency, the
Contractor shall restrict or stop affected work without being entitled to extra
payment. Any control by the Owner shall not relieve the Contractor of his full
responsibility for the accuracy of the position and dimensions of the work and
parts thereof.
4.4.2.5 CONCRETE WORKS
This specification covers design and supply of all materials, labor and
equipment necessary to produce all the cast in place and precast concrete
included in the Contractor's work or as shown on the drawing or as directed by
the Owner.
WORK INCLUDED
 Furnishing and testing cement, aggregates, and all other materials for
the production of concrete and grout.
 Receiving and handling, storing, and protecting materials for the

production of concrete and grout.
 Installation of anchor bolts and embedment in conjunction with

concrete work.
 Detailing, furnishing, testing and fabricating, reinforcing steel.
 Providing concrete mix designs.
 Batching, mixing and delivering Portland cement concrete mixtures.
 Furnishing, installing and removing forms
 Placing reinforcing steel
 Furnishing and installing bar supports, spacers, and tie wire
 Placing, finishing and curing concrete
 Forming, placing and curing non shrink grout and dry.

BOOK III
 Furnishing and installation of material for all expansion, contraction and

construction joints, including water stops, pre-molded expansion joint
filter and other concrete related materials.
 Installation of anchor bolts and embedment in conjunction with

concrete work.
 Inspection of all work.
The Contractor shall comply with requirements of the requirements of the

applicable codes and standards published by the following organizations:
ACI American Concrete Institute.
CRSI Concrete Reinforcing Steel Institute, U.S.A.
AASHTO American Association of State Highway and Transportation Officials.
SNI Standar Nasional Indonesia
SII Standard Industri Indonesia.
When references are made in this specification to the provisions of specific

codes or standards the Contractor shall strictly comply with those provisions,
unless deviations or substitutions are specifically requested and approved by
the Owner in writing.
4.4.2.5.3 QUALITY ASSURANCE/QUALITY CONTROL (QA/QC )
Contractor shall fully comply with the Project Quality Assurance/Quality Control
Requirements. For submitting Quality Assurance/Quality Control Procedures
and Documentation the provision of Clause “Submittals” of this specification
shall apply.
4.4.2.5.4 SUBMITTALS
PRELIMINARY REVIEW
The source and quality of concrete materials and the concrete proportions
proposed for the work shall be submitted to the Owner for review and approval
before the concrete works is started. Complete certified reports prepared by an

BOOK III
independent testing laboratory and covering the materials and proportions

shall be submitted to the Owner.
REPORTS
Mill Test Reports of Reinforcing Bars: The reports from manufactures shall
accompany each delivery of reinforcing bars, indicating that such bars have
been tested in accordance with ASTM A615. At the same time, two copies of
the respective reports shall be submitted to the Owner for information
purpose.
Reports from the cement manufactures shall accompany each delivery of
cement which shall include the type, brand, manufacturer, composition and
method of handling (scale or bulk) and compliance with ASTM C 150, ASTM C
595 and all other requirements of this specification.
Reports on fine aggregates shall include the source, type, gradation, deleterious
substances, soundness and the results of all tests required to verify compliance
with the standards specified.
Reports on coarse aggregates shall include the source, type, gradation,

deleterious substances, soundness, abrasion loss and the results of all tests
required to verify compliance with the standards specified.
Reports on admixtures shall include the ASTM C 494 classification, brand,

manufacturer, and character of the material and lot number. All admixtures
shall be the products of one manufacturer.
When required by the Owner, the Contractor shall at his expense have the
water tested in accordance with ASTM C 94.
4.4.2.5.5 STORAGE OF MATERIALS
At all times cement shall be stored in such a manner as approved by the Owner.
The cement storage area for bagged cement shall be a weather-proof building,
well ventilated, lighted and free from dampness. The contractor shall keep on
site sufficient stock to allow operation of his batch plant for two ( 2 ) weeks
with average daily output.
Any bag, package or container which has been damaged or any consignment of
cement showing signs of deleterious shall be rejected naturally and Contractor
shall remove all rejected cement from the Site without delay.
Concrete batching operations shall be organized such that cement which has
been longest on site should be issued first.

BOOK III
Aggregate shall be stored in such a way to keep them clean and free from
contamination and in such a manner to protect against deterioration or
inclusion of foreign material, or contact with sea water. Aggregates of different
sizes shall be stored in separate piles in a manner to avoid segregation. If
segregation does occur, the aggregates shall be removed to conform to the
specified grading requirement.
Reinforcement shall be stored in such a manner to avoid excessive rusting,

coating with grease, oil, dirt and/or other objectionable materials. All
reinforcement shall be stored on site timber or concrete supports suitably
spaced and of sufficient height to keep the steel clear of the ground.
Admixture shall be stored in such a manner as to avoid contamination,
evaporation or damage.
4.4.2.5.6 MATERIALS
Materials used for Concrete Work shall generally be the product of local
manufacturing plants.
All material used in the Work shall be new and of the best quality of their
respective kinds from approved sources and shall comply with the
requirements of the latest edition of the approved standards or codes of
Practice.
The Contractor shall be deemed to have satisfied himself that suitable materials
for concrete and mortar can be obtained in sufficient quantities to carry out the
works.
As soon as possible after the contract has been placed the contractor shall
submit a list giving details of the sources from which he proposes to obtain
concrete and mortar materials. Only materials from approved sources shall be
brought to site. Approval of sources shall not imply acceptance of any material
found not conform to this Specification.
Materials shall conform to the requirements specified in the following Table
4.4.2.5-1 or approved equal.

BOOK III
Table 4.4.2.5 – 1
Material for Concrete Work
ITEM MATERIAL ASTM RESTRICTIONS

NO STANDARDS OR EXCEPTIONS
1. Cement C150, C595 Moderate Sulphate Resistance

only for foundations structures
below grade and marine
Structures.
Ordinary Portland Cement for
above grade Work.
2. Fine C33, C289, C295 Subject to results of additional

Aggregate ground investigation.
Use only graded natural sand
unless otherwise indicated.
Use only graded crushed stone
unless otherwise indicated,
3. Coarse C33, C289, C295 For all reinforcing unless other

Aggregate wise indicated.
4. Reinforcing 4.1 A615 Grade Reinforcing bars conforming to

Bars 60 ASTM A615 with a yield strength
(Deformed of 40N/mm² are also acceptable
Bars) For dowels of equipment
foundation over grade slab only
where specifically indicated.
5. Bar supports 4.2 A615 Grade CRSI Manual of Standard Practice

40 Class C. For mat foundations on
soil or mud mats, use precast
concrete blocks having the same
compressive strength as the mat
foundation

BOOK III
Table 4.4.2.5 – 1
Material for Concrete Work (Continued)

NO STANDARDS OR EXCEPTIONS
6. Form Ties 6.1 Steel ties with PVC sleeves

for structure contact with
sea water.
6.2 For all other structural,
steel snapties architectural
type with out washers, or
better.
Spacing and gauge of wires as

indicated on approved drawings.
7. Welded Steel A 185
Wire Fabric
8. Air Entraining C 260

Admixtures
9. Water C 494
Reducing
Admixture
10. Membrane C 309 Type 1, for concrete floor and

Curing tread finished, Type 1-D with
Compound fugitive dye for all other work,
(wax base not permitted)
Shall be fresh, clean and drink-
able
11. Water C 94
12. Forms Waterproof, resin bonded,

12.1 Plywood exterior type
(Exposed
Surface)

BOOK III
Table 4.4.2.5 – 1
Material for Concrete Work (Continued)

NO. STANDARDS OR EXCEPTIONS
12.2 Lumber Straight, uniform width and
thickness, and free of knots
offsets, holes, and other surface
defects
12.3 Chamber ASTM A525 Wood, surface against concrete

strip (Beveled planed.
corner)
12.4 Metal Deck Shall be galvanized, Thickness

shall be fluted as required for
loading and span.
13. Expansion joint ASTM D1752 Type I (Sponge rubber) or closed

material cell plastic foam.
13.1. Filler Fed spec TT- Type I, Class A, greycolour

S-00227E-70
13.2.`Urethene Recommended
sealant by manufacture
13.3. Primer ASTM C 881 Type component moisture

intensitas epoxy adhesive
13.4. Epoxy ASTM C 309 Styrene-acrtlate or styrene

Bonding butadiene min. 18 % percent
solid, nou yellowing moisture
loss 0.0399/kg/ cm2 max.
13.5.Membrane meeting water retention
Curing requirement.
Compound
hardness and ASTM C 618 -
floor sealer 619 Class C or F
14. Class C fly ash shall not be used

Fly Ash

BOOK III
CEMENT
The cement used throughout the works shall be in accordance with ASTM C150,
C595 or equal.
All cement shall be delivered to the site under cover in strong, sealed
waterproof bags or by bulk trucks in such quantities and at times suitable for
the amount of work in hand. All cement shall be effectively protected against
deterioration during storage on the site. Only sufficient cement shall be stored
at site to ensure continuity of the works, and to allow testing of any
consignment before it is required for use.
Cement manufacturer's test certificates shall be made available to the Owner

on request.
ADDITIVES GENERALLY
Air entraining, water reducing, set accelerating, set retarding, or other additives
shall not be used except with the written approval of the Owner, following
comparative concrete durability and compression strength tests carried out on
concrete made with and without additives. Any request for approval of use of
additives shall be accompanied by comprehensive documentation setting out
the particular benefits and effects of the product on the concrete mix intended
to be used. The additives shall be used strictly in accordance with the
manufacturer's instruction and to the Owner's directions.
Test with additives shall give durability and compressive strength at least equal
to those without additives except for water reducing agents which shall
increase the compressive strength by ten (10) percent.
AGGREGATES
Coarse Aggregates
Coarse aggregates shall be crushed stone with well graded and showing general
compliance with the requirements of the appropriate standards. It shall be
clean, hard, strong, fine grained, non friable, non porous and durable stone of
approved quality and shall be obtained from an approved source. It shall be
roughly cubical in shape and free from dust.
The granulometric curve of the coarse aggregate shall be within the following
tolerances (Tables 4.4.2.5-2 and 4.4.2.5-3), which shall be achieved by means of
sifting and screening of the material.

BOOK III
Should the loss by weight, when the aggregates is subjected to abrasion test by
use of the Los Angeles Machine (ASTM 31), exceeded 10 % at 100 revolutions
or 40 % at 500 revolutions, the coarse aggregate shall be rejected.
Table 4.4.2.5 - 2
Passing Nominal of Coarse Aggregate (% Weight)
Maximum Size
Screen Size
40 mm 20 mm 10 mm
37.5 mm 95 - 100 100 100

19.0 mm 30 - 70 95 - 100 85 - 100
9.5 mm 10 – 25 25 - 55 0 - 20
4.75 mm (no.4) 0–5 0 – 10
Table 4.4.2.5 - 3
Size of Coarse Aggregates
GRADING REQUIREMENTS-ASTM C 35
ITEM
PORTION OF THE WORK Nominal Size
NO. Size Number
(Sieves)
1. All concrete 300 mm or less 19 mm to no. 4 (4.75) 67

in thickness, unless other-
wise indicated
38 mm to no. 4 (4.75)
2. All other concrete work, 467
unless otherwise indicated
Fine Aggregate (Sand)
The fine aggregate for concrete and mortar shall comply with ASTM C 33. The
fine aggregate for concrete shall be clean, sharp, fresh-water or pit sand, or
other suitable and approved material, and shall be free from all impurities.
The clay, silt and fine dust in, or adhering to, the aggregates shall not exceed
five (5) percent by volume. The fine aggregate shall be well graded within the
limits of four and three-quarters (4.75) mm to six hundred (600) micrometers in
size.
BOOK III
The fine aggregates for mortar shall, unless otherwise specified, be rounded
sand or other suitable and approved material and shall be free from all
impurities. The clay, silt or fine dust shall not exceed five (5) percent by volume.
The sand shall consist of particles between two point three six (2.36) mm and
six hundred (600) micrometers in size.
WATER
Water used for mixing concrete and mortar shall be clean, fresh water obtained
from an approved source and free from harmful chemicals, oils, organic matter
and all other impurities, conforming with the requirements of the ASTM C 94.
STEEL BAR REINFORCEMENT
The reinforcement shall comply with the requirement of ASTM A 615.
The bars shall be round and free from corrosion, cracks, surface flaws,
laminations, rough, jagged and shall not exceed two and one half (2.5) percent.
All bars shall be clean, new and of the diameters described on the drawings,
and shall be transported and stored on site such that they remain straight,
clean, undamaged and free from corrosion, rust or scale.
Bars of different diameters shall be separately bundled and bars from different
sources shall be separately stored, free from direct contact with wet ground.
Deformed bar shall be used for diameters more than 13 mm and for other sizes
plain bar may be used.
THREADED INSERTS
Threaded inserts for casting into concrete shall be of the diameters and
dimensions shown on the drawings and shall be electro-galvanized and shall be
of malleable iron or mild steel.
LIME PUTTY
Lime putty used for mortar shall be well slaked and kept in the lime pool for a
minimum of four days. It shall be prevented from drying while in the lime pool.
ADMIXTURE
The use of admixture shall be approved by the Owner.

BOOK III
Any request for approval to use admixtures shall be accompanied by

comprehensive documentation setting out the particular benefits and effects of
the product on the concrete mix intended to be used.
The admixture shall be used strictly in accordance with the manufacturer's
instructions and to the Owner's directions.
Admixtures containing calcium chloride in any form shall not be used. All
admixtures shall be the product of one manufacturer and shall be compatible
with all other admixtures used.
Waterproof concrete and mortar shall be used whereas shown on the drawing.
Waterproofing shall use a reliable and approved brand of admixture. The
admixture shall be used strictly in accordance with the manufacturer's
instructions.
4.4.2.5.7 STRENGTH, LIMITING, PROPORTIONING AND MIXING REQUIREMENTS
GRADES OF CONCRETE
Applicable grades are shown on the design drawings.

The concrete shall have the minimum compressive strengths as shown on the
table below:
MINIMUM
CLASS COMPRESSIVE STRENGTH (Kg/cm2)
A 500
B 350
C 280
D 200
E 150
Such values shall be tested by a cylindrical compressive strength method.
Unless otherwise specified, the use of the various concrete classes shall be as
follows:
Class A : pre-stress concrete spun piles/bore pile and concrete

sheet piles
Class B : coal silo and ash silo, Jetty, offshore facility, machine
and heavy equipment foundations

BOOK III
Class C : rigid pavement (road), all concrete works in the

buildings and structures of the power plant, chimney or
unless otherwise specified.
Class D : slabs on grade, unless otherwise specified
Class E : lean concrete as specified and all non-reinforced

concrete, unless otherwise specified
LIMITING REQUIREMENTS
General
The acceptability of concrete shall be decided on the basis of compliance with

all of the specified requirements, not only on the basis of strength alone.
Chlorides
The amount of the total water soluble chloride ion content in any mix shall not
exceed the following:
Reinforced concrete : 0.15 % by weight of cement
Mass concrete with -

out reinforcing : 1.00 % by weight of cement
Pre-stressed concrete : 0.06 % by weight of cement
Sulfates
Should any sulfates in the aggregate are detected, it shall be washed to

eliminate the water soluble sulfate content.
The total sulfate content of any mix is excluding the one present in the cement
but including any presentation in other ingredients which shall not exceed 0.5
by weight of cement in the mix.
Water
Water for each batch of concrete shall be accurately gauged by measuring its
volume in calibrated tank or by weighing. One liter of water shall be equivalent
to one kilogram of weight.

BOOK III
If the fine and coarse aggregates contains water, adjustment shall be made to
the water quantity to be added to the mix by carrying out moisture content test
on the aggregate and by slump test on the freshly mixed concrete.
The water used to mix the concrete shall be fresh and clean and drinkable. The
water chemistry shall be in accordance with the following:
 Total solids as per AASHTO T.26
 Chlorides as per ASTM D512
 Sulfates less than 500 mg/liter
Fine and Coarse Aggregate
Quantities of the coarse aggregate shall preferably be determined by weight

but in case prior approval has been obtained from the Owner, it may be
determined by volume.
The conversion of "weight" to "volume" or vice versa shall be based on the

weight per cubic meter of the preliminary tests on aggregates. Should batching
by volume be approved, suitable batch boxes for measurement of the
aggregate shall be made and used.
Allowances shall be made in gauging fine aggregate to increase the volume due
to bulking because of moisture content.
Fine and coarse aggregate shall comply with ASTM C 33 and also the following:
Water absorption to ASTM C127 to be less than 2 %
The severe weathering regions indicated in Table 3 of ASTM C33.
Magnesium sulfate soundness loss to ASTM C88 to be less than 14 %

(compared to 15 % and 18 % limit of ASTM C33).
The apparent specific gravity of aggregate as determined by an approved test,

such as in ASTM C127, shall not be less than 2.5.
The potential alkaline reactivity of the aggregates and the concrete mixes shall
be determined by tests in accordance with the requirements of ASTM C227,
C289 and C295.
Elongation index according to B.S 812 shall be less than 30 %.
Flakiness index to B.S 812 shall be less than 25 %.

BOOK III
PROPORTIONS AND SLUMPS
The proportions of cement to aggregate shall be the least which will produce a
plastic mix of suitable workability for each portion of the works so as to result
in uniformly dense concrete free from aggregate pockets or honeycomb.
Slumps shall be not less than 50 mm and not more than 120 mm.
Proportions to meet such requirements shall be established by design mixes in

accordance with the Chapter 4 of ACI 318 and all concrete work shall be in strict
conformance with the design mixes.
An air-entraining admixture conforming to the requirements of sub section 6.8,

Admixtures, shall be added at the mixer in such quantities as to produce
concrete with total air content conforming to the moderate exposure
requirements of table 4.5.1 of ACI 318-83. The admixture shall be added as a
solution in a portion of the mixing water, using a suitable mechanically
activated dispenser.
CONCRETE DESIGN MIXES
Contractor shall furnish the testing laboratory sufficient quantities of cement,

aggregates, water and admixtures, from the same sources as will be used for
the Work, for testing of those materials and preparations of trial mixtures.
Materials thus furnished shall be used for the entire project without changes.
Changes in the source of materials will require the preparation of trial mixes
and a revised mix design.
Trial mixtures shall be designed to produce a slump of max 120 mm and within
0.5 percent of the maximum allowable air content. For each proposed mixture
at least three compressive of cylinders for each age shall be made and cored in
accordance with ASTM C192. The cylinders shall be tested for strength in
accordance to ASTM C39 at 3, 7 and 28 days. When fly ash or pozzolan is used,
control tests shall be made also at 90 days from the test results curves which
shall be plotted showing the water-cement ratio relationship with the strength.
Using such curve concrete proportion shall be selected to produce the average
strength required by ACI 318.
When the mix proportions of each grade of concrete have been finalized and
approved by the Owner, the Contractor shall not vary those proportions
without any good and valid reasons for doing so and shall be subjected only to
the Owner's approval. Any such change in proportions, arising from any cause
whatsoever will not be considered as a basis for a claim to an increase in unit
rate for concrete.

BOOK III
The Contractor shall submit the test result of design mixes to the Owner at least
six weeks before starting the concrete work.
Mix Proportions for Concrete Grades
It shall be the contractor’s responsibility to design the concrete mixes, using the
constitute materials specified, to comply with the requirements of the various
grades of concrete.
The contractor shall, as soon as possible after the contract has been placed,
obtain representative samples of water and fine and coarse aggregates in
sufficient quantities for testing as directed by the Owner. Tests so designated
by the Owner shall be in accordance with the provisions of the appropriate
standards by the Owner.
In determining the mix proportions, the contractor shall use trial mixes in
accordance with the recommendation of Codes and Standards specified in
Section 4.4.3.1 to establish the most suitable combination which will give
concrete of the maximum water/cement ratios consistent with the strength
specified for the different concrete grades. Water cement ratios will normally
be not greater than 0.50 by weight otherwise specified, approved or instructed
for each grade of concrete.
Approval of Mix Proportions
The contractor shall submit to the Owner for approval the proportions of
ingredients he proposes to use in each grade of concrete, and as the basis on
which he has designed the mix.
Under the supervision of the Owner the contractor shall make nine (9) test
cylinders or cubes of each grade of concrete, using his proposed proportions.
Three (3) cylinders or cubes of each set shall be tested at three (3) days and
seven (7) days by an independent authority approved by the Owner, the
remainder shall be tested at twenty-eight (28) days.
All test cylinders or cubes shall be reference numbered and the contractor shall
supply the Owner with a record, in duplicate showing the reference number,
mixing date, concrete grade, proportions of mix, water cement ratio and the
concrete slump.

BOOK III
CRACK CONTROL
A maximum crack width of 0.3mm shall be considered in the design of

foundations and ground slabs. Any reinforced concrete construction required to
retain liquid or be watertight and incorporated in the civil work for the
basements shall be design for a maximum crack width of 0.2mm
4.4.2.5.8 FORMWORK
Formwork shall be constructed from timber, metal, plastic or concrete, lined as

necessary for special finishes and shall be designed with the quality and
strength required to ensure rigidity throughout placing, ramming, vibration and
setting of the concrete, without detrimental effect.
GENERAL REQUIREMENTS
Forms shall be designed and constructed to produce hardened concrete having

the shape, lines, grade and dimensions required by the approved drawings and
conform to the applicable requirements of ACI 301 and ACI 347.
In the design of formwork, consideration shall be given to the following :

 Rate and method of placing concrete.
 Weight of concrete.
 Construction loads including vertical, horizontal, and impact loads.
 Concrete pressure and form tightness, particularly when high range water
reducer concrete is used.
Forms shall be easily removable without damaging the concrete. The form
material shall produce the required surface finish. Defects, such as chipped
plywood or kinks in steel forms, will not be permitted on exposed surface.
Forms shall be supported by a propriety steel formwork support system

approved by the Owner, shall be braced and tied to maintain position, shape,
and alignment during and after placing concrete therein. Wales, studs, internal
ties, and other form supports shall be of sufficient size and number and shall be
located and neatly spaced such those proper working presses therein are not
exceeded.
The top edges of forms for walls, equipment bases, and other concrete which
has to be finished to a specified elevation, slope, or contour, shall be brought to
a true line and grade such that the top concrete surface can be finished with a
screed or template resting on the top edges of the forms. Wall forms, on one
side at least, shall not extend above horizontal construction joints.

BOOK III
Completed work shall have a smooth finish and uniform color, and shall be
level, plumb and true. Forms shall be substantial and sufficiently tight to
prevent leakage of mortar. Suitable closures to prevent leakage of mortar shall
be provided by the Contractor when using metal decking forms for slabs and
roofs.
Bolts and rods used for internal ties shall be arranged such that all metal
remaining in the concrete shall be not less than 75 mm from concrete surface
after ties are removed for concrete exposed to sea or river water and 25 mm
from concrete surface for all other works unless otherwise indicated on the
design drawings.
Temporary openings shall be provided at base of forms for columns, walls,

piers, and at other points where necessary to facilitate cleaning and inspection
prior to concrete pouring.
All exposed projecting corners of concrete work, such as piers, columns,

equipment foundations, etc shall be beveled. Bevel size shall be 25 mm by 25
mm unless otherwise specified.
CLEANING AND TREATMENT OF FORMS
No concrete shall be poured-in in any portion of the work until the forms of the
position have been completed by the Contractor and reviewed by the Owner.
All rubbish shall be removed from the interior of forms prior to concrete
pouring.
Forms for exposed concrete surfaces shall be coated with non-staining mineral
oil, which has to be applied before placing the reinforcement. For unexposed
concrete surfaces, forms may be wetted thoroughly with water. Surplus
coating shall be removed before concrete placement. Forms which will be used
for forming concrete surfaces, on which tile adhesives, paint, epoxies, masonry
coatings or overlays would be applied, shall not be treated with form coatings
or release agents which would leave residuals on the surface of the concrete.
The proper release agent shall be chosen by the Contractor and approved by
the Owner. Only one agent shall be applied for all permanently exposed
surfaces.
REMOVAL OF FORMS
Forms may not be removed until the concrete has acquired its sufficient
strength to safely carry its own weight and any construction loads might be
imposed on it.

BOOK III
Forms for columns, walls, sides of beams, slabs and girders and other parts
which would not supporting the weight of the concrete shall be removed as
soon as practicable to avoid any delay in curing and in repairing imperfections.
Methods used for removal of formwork shall be such that to prevent marring,
breakage or other damage to concrete. Removal of formwork shall conform to
the applicable requirements of ACI 301.
Temporary shoring for suspended elements shall not be disturbed during

removal of column forms.
FORMS FOR EXPOSED SURFACES
'Exposed Surfaces’ shall mean all formed concrete surfaces which are exposed
to view on completion of work, unless otherwise indicated.
Forms for all exposed surfaces shall produce extremely smooth, dense and true
finishes free of fins, imperfections or other defects. For exposed surfaces of
structures in contact with ground, such finish shall extend 300 mm below finish
grade.
Forms shall consist of plywood, lined forms or accepted as equal. Plywood shall
be water-resistant and shall be treated to prevent rising of grain. Linings shall
consist of accepted non-absorptive fiber board plastic coated to resist moisture
with a hard smooth surface on the contact side.
4.4.2.5.9 CONSTRUCTION DETAILS
OPENINGS IN CONCRETE
Openings, pockets, chases, recesses, slots etc. shall be provided in walls, piers,
floors or other portions of concrete work for structural steel, conduit, pipe,
sewers, sleeves, and similar items, as may be required.
All such openings, pockets, chases etc. shall be filled with concrete after the
proceeding items has been installed as the work progresses. Finishings shall be
applied to exposed surfaces of such concrete fills to match the adjoining
concrete work.
Concrete walls and floor openings for pipings and other fixtures which will be
installed after the walls and floors are built shall be of sufficient size such that
adequate space shall be available for the proper compaction of concrete which
would be placed later around such pipes or fixtures. The top of each wall
opening shall be sloped or beveled to provide adequate space for placing and
compacting the pipe embedment concrete. Water stops shall be provided

BOOK III
around wall openings below grade and on floor openings which are exposed to
weather or sub-emergence.
EMBEDDED MATERIALS
Embedded materials include all works done by the Contractor and also all
pipes, conduits, ground bars, electrical equipment, etc. placed and secured by
others. During placement of concrete proper protection and care shall be taken
such as not to dislodge any of those installations.
CONSTRUCTION JOINTS
All construction joints shall be provided as shown on design drawings and/or as

proposed by the Contractor and duly accepted by the Owner.
In case it is not indicated on drawings, the Contractor shall locate such joints in
order to satisfy and shall not impair the strength of the structure. The
Contractor shall submit the locations for the Owner's acceptance prior to their
placement.
Should the Contractor need to revise the locations of construction joints or to
add or to delete them, relevant drawings showing the proposed changes shall
be submitted for the Owner’s review on request. Any changes, including
required waterstops if any, shall be made at no cost to Owner.
Space of construction joints in slabs shall not be greater than 15 m in plan.

Vertical construction joints in walls shall be arranged such that the horizontal
length of placement would not exceed 15 m. Maximum spacing between
horizontal construction joints shall not exceed 5 m, unless adequate space is
available for working inside the forms.
Construction joints shall be cleaned by sandblasting, water blasting, or

scarifying and roughening until all unsatisfactory concrete, laitance, coatings,
stains, debris, and other foreign materials are removed. All loose materials shall
be removed by washing the concrete surface thoroughly.
Air-water cutting of horizontal joints may be performed in lieu of sandblasting

or water blasting. Before placing the next lift, supplement air-water cutting by
any of the methods shall be performed on the coatings, or stains which have
not been satisfactorily removed.
When air-water cutting is used, it shall be accomplished between initial and

final set. When the surface of a lift is congested with reinforcing steel, and it is
relatively inaccessible, or when it is undesirable to disturb the surface,
sandblasting, water blasting or scarify and roughening shall be provided after
the final set.

BOOK III
Horizontal surfaces shall be covered with grout or starter mix immediately

before the concrete is placed. Grout with the same sand cement ratio as such
to be used in the concrete mix shall be provided.
EXPANSION JOINTS
Expansion joints shall be located and constructed as such indicated on the

design drawings. Expansion joint filler shall be firmly bonded to the previously
poured joints. Face with a suitable adhesive and the new concrete shall be
poured directly against the joint filler.
Accessible edges of each expansion joint shall be sealed with the sealer applied
in accordance with the manufacturer's directions.
Expansion joint designated on the design drawings which will be subjected to

differential hydrostatic pressure shall be provided with a flexible waterstop.
Such waterstop embedment shall be equal on each side of the joint.
Flexible waterstops shall be spliced in strict conformity to the recommend-

ations of the waterstop manufacturer.
CONNECTIONS TO EXISTING CONCRETE
Connections between new concrete and the existing one shall include all
necessary cutting, patching and fitting required for a neat and workmanlike job.
All exposed surfaces shall be cut true and smooth and shall be patched and
finished to match adjoining concrete surfaces.
WATERSTOP
General
Flexible waterstops shall be employed for all construction joints in concrete

below grade level and shall be as shown on design drawing. Such waterstops
shall be suitable for hydrostatic pressure.
Material
The waterstops shall be made from a high grade rubber compound conforming
to the requirements of CRD-C572. The Contractor shall provide standard factory
fabricated tees, ells, crosses and other joint fittings required for all
intersections.
Unless shown otherwise on the design drawings the rubber waterstops shall be
of 230 mm by 10 mm with "0" bulb closed center section.

BOOK III
Fabrication
The rubber waterstop may be molded or extruded type. All materials shall be
molded or extruded and cured in such a manner that any cross section shall be
dense, homogeneous and free from porosity or other imperfections.
Tests and Test Reports

Rubber waterstops shall be subjected to laboratory tests prior to shipment to
the Project Site. Testing of rubber waterstops shall conform to the
requirements of CDR-C572.
The rubber waterstop shall be capable of withstanding a maximum designed
hydrostatic head of 20 meters. The manufacturer shall furnish the relevant
certified copies of all laboratory test reports.
Installation
The waterstops shall be installed with approximately one-half of its width
embedded in the concrete on each side of the joint. Nailing of waterstop to
formwork is not permitted. Care shall be exercised in placing and vibrating the
concrete about the waterstop, to ensure complete filling of the concrete
around the waterstop, and to obtain a continuous bond between the concrete
and the waterstop at all points around the periphery of the waterstop.
Waterstops shall be cut and spliced at any changes of directions as necessary to
avoid buckling or distorting of the web or flange. All joints shall be secured to
develop water tightness as of the continuous waterstop material. Rubber
unions and rubber cement shall be used for splicing waterstops at all joints and
fittings.
The Contractor shall take suitable precautions to support and protect the
waterstops during the progress of the work and shall repair or replace any
damaged waterstops as directed by the Owner. All waterstops shall be
protected from oil or grease.
In case the waterstop should be installed in the concrete at one side of a joint
more than one month prior to the scheduled date of placing concrete on the
other side of the joint, the exposed waterstop shall be covered or shaded to
protect it against direct sunray exposure.
Manufacturer's Representative
The Contractor shall provide the services, at no additional cost to Owner, of a
technically qualified manufacturer's field representative to instruct Contractor's
field installation personnel on the proper waterstop installation procedures.
PREMOLDED EXPANSION JOINT FILLER

Premolded expansion joint filler employed shall conform to ASTM D 1752 Type
III self-expanding cork. The respective thickness, widths, and lengths shall be as
shown on drawings.

BOOK III
4.4.2.6 DETAILING FABRICATION AND PLACING OF REINFORCEMENT
MATERIALS INCLUDED
Reinforcement shall include all reinforcing bars, stirrups, spirals, and other
reinforcement materials with all necessary wire ties, bar supports, spacers,
block supports and other devices required to install and secure reinforcement
properly.
DETAILING
The Contractor shall submit placing drawings and accompanying bending

details to the Owner prior to fabrication. The placing drawings shall reference
the design drawings. Bar lists or bills of material shall reference the related
placing drawings.
FABRICATION
The details of fabrication shall conform to ACI 315 and 318. In case of any
conflict, ACI 318 shall govern.
Cutting, bending and tolerances shall be in accordance with CRSI Manual of

Standard Practice Reinforcement. It may be supplied pre-bent from the
manufacturer or in stock lengths and to be cold-bent on site. Bending of
reinforcing bars in hardened concrete will not be permitted.
Heating, welding and tack welding of reinforcement as part of the fabrication

process, is expressly prohibited.
SPLICING OF REINFORCING BARS
Splicings shall conform to the applicable requirements of ACI 318. Mechanical

splices shall be approved by the Owner and shall be in accordance with
manufacturer's recommendations.
Splices shall be located in accordance with the design drawings. Splices shall
not be used in the maximum bending stress regions.
Welded splices shall not be used.
CONCRETE COVER
Thickness of concrete cover shall be in accordance with the applicable

requirements of ACI 318 and CRSI Manual of Standard Practice, unless
otherwise indicated. Concrete cover shall be clearly indicated on the approved
drawings.

BOOK III
Except as otherwise indicated on the drawings, the reinforcement of concrete

deposited against the ground shall not less than 85 mm of concrete between
the concrete surface and the ground surface. For concrete below grade level
but consolidated between forms the minimum cover shall be 75 mm. For
concrete surfaces to be exposed to the weather, the reinforcement shall be
protected with concrete of not less than 50 mm for bars larger than 16 mm
diameter; and concrete of not less than 40 mm for bars with 16 mm diameter
or smaller.
The concrete protective covering for any reinforcement on any surfaces which
are not exposed directly to the ground or weather shall be not less than 40 mm.
PLACEMENT
All reinforcement shall be free of loose rust or scale, grease, dirt or any other
coating which would reduce or destroy the bond. Reinforcement shall be
accurately positioned on supports, spacers, hangers, concrete blocks or other
reinforcements, and shall be secured in place during course of construction.
With the exception of lapped portions of spliced bars which are wired or
clamped together, the clear distance between parallel bars shall be not less
than 1.5 times the maximum size of coarse aggregate in the concrete, or less
than 25 mm in beams, 40 mm in columns, or 50 mm in other locations.
Where reinforcement in beams shall be placed in two or more layers, the bars
in the upper layer shall be placed directly above the bars in the lower layer and
the clear distance between bars shall be not less than 25 mm.
Bar supports may be used provided they are clamped or wired to the
reinforcement.
FIELD BENDING
If necessary and approved by the Owner, reinforcing bars projected from

existing concrete might be bent, provided that the bending and the subsequent
straightening process are performed as specified herein.
The minimum distance from existing concrete surface to the beginning of bend
and the minimum inside diameter of bend shall be :
- Bar diameter 8 - 16 mm, 6x bar diameter

- Bar diameter 16 - 36 mm, 8x bar diameter
- Bar diameter over 36 mm, 10x bar diameter

BOOK III
Bars up to 19 mm inclusive may be cold bent once. Preheating is required for

subsequent bending and straightening, as specified hereafter.
Preheating is required for bars over 19 mm diameter in all cases. Heat for
bending or straightening of bars shall be applied as uniformly as possible over
the length of bar equal to approximately 10x bar diameters. The heated length
shall be centered at the middle of the arc of the completed bend. The bar
temperature shall be between 58 °C and 64 °C, and maintained at such level
until bending or straightening is completed. The temperature of the bar at the
concrete interface shall not exceed 25 °C. Temperature-measuring crayons or a
contact pyrometer shall be used to determine the temperature. Care shall be
taken to prevent quenching of bars, either by application of water spray or by
exposure to rain.
Straightened bars shall be thoroughly inspected for any cracks or otherwise

damaged. Any damaged portions shall be removed and replaced as required by
the Owner.
All costs in connection with any such preheating, bending, or straightening one
for the convenience of the Contractor and all costs in connection with any
repair or replacement required by reason of such heating, bending, or
straightening shall be borne by the Contractor.
PLACING OF WELDED WIRE FABRIC
Fabric reinforcement shall be carefully placed and maintained in the position

before and during placing of concrete.
ANCHORING DOWELS
All dowels shall be securely anchored in place by wire tying, etc, before starting
the placement of concrete.
COATING DOWELS FOR FUTURE EXTENSION
Exposed reinforcing bars and metal waterstops intended for bending in future
work shall be protected from corrosion with two coats of "Bitumastic" coating.
Before coating the dowels, two coats of Bitumastic Concrete Penetrant shall be
applied on the surface adjacent to the dowels. When the dowels are coated,
the coated concrete surface shall be included as an integral part of the dowel
coating.

BOOK III
4.4.2.6.1 COMPLIANCE WITH STRENGTH REQUIREMENTS
COMPRESSIVE STRENGTH
Compliance with the specified compressive strength shall be measured by tests
made on cylinders at an age of 28 days; if fly ash or pozzolan will be used to
substitute part of the cement, 90 days test cylinders shall be used.
STRENGTH TEST RESULTS

Strength test results shall conform to the following requirements.
TABLE 4.4.2.5 - 4
REQUIREMENTS FOR STRENGTH TEST RESULTS
ITEM
TEST RESULTS REQUIREMENTS
NO
1. Average of any 3 consecutive Equal to, or greater than

strength test results specified strength
2. Individual strength test No individual strength test falls

Average of two cylinders below specified strength by more
than 3.5 Mpa.
CONCRETE BELOW SPECIFIED STRENGTH

Should the results of strength tests indicate that such concrete does not meet
specified requirements, the concrete production shall be stopped until
corrective actions has been implemented to guarantee conformance with
specification.
Contractor may be directed to take concrete cores and/or make load tests, at
his own expense, on any work which has been installed with such non-
conformance concrete. If such cores and/or load test indicate that the work in
place does not meet requirements, Contractor shall correct the work as
directed without cost to the Owner.
4.4.2.6.2 BATCHING, MEASURING AND MIXING CONCRETE
GENERAL
Measurement of batch and mix concrete materials shall be in accordance with
ASTM C94, Sections 8, 9, 10 and 11, with a manual, semi-automatic or
automatic batching plant.
EQUIPMENT
BOOK III
Batching and mixing equipment shall be acceptable to Owner. Equipment shall

be brought to the Site sufficiently in advance of its use to permit inspection and
acceptance.
The concrete shall be mixed in pan or drum type mixers and the weight of
materials used for each batch shall not exceed the manufacturer's rated
capacities for the machines. Other types of mixer shall be used only after
permission has been obtained from the Owner.
All mixing machines shall be kept clean, free from hard or partially set concrete
and well maintained in good working order.
Mixers and agitators shall be examined from the time to time for changes in
conditions due to the accumulation of hardened concrete or mortar or through
wear of the blades, and if found defective shall be corrected by the Contractor
at the Contractor's cost.
The materials used in the concrete shall be measured solely by weight, by

means of an approved weight batching machine. Due allowance shall be made
for the water content of the aggregates.
Prior to delivering the concrete, the plant shall be tested by manufacturing

several batches of concrete and perform uniformity tests on the mixers in
accordance with ASTM C94, Annex A1. The plant and mixer uniformity tests
shall be documented. The test batches of concrete may be used for
construction where determined suitable by the Owner.
Batching and mixing shall be carried out in plant approved by the Owner.
The time allowed for mixing after all ingredients are in the machine shall be not
less than two minutes.
Small quantities of concrete less than half (0,5) cubic meter may be hand mixed
on a clean water tight platform. The fine and coarse aggregate shall be
thoroughly mixed together, cement then shall be added afterwards, and the
whole shall be turned over three times dry. Next, the material shall be turned
over whilst adding water, then finally turned twice and worked to produce a
mixture of uniform colour and consistency.
For hand mixing the specified quantities of cement shall be increased by 10

(ten) per cent without alteration in price.

BOOK III
MEASURING
The Materials used in concrete shall be measured solely by weight, by means of

an approved weight batching machine. Due allowance shall be made for the
water content of the aggregates.
Documentation shall be furnished on testing the metering devices. All

measuring devices shall have accuracy upto within 1 % before any concrete is
mixed, and at such other times as may be directed by the Owner.
MIXING
All concrete shall be mixed until the material has uniformly distributed. All
concrete shall be discharged completely prior to recharge the mixer.
Production of concrete shall be in accordance with the applicable requirements
of ACI 301 and ASTM C94.
The time allowed for mixing after all the materials have been placed in the
mixer, shall be sufficient for thorough mixing to take place, but segregation of
the constituent materials shall not occur. When uniformity tests in accordance
with ASTM C94 would not be performed, a minimum mixing time of 1 1/2
minutes for drum type mixers shall be allowed or such other time as the Owner
would direct. For batches larger than one cubic meter, mixing time shall be
increased 15 seconds for each additional cubic meter or for a fraction thereof.
Cement contained in bags shall be used in such a way that each batch of
concrete requires no part of bags. If the cement is stored in bulk, the measuring
device shall be approved by the Owner before its use.
The water quantity for each batch shall be accurately measured and discharged
to the mixer while the later is being charged.
Concrete shall have as a minimum water cement ratio as practicable and shall
be of such a consistency that it can be really worked into corners and angles of
the formwork; and around the reinforcement without segregation of the
materials or bleeding of the free water at the surface. On striking the
formwork, it shall present a uniform face, free from honeycombing, surface
crazing or excessive dusting. The water cement ratio applied shall be approved
by the owner.
Ready-mixed concrete may be used upon written consent from the Owner and
shall be mixed and delivered in accordance with applicable requirements of
ASTM C94, except that only trucks equipped with a rotary drum or agitator shall
be used. The Contractor shall have adequate plant to produce the required
output, and shall have satisfactory control on the mix proportions and on the

BOOK III
mixing process of the concrete. The Owner shall have access to all parts of the
plant during working hours.
It shall be the Contractor’s responsibility to design the concrete mixes, using

the constituent materials specified, to comply with the respective requirements
of the various grades of concrete.
The Contractor shall, as soon as possible after the contract has been placed,
obtain representative samples of water and fine and coarse aggregates in
sufficient quantities for testing as directed by the Owner. Tests as designated
by the Owner shall be in accordance with the provisions of the appropriate
standards by the Owner.
4.4.2.6.3 CONVEYING, PLACING AND CONSOLIDATING THE CONCRETE
CONVEYING
After being discharged from the mixer the concrete shall be transported as
rapidly as possible, which in any case shall not exceed 30 minutes, to its final
position in the Works, by means of which shall be approved by the Owner
which will prevent segregation, loss or contamination of the ingredients. The
containers conveying the concrete shall at all times be kept clean and free from
hardened or partially hardened concrete.
Chutes or other equipment for conveying concrete shall be of such size and
design as to ensure a continuous flow of concrete at delivery and without
separation of ingredients, and shall be thoroughly cleaned before each run. In
case concrete pumping would be employed to convey the concrete the use of
aluminum pipe is prohibited. Pipes or other equipment in which aluminum
surfaces will be in contact with plastic concrete shall not be used. A steel piping
arrangement utilizing a "Y" will be permitted if provided with a valve installed
at the branch point to direct the flow into one branch at a time. Minimum
pump line size of 150 mm shall be provided for 20 mm upto 40 mm maximum
size aggregate mixes. For mixes containing aggregate less than 20 mm size, a
smaller pump line may be used.
Concrete shall not be allowed to drop freely from the height of more than 1.50
m. For drop height exceeding 1.50 m, a hopper and drop chute shall be
employed.
PREPARATIONS FOR PLACING CONCRETE
Before concrete is placed or poured, forms and reinforcing shall be cleaned,

free from any dirt or debris. All necessary trenching, damning, draining and
pumping shall be done as such that all concrete can be placed in the dry.

BOOK III
For preparation of construction joints, the provision mentioned herein in this

specification shall be strictly complied before fresh concrete is placed on or
against hardened new concrete or old (existing) concrete, i.e. thoroughly clean
surfaces of all laitance, soft or loose materials and deleterious substances. The
surfaces shall then be washed clean and thoroughly moistened.
Dry concrete surface shall be saturated for at least 24 hours. Immediately,

before fresh concrete is deposited, horizontal surfaces shall be covered with
cement mortar of the same mix with the concrete to be poured. Fresh
concrete shall then be placed before cement mortar has reached its initial set.
All reinforcing and embedded steel shall be immediately washed with clean
fresh water using a high pressure jet to remove possible surface chloride
contamination prior to placement of the concrete.
Washing shall be repeated if the steel is subsequently immersed in or

contaminated by sea water.
PLACING OF CONCRETE
The Owner shall be noticed within 24 hours in writing before any concrete is
poured in order that he may inspect the work.
Concrete shall not be placed until all forms, embedded items and the surfaces
upon which the concrete will be placed have been approved by the Owner.
Concrete shall be delivered into the forms by any methods ensuring its required
consistency without excessive loss of slump or segregation. Concrete shall be
deposited in all cases as nearly as practicable directly into the final position and
shall not be allowed to flow in such a manner as may cause segregation.
Concrete shall not be moved to its final location using vibrator.
All concrete shall be placed in a continuous pour over the area between
construction joints in an uninterrupted operation in such manner as to form a
monolithic structure, i.e. the component parts of which are securely bonded
together. Segregated concrete; or concrete which has partially hardened or
been contaminated by foreign materials shall not be deposited. The use of
retempered concrete is strictly prohibited. Time interval between placing of
successive batches of concrete shall not be greater than 30 minutes.
All concrete shall be deposited into forms within 1 hours after introduction of
mixing water to cement and aggregates unless otherwise required.

BOOK III
All concrete in vertical members, such as columns, and walls, shall be in place
not less than 2 hours before any concrete would be placed in girders, beams or
slabs to be supported thereon. Concrete for beams, girders, brackets, column
caps shall be placed monolithic with floor slabs.
Concrete shall be deposited in horizontal layers no thicker than 60 cm.
Hot Weather Concreting
Hot weather concreting shall comply with ACI 305 and also the following:
 Suitable means shall be provided to ensure that the temperature of the

concrete upon placement on the work shall not exceed 32 oC.
 When necessary aggregate stockpiles shall be shielded from direct

sunlight and/or shall be periodically sprayed with fresh water especially
when evaporation rates are high. Due allowance shall be made for the
extra water in the concrete mix design. Mixing water shall be kept cool
within insulated pipes and open tanks, refrigeration or ice may be added
as necessary, and cement shall be stored in light colored silos or sheds.
 When necessary the surfaces, including reinforcement, against which

concrete would be placed shall be shielded from direct sunshine and
shall be sprayed with fresh water to prevent excessive absorption of
water of the fresh concrete by the surface.
 Concrete placing shall be completed as quickly and efficiently as

possible, and the exposed surfaces shall be immediately covered to
reduce excessive water evaporation from the concrete and conform to
the applicable requirement of ACI 301.
 The Contractor shall present, for the Owner's approval, his proposal for
dealing with the following problems related to hot weather concreting:
a) Reduced workability
b) Excessive plastic shrinkage
c) Rapid strength gains but possible low final strength
d) Rapid drying-out of concrete
e) Concrete mixing to counteract hot weather
f) Mixing water to counteract hot weather
Under-water concrete shall be placed in position using tremie tube specified in

Section 17 and the Contractor shall submit relevant fully detailed method
proposal in advance to the Owner for approval before concreting.

BOOK III
CONSOLIDATION OF CONCRETE
Concrete shall be consolidated by means of mechanical vibrators, subject to the

following minimum requirements:
a) Vibrators shall be electric or pneumatic power driven type and when fully
immersed, shall operate at frequency of 7,000 to 10,500 vibrations per
minute for vibrating heads size of 80 to 150 mm in diameter, and of 8,000
to 13,500 vibrations per minute for vibrating heads of 30 to 60 mm in
diameter or greater.
b) Intensity of vibration shall be as such that it visibly affect a mass of concrete

of 250 mm slump over a radius of at least 450 mm.
c) The vibrators shall be inserted and withdrawn out of the concrete slowly.
Application of vibrators shall be at uniformly spaced points and shall not
farther apart than twice the radius over which the vibration would visibly
effective. If requested by the Owner concrete shall be re-vibrated.
d) Vibration shall not be applied directly on the reinforcement to sections of

layers of concrete which have hardened to the degree that the concrete
may cease to be plastic under vibration.
At least one spare vibrator shall be provided for each three vibrators in use for
immediate use in the placement.
Vibration shall continue until the concrete has been compacted to its maximum
practicable density, free from air pockets, closes saugly against all surfaces and
shall be in perfect and complete contact with all reinforcement bars and other
metal embedded in the concrete. The manufacturer of the vibrators and the
total number of vibrators required shall be subject to the Owner’s approval.
Duct banks and slabs less than 150 mm thick shall be consolidated by rodding
or spading.
4.4.2.6.4 SURFACE TREAMENT OF STRUCTURAL CONCRETE
GENERAL
"Surface Treatment" of structural concrete shall mean a finish as an integral

part of the structural concrete.
Surface treatments shall conform to the requirements and uses as specified in
this section.

BOOK III
EXPOSED SURFACE FINISH
Upon removal of forms, all fins and other projections shall be removed and off
set leveled. All voids, holes, honeycomb or other damaged surfaces shall be
cleaned back to solid concrete, saturated with water and filled with cement
mortar of the same composition as used in the concrete. The concrete shall be
finished free from streaks, discolorations or other imperfections so as to
produce an extremely smooth dense and true finish of uniform color.
Such finish shall be used for all exposed formed surfaces.
UNEXPOSED SURFACE FINISH
Upon removal of forms, all voids, holes, honeycomb or other damaged surfaces
shall be cleaned back to solid concrete, saturated with water and filled with
cement mortar of the same composition as used in the concrete.
Such finish shall be used for all unexposed formed surfaces.
ROUGH SLAB FINISH
Top surface of structural concrete slabs and equipment foundations shall be

beveled unless otherwise indicated. Screed shall be used for all structural slabs
and shall be securely and accurately set to elevations indicated. After concrete
has been consolidated by vibrating, it shall be screeded to the required level.
After screeding, and when concrete has partially hardened and if it would be
required to retain impressions of a broom, then it shall be broomed with a still
bristled broom and all laitance and scum shall be removed. The brooming shall
expose some of the aggregate and shall score the surface to provide
mechanical bond for separate finish.
Such finish shall be applied for the followings :
a. Structural concrete floor slabs or bases where separate concrete floor

finish, concrete floor-fill-finish, quarry tile, terrazzo or similar separate
finishes are indicated or required.
b. Top surface of equipment foundations
c. Top of concrete ductruns

BOOK III
MONOLITHIC FINISH
Monolithic finish is the one produced on structural concrete slabs in which one
concrete mix are poured all at one time. Concrete for structural slabs with
monolithic finish shall be of the driest consistency possible to work with in a
sawing motion of screed.
Surface at first shall be screeded, and then shall be floated to a smooth,

compact surface. Any water sheen shall be allowed to evaporate or removed
prior to floating operation by covering surface with burlap or similar material.
Spreading of cement or cement-sand mixture directly on top of concrete will
not be permitted.
After floating, the surface of concrete shall be steel troweled to a smooth,

state-like surface. Final troweling shall then be done after the concrete is hard
enough to prevent mortar accumulation on trowel and a ringing sound would
be produced as trowel is drawn over the surface. Finish surface shall not be
marked off in areas or scored in any manner.
a. Structural concrete floor slabs where monolithic finish is indicated or

required.
b. Floor areas where resilient tile finishes (asphalt, rubber, vinyl, etc.) are
indicated or required.
FLOAT FINISH
Surface shall first be screeded, and then shall be ball floated to a smooth,
compact surface. After ball floating, surface shall be floated after concrete has
hardened sufficiently to retain the float finish and water sheen has
disappeared.
a. Structural concrete roof slabs. Finish shall be free of all depressions or

projections which would prevent proper application of roofing.
b. Structural floor slabs only where specifically indicated or required.
c. Top of concrete walls, curbs, piers, pads, pedestals, and outdoor equipment
foundations.

BOOK III
d. Manholes, sump pits, elevator pits etc. Roofs, if any, of these structures
shall also have a float finish except where such roof would be an integral
part with other concrete work, in which the roofs shall have the same finish
with the other concrete work.
STEEL TROWEL FINISH
The same requirements as for monolithic finish shall be applied except in the
consistency of concrete to be used for the portion of work in which steel
troweled finish is specified.
Such finish shall be applied for stair treads.
BROOM FINISH
The surface shall first be screeded, and shall then be ball floated to a smooth,
compact surface. Following the ball floating, the surface shall be broomed with
a medium-stiff bristled broom only after the concrete has hardened sufficiently
to retain the scoring. The strokes shall be square across the surface and shall
be made such as to produce regular scoring without leaving the surface or
exposing any aggregate. The scoring shall run transverse to the direction of
traffic.
Such finish shall be applied for sidewalks and driveways. It shall be used for
other surfaces only if specifically indicated.
4.4.2.6.5 PROTECTION OF CONCRETE
SURFACE PROTECTION
Exposed surface of fresh concrete shall be protected from rain during and after
placement.
All concrete shall be protected from damage during construction. Exposed

external corners of concrete shall be protected with wood strips securely
fastened in place. Tarpaulins or other coverings may be used when necessary,
to completely enclose freshly finished concrete.
Proper protection shall be provided to prevent cement from being taken or

washed away; and to prevent the concrete dilution during the process of
storing, handling, transporting, apportioning and mixing the materials, and also
during transporting, placing, compacting and curing of the concrete.

BOOK III
After placement and during the early stages of hardening the concrete shall be
protected against moisture loss, harmful effects of sunshine, wind, rain,
running surface water and shocks/vibrations.
CLEANING OF SURFACE
After concrete is placed, all surrounding exposed surfaces which have been
contaminated by concrete splashing, dripping, etc., caused by such concrete
work shall be cleaned to restore those surfaces to their original condition.
4.4.2.6.6 CURING
GENERAL
Concrete shall be cured by one or a combination of the methods given in ACI

308, Chapter 2.
Sea water shall not be used for such curing.
Concrete shall be shaded from the wind and sun for a minimum of seven days
after placement.
CURING PERIODS
The following curing periods shall apply.
- Concrete floors and stair treads with monolithic or steel trowel finish: 10 days.
- Roof slabs of job-placed concrete: 7 days.
- All other concrete works: 7 days.
MEMBRANE CURING
Immediately after completion of required surface treatment, the surface of the

concrete shall be covered by membrane curing compound.
Where forms are left in place for entire period for a specified curing, the use of
curing compound may be omitted, provided that such forms shall be wet down
with water. Where forms are stripped before completion of specified curing
period, curing compound shall be applied to such surfaces immediately after
completion of specified surface treatment.
Approximately a square meter per liter of curing compound shall be applied

unless otherwise instructed by its manufacturer.

BOOK III
Smoking, open flame or fires shall not be permitted while curing material is
being applied. Adequate ventilation shall be provided. Workmen shall be
equipped with respirators if required.
Prior to initial use of any specified compounds, the Contractor shall make
arrangements for manufacturer's technical representative to visit the project
site who shall give instructions on the proper use of such material.
CURING COMPOUNDS CONTAIN VOLATILE THINNERS

Do not permit smoking, open flame or fires while materials is being applied.
Provide adequate ventilation. Equip workmen with respirators if required.
4.4.2.6.7 TREMIE CONCRETE
MATERIAL
Materials shall meet the requirements specified for Class B concrete unless
otherwise indicated, except the use of 10 % additional cement in a mix and
limit slump shall be upto 140 mm maximum.
TREMIE EQUIPMENT
Pipe or tube with minimum diameter of 250 mm shall be installed in sections

with flanged and gasketed couplings and hopper at top.
Tremie shall be properly supported such as to permit free movement of
discharge over entire top surface of work and shall be rapidly lowered, when
necessary, to choke off or retard of concrete.
PLACING
Concrete shall be deposited carefully in its final position by means of tremie.

The concrete shall not be disturbed thereafter.
Special care shall be taken to maintain still water at point of deposit. Tremie
shall not be used to place concrete in running water.
The consistency of concrete shall be carefully regulated and special care shall
be taken to prevent segregation of materials.
Concrete shall be placed in continuous horizontal layers, with thickness of each

layer generally not exceeding 300 mm. Method of depositing concrete shall be
carefully regulated to produce approximately horizontal surfaces on each layer.

BOOK III
Tremie hopper shall be completely full of concrete during entire placing

operation in order to maintain sufficient head. The concrete flow shall be kept
continuous, and in no case shall be interrupted, until it is completed.
4.4.2.6.8 CONCRETE FILLS FOR EQUIPMENT BASES
Hollow bases of equipment shall be filled with concrete unless otherwise

indicated on the contract drawings, after bedplates have been grouted.
Concrete fill shall conform to requirements for class of concrete specified for
the work, except maximum size of coarse aggregate shall be 19 mm.
4.4.2.6.9 REPAIR OF CONCRETE
Repair of concrete shall be made in accordance with USBR, Chapter 7, "Repair

and Maintenance of Concrete".
Imperfections in formed concrete shall be repaired as soon as practicable after

removal of forms.
4.4.2.6.10 CAST-IN-PLACE ELECTRICAL DUCTRUNS
Cast in place for electrical ductruns shall conform to the requirements of

applicable Electrical specification and class of concrete specified for the work.
4.4.2.6.11 INSPECTION AND FIELD CONTROL TESTING
GENERAL REQUIREMENTS
Inspection program shall be submitted for inspecting items and activities

affecting quality. The following items shall be included in the inspection
program:
 Pre-placement inspection on area to be concreted which includes but does

not limited to formwork, reinforcing steel, embedded items, and final
cleanup.
 Concrete placement.
 Finishing and curing.
 Formwork removal.
 Concrete repair.

BOOK III
Field control tests shall include all material and concrete test required, but shall
not be limited on the following:
 Slump tests (ASTM C143), shall be conducted on every trip before placing at
site,
 Aggregate Gradation Tests (ASTM C136), weekly
 Specific Gravity Tests (ASTM C127), weekly
 Organic Impurities (ASTM C40), daily
 Surface Moisture (ASTM C70), daily
 Concrete Temperature, random
The Contractor shall provide at his own expense an approved and fully
equipped independent material and concrete Testing Laboratory to carry out all
testing to meet the requirements of the ASTM & ACI Specifications. Evidence
shall be provided that the equipment and procedures are comply with ACI or
other approved standards and the equipment are regularly checked, calibrated
and adjusted for its accuracy. Field tests shall be performed by the Contractor.
The Contractor shall be responsible for conducting field test, preparing test
specimen and supplying material for laboratory tests with the proper quantities
and frequencies as specified herein.
The Contractor shall provide the services of qualified employees as required for
making such field tests, preparing, storing, curing, and handling test specimen
and to deliver the test specimen materials to the independent laboratory.
All field control tests including the preparation of concrete test specimens shall
be made by the Contractor's employees. Tests shall be made upon request and
in the presence of the Owner's representative.
Minimum frequencies shall be specified for each field control test. Should there
any additional field control tests necessary, in the opinion of the Owner, the
Contractor shall carry out or supply the material for such additional tests
without any additional cost to the Owner.
Up-to-date records shall be kept by the Contractor consists of positions in the

works for every batch of concrete, its grade and all test cylinders, core, or other
specimens taken. Copies of the records shall be supplied to the Owner at
weekly intervals or upon request by the Owner.

BOOK III
In case unacceptable test result the Owner on site shall have the authority to
stop all further concrete work until acceptable test results are forth coming.
AGGREGATE GRADATION
Fine and coarse aggregate shall be sampled and tested in accordance with
ASTM D75 and C136.
SPECIMEN FOR CONCRETE TESTING
Specimen for concrete testing shall be made at the same frequency as the
compression test cylinders and shall be taken from the same batch of concrete
and from the first batch mixed each day. Each set of compression test cylinders
shall be marked or tagged with the slump.
CONCRETE TEST CYLINDERS
Production Test
To verify the compatibility of the Laboratory Designed Mixes with the working
conditions on site, the Contractor shall carry-out trial mix under full scale
production conditions.
Procedures and number of test cylinders to be tested shall be the same with
the Laboratory Designed Mix.
Trial mix under full scale production conditions shall be carried out at least four
weeks before commencement of any concreting in the works under supervision
of the Owner.
Concrete Testing
Cylinder molds, curing and tests shall be in accordance with ASTM C31, C39,
C143, C172, C231 and C511. The Contractor shall provide cure boxes for storing
test specimens, shall meet the temperature and other requirements of ASTM
C31.
The testing laboratory will provide cylinder molds and instructions to

Contractor for proper making, storing and shipping of job concrete test
cylinders and instructions for checking percentage of air entrainment and for
making slump tests.

BOOK III
Production Control of Concrete
Control of concrete production shall be taken by Contractor as follows:
 Contractor shall make all production concrete test cylinders, as specified

in the following table, from fresh sample of concrete taken from site,
from discharge of stationary mixers, concrete pump machines, truck
mixers or truck agitators. Locations for taking samples shall be acceptable
to the Owner. Making of test cylinders shall include slump test followed
by preparation of storing, packing, and delivering of test cylinders to
Testing Laboratory completed with required data such as materials,
water-cement ratio, proportions, slumps etc.
Table 4.4.2.5 - 5
Schedule of Production Concrete Test Cylinders
Cylinders required
Total cylinders required from a
sample representing each 50 m3 of For Strength Test At
concrete, or from each day's pour if
less than 50 m3. 3 days 7 days 28 days
3 sets of 3 each - Total 9 3 3 3
NOTE :
1) One set of cylinders comprises a strength test.
2) Add 90 days sets, when fly ash or pozzolan is used.
 Unless otherwise indicated, the Contractor shall at his own expense,

furnish equipment for and shall check the slump of concrete and air
content of air-entrained concrete by direct measurement of fresh
concrete samples taken on site from discharge of stationary mixers,
pump Crete machines, truck mixers or truck agitators. Such equipment
shall consist of slump cones, one air meter and one or more pocket-type
air indicators. Locations of samples for testing slump and air
entrainment shall be the same as for test cylinders.

BOOK III
4.4.2.7 GROUT WORK

4.4.2.7.1 SCOPE
The scope of grout work shall include but not limited to the Contractor's
furnishing, mixing, placing, curing, inspecting and testing of grout as required
for the work by this specification and as shown on the drawing.
WORK INCLUDED
All grouting for the column bases and stair bases, bases and supports of all
mechanical and electrical equipment.
All grouting for anchor bolts including sleeves.
All grouting for conduit, piping etc., passing through concrete floors or walls.
Formwork required for placing grout.
WORK NOT INCLUDED

Furnishing and installation of structure, equipment bases, piping and conduits,
including anchor bolts where the grouting required to be placed.

Shall comply with the requirements of the applicable codes and standards
published by the following organizations:
ACI American Concrete Institute
CRD Chief of Research and Development, U.S. Army Corps of
Engineers
CRD 621
CRD-C 261-83
Shall conform especially to the applicable provisions of the following codes and
standards
ASTM C 31 Making and Curing Concrete Test Specimen
in The Field
ASTM C 33 Concrete Aggregates
ASTM C 39 Compressive Strength of Cylindrical Concrete
Specimens
ASTM C 109 Compressive Strength of Hydraulic Cement Mortars
ASTM C 143 Slump of Portland Cement Concrete
ASTM C 150 Portland Cement
ASTM C 494 Chemical admixtures for concrete
ASTM C 1107 Determining Consistency and Density of Roller-Compacted
Concrete Using a Vibrating Table

BOOK III
4.4.2.7.3 QUALITY ASSURANCE/QUALITY CONTROL (QA/QC)

shall apply.
The installation procedures shall be submitted by the Contractor for the
Owner's Review.
4.4.2.7.5 STORAGE
All materials shall be stored in such a manner as to avoid contamination,
evaporation or damage.
Cement shall be stored in weather tight buildings, bins or silos which will
exclude moisture and contaminants.
Liquid admixtures shall be protected from temperature changes which would

adversely affect their characteristics.
4.4.2.7.6 TYPES AND USES

Grouting equipment shall conform in every respect to requirements of
equipment manufacturers. Installation of grout shall be in strict accordance
with the manufacturer's printed instructions. Should there any different
requirements for grout and grout installation between this specification and
equipment manufacturer's requirements, the equipment manufacturer’s
requirements shall apply, subject to review by the Owner.
Types and specific uses of grout shall conform to the following Table 4.4.2.6-1
or approved equal:
TABLE 4.4.2.6-1
Type and Specific Uses of Grout
Type of Grout Specific Use (Grouting)

a) Plastic Grout (Regular (1) Anchor bolts including sleeves and column base plates
sand and cement grout) (2) Conduit, piping etc. through concrete floors or walls
b) Drypack Grout Equipment bases where required by manufacturer
c) General Grout Work Bases and support of mechanical and electrical equipment
Nonshrink Grout and as directed by the Owner
d) Precision Grouting (1) Anchor bolts in drilled holes in concrete

Nonshrink Grout (2) Equipment bases where required by manufacturer or
subject to high repetitive and dynamic loads

BOOK III
4.4.2.7.7 MATERIAL
Grout components and products: shall conform to the requirements specified

in Table 4.4.2.6-2 below, unless otherwise indicated.
TABLE 4.4.2.6 – 2
Grout Components and Products
Type of Admixture Mixing Grout

Cement Aggregate
Grout (if used) Water Product
a. Plastic a.1 Portland a.2.2 Gro Conforming to a.4 Clean, Not specified
Grout cement, ut 75mm ASTM C494, Potable,
ASTM C150 thick or less Type A water- and free
Fine reducing from
Type II or aggregate, admixtures; injurious
III, unless ASTM C33 and containing of oil,
otherwise chloride not acid, salt,
indicated a.2.2 Gro more than 1% alkali,
ut thicker by weight (Use organic
than 75mm only if reviewed matter
Fine by the Owner) and other
aggregate, deleteriou
ASTM C33, s
or coarse substance
aggregate, s
Size No. 7 or
8, ASTM C33
b. Dry- Same as Item Fine aggregate, --- Same as Item Not specified
pack a.1 ASTM C33 a.4
Grout
c. General Manufacturer’s standards (this grout shall not contain Same as Item Not specified
Grout oxidizing and gas producing agents, catalysts, a.4
Work inorganic accelerators and chlorides) ASTM C109
Non
shrink
d. Precisio Manufacturer’s standards (this grout shall not contain Same as Item Not specified
n Grout any metallic aggregates, oxidizing and gas producing a.4
no agents, catalysts, and more than 300 ppm chloride)
shrink ASTM C109
Grout Properties shall conform to the requirements of Table 4.4.2.6-3, unless

otherwise indicated.

BOOK III
TABLE 4.4.2.6 – 3
Property Requirement for Placed Grout
Type of Admixture Grout

Cement Aggregated Mixing Water
Grout (if used) Product
a. Plastic 250 kg/cm2 at Plastic with No requirement Not required No visible
Grout 28 days maximum slump bleedings
unless 125 mm for
otherwise grout of 75 mm
specified thick or less; and
maximum slump
75 mm for grout
thicker than 75
mm
b. Dry-pack 350 kg/cm2 at Stiff with hand No expansion Not more No

Grout 28 days shaping than 1.0% bleeding
unless workability, and
otherwise no measurable
specified slump
c. General 600 kg/cm2 at Flowable, 35 – Not more than No shrinkage No
Grout 28 days 45 cm lateral 0.4% at 7,14 or bleeding
Work Non ASTM – C109 flow at 22oC - 28 days CRD621
shrink 30o C
d. Precision 800 kg/cm2 at Flowable, 35 – Not more than No shrinkage No
Grout Non 28 days 45 cm at 22o - 0.4% at 7,14 or bleeding
shrink ASTM – C109 30o C with efflux 28 days CRD621
time not more
than 30 second.
ASTM 1107
4.4.2.7.8 PREPARATION AND MIXING
SURFACE PREPARATION
Concrete surfaces to be grouted shall first be cleaned and then be uniformly

roughened to a minimum depth of 3 mm. Prior to placing grout, all concrete or
metal surfaces to be in contact with grout shall be thoroughly cleaned to
remove all laitance, oil, grease, paint, dirt, rust, loose mill scale, damaged
concrete and any other loose particles which may interfere with complete
bearing and bond or may react with grout materials. Special care shall be taken
to assure that all waste materials and water are removed from anchor bolt
holes and sleeves in concrete.
The cleaned concrete surfaces to be in contact with plastic grout shall be

dampened but not saturated and free surface moisture shall be removed just
prior to grout placement,

BOOK III
For dry pack grout uses, the equipment manufacturer’s requirements for
surface preparation shall be met, but as a minimum the followings will be
required:
The cleaned surfaces of the concrete to be in contact with dry pack grout shall
be pre-soaked for at least 6 hours before grouting.
Just prior to placing grout, the concrete surfaces should be blown with
compressed air to remove any free water on the surfaces.
All cleaned surfaces to be in contact with non-shrink grout shall also be

prepared in accordance with manufacturer's instructions.
For metal surfaces where bond between metal surfaces and grout is not desired
flake graphite, paraffin or other form release agent shall be applied to these
surfaces, and no grease or oil shall be used.
SHIMMING AND WEDGING
Prior to placing grout, column base plates and other structural elements shall
be properly supported with shims or wedges, the smaller dimensions of which
shall be oriented in the direction of grout flow or packing. Mechanical and
electrical equipment shall be shimmed or wedged before grouting in strict
accordance with equipment manufacturer's printed instructions. Unless
otherwise specified, shims and wedges to be removed shall be made of carbon
or stainless steel, and those to be left in place shall be made of stainless steel.
All shims and wedges used for support shall be carefully removed except those
required by the equipment manufacturers to be left in place, after the grout
has set and hardened. The voids resulting from the removal of these shim,
wedges and levelling screws, shall be filled with the same grout unless
otherwise specified. All shims and wedges shall be coated with a film of
paraffin or form release agent to facilitate their removal, and no grease or oil
shall be used.
FORMWORK
Forms for placing grout shall conform to grout or equipment manufacturer's
commendations and the applicable requirements of Chapter 4 of ACI 301.
MIXING
Grout shall be thoroughly and uniformly mixed in proper proportions in
accordance with the following requirements and the grout manufacturer's
instructions, in order to obtain the properties indicated in Table 4.4.2.6 - 3.

BOOK III
Batches of plastic grout for mixing shall be less than 0.2 m3 and shall be mixed
in a paddle type mortar mixer for not less than 1 minute, with the water added
slowly to assure efficient mixing and water cement ratio shall not exceeding 0.5
by weight.
For drypack grout, the equipment manufacturer's requirements for mixing shall
be met, but as a minimum the following are required:
Drypack grout shall be thoroughly and uniformly mixed in a paddle-type mortar
mixer for at least 5 minutes, and in quantities suitable to be placed within one
hour.
Grout mix proportion by weight shall be 1 part of cement to 2-1/4 parts of fine
aggregate, with water content which shall give a 0.0 mm slump (ASTM C 143)
and no exuded water when packing.
Grout shall be remixed every 30 minutes; however, retempering of grout will
not be permitted.
Nonshrink grout shall be mixed in strict accordance with manufacturer's
instructions.
4.4.2.7.9 PLACING AND CURING
GENERAL PLACING REQUIREMENTS

Grout shall be placed in strict accordance with the following requirements and
manufacturer's grouting procedures.
Grouting of a plate or base shall be a continuous operation until the whole
plate or base is completely grouted, except for shimmed and wedged areas
which shall be grouted in accordance with aforementioned Clause.
Special care shall be taken to ensure that the space under grouted base plate or
equipment base shall be entirely filled with grout. Plastic or non-shrink grout
shall be poured from one side and continuously rodded with care until it flushes
up to the top of the form on all other sides and through grout holes, if any, on
the plate/base. Base plate with shear bars in more than one direction may be
grouted through a central hole, only if air-relief holes are provided in the
vicinity of the shear bars where air might be trapped.
HOT WEATHER PLACING OF GROUT
Grout temperature during placing shall not exceed 32oC, unless otherwise
indicated.
Retarding admixtures shall not be used unless otherwise indicated.

BOOK III
ADDITIONAL PLACING REQUIREMETS FOR DRYPACK GROUT
Drypack grout placement shall meet the equipment manufacturer's

requirements, but as a minimum the following are required:
Grout shall be placed and packed within one hour after mixing.
Grout shall be placed and packed in small amounts to eliminate the possibility
of a porous pack. Each layer shall be thoroughly rammed into place before
succeeding layers are placed, and such procedure shall be repeated until the
form is fully packed.
ADDITIONAL PLACING REQUIREMENTS FOR NONSHRINK GROUT
Nonshrink grout shall be placed in accordance with manufacturer’s detailed

instructions.
CURING
Curing of Plastic Grout
Exposed surfaces of grout shall be cured immediately after completion of grout

finishing and/or form removal by applying curing compound.
Curing compound shall conform to ASTM C309 and shall be applied in
accordance with manufacturer's recommendations, immediately after any
water sheen which may develop after finishing has disappeared from the grout
surface.
Exposed surfaces of grout and the plate in contact with grout shall be protected
from heating by the sun for at least a week after grout placement.
No load shall be applied on the grout until compressive strength of the grout
has reached 75 percent of the specified strength or until the grout has been
moist cured for at least 7 days.
Curing of drypack grout shall meet the equipment manufacturer's
requirements, but as a minimum the following are required:
Exposed surfaces of grout shall be kept continuously moist for at least 7 days
after grout placing. Following moist curing and while the surface is still damp a
coat of curing compound shall be applied.
Moist curing may be achieved by any of the following methods:
a) Ponding or continuous sprinkling
b) Application of absorptive mats or fabric which continuously
kept wet
c) Application of continuously kept wet sand

BOOK III
Exposed surfaces of grout and the plate in contact with grout shall be protected
from heating by the sun for at least a week after grout placement.
Curing of Nonshrink Grout

Nonshrink grout shall be cured in accordance with manufacturer's instructions.
4.4.2.7.10 INSPECTION
The Owner may, during the course of the work, inspect the various phases of
the work for full compliance with all requirements of this specification.
TESTING
All grout for the work shall be tested in accordance with the requirements of
Table 4.4 , “Grout Testing”. If requested, reports of the test results shall be
submitted to the Owner for review.
Initial tests shall be performed prior to the use of the grout. All grout
components, including the water, to be used for the initial tests shall be the
one specified for use in the Works.
Table 4.4 .2.6-4

Grout Testing
Test ASTM Designation Frequency
Compressive strength at 7 ASTM C109 or One test for each grout

and 28 days ASTM C31 mix or as directed by the
ASTM C39 Owner
CRD-C261-83
4.4.2.8 JETTY (Not Applicable)
Jetty elevation is ± 4.5 m to anticipate the rise of water due to tides and waves.
Jetty planned to serve a coal barge 12000 DWT. Construction dock using
reinforced concrete construction carried out by the system deck on piles, ie the
construction of floors Jetty on beam lengthwise and crosswise were in the
abutting by pile foundation steel protected anti-corrosion and concrete, where
the beams and poles connected by pile cap.
The length of the jetty construction is 120 m wide and 12 m with jetty trestle ±
260 m and a width of 6 m, it is necessary for the dilatation of plates and beams.
Dilatation planned every 15 m. Dilation is to reduce the effects of the

BOOK III
earthquake.
Jetty is also designed to provide space for loading and unloading vehicles such
as coal conveyor, pipeline route, excavators, dump trucks, and road vehicle
access
The required design life for the overall floating moorings is thirthy (30) years. It
is a fundamental requirement of this contract that the primary Floatation Units
(that provide buoyancy to the assemblies) and the S ructural Frame (that
surrounds the primary Floatation units and supports the deck) shall have a
minimum design life of 30 years.
It is recognised, however, that not all of the components of the goods may
meet the specified design life and to achieve the required overall design life
some items or components with a lower design life must be replaced or
renewed as appropriate. The award of the contract shall be based partly on the
“whole –of life” cost of the goods over the required design life.
MATERIALS
All timber materials used must be of the appropriate Building Grade F7 and
Hazard level H5. All metal components shall be hot dipped galvanize coated.
All posts shall be minimum 125 mm Diameter and double treated permapine.
All cross bearers shall be minimum 150 x 50 mm F7 permapine.
All longitudinal beams shall be minimum 150 x 50 mm F7 permapine.
All walk boards shall be minimum 150 x 25 mm permapine.
All nails shall be Hot dipped galvanized flat head minimum 75 x 3.75 mm
All bolts for cross bearers & beams shall be hot dipped galvanized 12 mm
Diameter Coach head
CONSTRUCTION
All posts must be spaced at no more than 2400 mm longitudinally and 1000 mm
apart.
All posts will be embedded to a minimum depth of 900 mm

into the Lake bed. All posts must be at least 200 mm above
the tread boards.
A minimum of three (3) longitudinal beams are to be in place for jetties up to
an Industry 1200 m wide and four beams from 1200 to 1600 mm wide.
All longitudinal or cross beams shall be bolted to beams with 12 mm galvanized

bolts.

BOOK III
All cross beams, at least one per pair of posts shall be secured by two (2) 12 mm
galvanized bolts to the posts.
Walk boards to be minimum 600 mm above normal pool level & not exceed
900mm.
All nuts will be on the inside of the structure.
Safety Ladders
Safety ladders constructed of galvanized mild steel or aluminium shall be
provided at agreed locations on the walkway/mooring units or fingers. Ladder
rungs shall extend below low water -level to a depth not greater than the
bottom level of the floatation units with a minimum depth of 0.6 m.
4.4.2.9 STABILIZATION FOR RECLAMATION WORKS ( Not Applicable )
4.4.2.9.1 DEFLECTOR WALL
The structure of deflector wall shall be flexible enough and has the ability to
absorb the wave energy. Low reflection coefficient which means high ability to
absorb wave energy is very important requirement to prevent the wave
resonance inside the outfall basin. A common type of such structure is rubble
mound deflector having high porosity armor layer.
The deflector wall, such structure is used to deflect the current in order that
closed circulation can still be observed but with much lower temperature.
Based on similar experience in the construction of the PLTU Suralaya deflector

wall, stone (rock) above 2.0 ton was relatively difficult to get from the available
quarry. Stone armor will then be limited up to 2.5 ton. If the required stone
armor would be more than 2.5 ton, then concrete armor shall be used. There
are some preferences to use concrete armor such as : Tetrapod, Acropod,
Dolos or A-Jack (steel reinforcement).
4.4.2.10 TEMPORARY ROAD WORK

The method of transportation of large or heavy items to site is the
responsibility of the Bidder, who shall undertake his own load route studies to
determine the capability of the road. Any upgrading on the existing
infrastructure in respect of transportation of construction plant or equipment
to site shall be the responsibility of the Bidder.
Site roads shall provide his own temporary.

BOOK III
4.4.2.11 ASH POND LINING WORKS
4.4.2.11.1 SCOPE
The work specified in this section covers all design, labour, materials,
transportation, equipment and service necessary for the ash run off ponds as
shown on the Drawings or as directed by the Owner. There are two alternatives
of pond lining:
a) Clay lining
b) HDPE lining
4.4.2.11.2 MATERIALS
Materials shall be selected with an approved off-site borrow source. The
material shall have a plasticity index (PI) greater than or equal to 15. More than
50% of the materials shall pass a # 200 sieve as determined by ASTM D1140.
The material shall be free from roots, sticks, sod tufts and other organic matter.
The material shall be free from cobbles and boulders with less than 5% of the
dry weight of soil retained on a # 4 sieve with a maximum size of 25 mm.
Contractor shall procure all material required for the work from off-site
sources. All sources shall be approved by the Owner.
Protective Bedding Layer: As specified in Specification Slope Stabilization -
Riprap.
Protective Riprap Layer: As specified in Specification Slope Stabilization - Riprap.
4.4.2.12 PILING
4.4.2.12.1 GENERAL
Contractor shall furnish all labor, material and equipment necessary to design,
fabricate, deliver, install and test all piles as indicated in Book II, “Summary of
Work”.

Contractor shall comply with the requirements of section 4.4.3.1. “Codes and
Standards”.
Conform especially to the applicable provisions of the following codes and
standards.
ASTM .......... American Society for Testing and Material
ACI ......... American Concrete Institute
JIS ......... Japan Industrial standard

BOOK III
4.4.2.12.3 SOIL DATA

The Contractor shall carry out soil investigation and shall state it in his bid
proposal. The investigation program shall be subject to the Owner’s approval.
4.4.2.12.4 STEEL PIPE PILE

The steel pipe piles shall be used to support Pump house and pipe sleeper
cooling water pipe
The steel pipe piles shall be spiral welded with minimum size 600 mm outer
diameters, meeting at least one of the following specifications:
a. API 5L
b. ASTM A53 (with mill certificates to confirm minimum yield strength).
c. ASTM A252 with the following provisions:
i. Chemical analysis of material shall show that both the equivalent
carbon content and total carbon content are less than 0.30%.
ii. Unless spiral welds are certified as conforming to the
requirements of ASTM A53 or API 5L-1980 to the satisfaction of
the Owner, welds shall be 100 percent inspected by ultrasonic or
electromagnetic inspection according to the requirements of
ASTM A53. This inspection shall be conducted at the Bidder’s
expense.
iii. The pipes joint shall be fully penetration weld. All welds shall be
inspected by ultrasonic or electromagnetic inspection with 100%
for the first 3 m of weld for each position of each welder.
Thereafter, shall be 1 random spot examination of 1 pile joints for
each additional 10 piles joint of weld. If any random spot fails to
meet the acceptance standard, 2 additional random spots shall be
examined at locations on each pile joints from the failure random
spot, if it is still fail to meet the acceptance standard, the entire
welds of 10 pile joints shall be completely examined.
iv. The Bidder shall bear the expense of repairing and re-inspecting all
rejected welds.
The Bidder shall provide necessary certified mill test reports to demonstrate
the material meets the above standards.
Welding practice and qualifications of fabricators and erectors of welded
construction shall conform to the requirements of American Welding Society
(AWS) Welding Code AWS D1.1-86.
The upper part of steel piles shall coat with bitumen coating. The coating shall
be from top of piles up to one (1) meter bellow splash zone area.
Cathodic protection as specified in the electrical specification shall be provided
for all steel piles.

BOOK III
The driven piles shall have a maximum tolerance of 2 % from intended batter,
1% from intended verticality and its location at the cut off elevation within 75
mm of the true position as shown on the Drawings. Variation of pile elevation
shall not be more than 25 mm plus or minus.
If the pile location is not within the above specified limits, the Bidder shall be
liable for correction measures as directed by the Owner at no cost to Owner.
The steel pile shall be driven until the required final set. If piles do not achieve
the required final set at the specified depth, pile shall be driven deeper until the
requirement is met.
4.4.2.12.5 BORED PILES

MATERIAL
The bored piles shall conform to the requirements of BS8004-1986.
The concrete for piles shall use the Moderate Resistance Cement (Portland
cement type II or Portland Pozzolan Cement ).
DESIGN CRITERIA
The bored pile shall posses a minimum safety factor of 2.5 for normal condition
against bearing capacity failures and other force.
The contractor shall design and provide 600 mm, 800 mm to 1000 mm bored
piles for light structure and heavy structure
All details with respect to the pile dimensions, length, reinforcement, cover
plates etc. shall be indicated on the Bidder’s shop drawings, and shall be
subject to approval by the Owner.
Minimum concrete compressive strength ( f’c ) shall be 350 to 400 kg/cm².
All reinforcing shall be deformed steel bars conforming to Grade 60 ASTM
A615M.
PILING EQUIPMENT, INSTALLATION AND WORKMAN SHIP

BORING EQUIPMENT
The Bidder shall submit with the Bid Proposal full details of the proposed pile
boring equipment and the method of carrying out the work, such information
shall include, a full description of the frames lifting devices and other
equipment needed for the installation.
The equipment shall be capable of boring through bearing strata, boulders,
shales, staff clays, gravels, sand and limestone, and shall be capable of shunking
bore holes in several diameters and down to depths of 50 meters.
The diameters of both augers and clearing buckets shall be at least equal to the
diameter of piles to be installed. Where inclined rock surfaces are encountered,

BOOK III
a coring bucket shall be used to level the rock surface before commencing with
chiseling or coring. The Bidder shall allow, in unit rate of the pile, all costs for
consequent enlargement of the pile arising from overboring, including
additional concrete resulting from such enlargement.
LENGTH OF PILES
The length of the piles shall be as necessary to develop the required pile
capacity. The Bidder shall determine length of piles based on geotechnical data
and shall be proven by pile load tests.
SETTING OUT
The Bidder shall provide all pegs, rods, survey instruments, concrete posts etc.
needed for setting out the works. The Bidder shall ensure that boundary marks
defining the owner’s property are in their correct positions. The Bidder shall be
responsible for setting out the piles from the approved drawings and boundary
marks, and for date guarding the position and level of all reference pegs,
boundary and bench marks used for setting out the piles.
All surveying shall be in accordance with specification refer to Surveying and
setting out section 4.4.2.4.
BORING ON PILES
All piles shall satisfy the tolerances for position and inclinations as stated
herein. The deviation in position of center of pile or the projection of its center
line from the pile center point as shown on the setting out drawing shall not
exceed 75 mm in any direction from the true position of the same pile.
If any pile has been installed out of plan or line beyond allowable tolerance the
Bidder shall be responsible to remedy as noted above at no cost to the Owner.
Piles shall not be bored close to adjacent piles which have been recently cast
and containing workable, unset of fresh concrete such that flow of concrete
may be induced from or otherwise causing damage to the adjacent piles.
No pile shall be bored nor pile casing be driven nearer than five times its
diameter (measured center to center) from an unfilled pile borehole or from
uncased concrete pile where the concrete had been placed less than 24 hours
previously.
On completion of boring and immediately prior to casting, all loose, disturbed
or remolded soil or rock shall be removed from the base of the pile. Unless
otherwise agreed, cleaning of the pile base shall be carried out by means of a
flat bottom cleaning bucket. In case of deep piles with lengths in excess of 50
meters or where debris at the bottom of the bore cannot be broken down
sufficiently to facilitate extraction by cleaning bucket method, the air lift (grab
bucket) method may be employed in combination with the flat bottom cleaning

BOOK III
bucket to clean the base of pile. In such cases, a final round of cleaning by the
flat bottom bucket should always be carried out before casting might proceed.
In the event of rapid loss of drilling fluid from the pile excavation, the
excavation shall be backfilled without delay with available material up to a level
where no further loss of drilling fluid is observed.
The Bidder shall investigate and determine the cause of fluid loss while the pile
excavation is left to stabilize under the action of the drilling fluid. Based on the
outcome of his investigation, the Bidder shall submit for agreement his
proposed method of construction before resuming pile.
All reasonable steps shall be taken to prevent the spills of drilling fluid at site in
the areas outside the immediate vicinity of the bore. In particular, discarded
bentonite shall be removed from the site without delay. Any disposal of
bentonite shall comply with the regulation of the local environmental
controlling authority.
Any damage pile shall be abandoned, replaced or repaired as approved by the
Owner at the Bidder’s expense. Abandoned piles shall be filled with soil at no
cost to the Owner. Additional piles shall be installed as requested, to provide
for load conditions and to avoid overstressing of piles. The Bidder shall be
responsible to install additional piles at no cost to the Owner.
CONCRETING
The requirements of the Concrete Specification shall apply to the construction
of bored piles or spun piles (see section 4.4.2.5.17. Tremi Concrete).
The concrete for each pile shall be from the same source. The bidder shall
ensure that the supply from any source (whether site-mixed or ready-mixed) is
of sufficient quantity in order the concrete for each pile shall be placed without
any interruption as would significantly deteriorate the workability of the
previously placed batch one.
In the event of rain, the Bidder shall provide adequate shelter to keep the hole
dry and to concrete under cover.
The method of placing and the workability of concrete shall be such that a
continuous monolithic concrete shaft of the full cross-section is formed. The
method of placing shall be approved by the Owner. The Bidder shall take all
precautions in the design of the mix and the placement of concrete to avoid
arching of the concrete in the pile shaft. No spoil, liquid or other deleterious
matter shall be allowed to contaminate the concrete.
PILE CUT-OFF
Concrete shall be finished not less than 500 mm above the cut-off level
(“overcast”) to ensure that all concrete at and below cut-off level is
homogeneous and free of laitance and deleterious matter. A thicker overcast

BOOK III
may be required by the Owner depending on site conditions, and this shall be
carried out without extra cost. The overcast shall be chipped off level later by
the Bidder.
CONNECTION BETWEEN PILES AND PILE CAPS

Adequate structural connection between the piles and the caps shall be
provided to suit design taking into account the seismic requirements.
RECORDS OF PILE CONSTRUCTION

During the course of the work, the Bidder shall maintain a complete record of
pile construction and the Bidder shall submit to the Owner, in an approved
format, a record of each pile. Each pile record shall be submitted immediately
after completion of each pile and shall include:
 Type, location and site of pile.
 Pile number and all principle characteristics of pile including dimensions.
 Details of boring and concreting sequence progress, including dates, times,
equipment used and personnel (operator, Employer, etc).
 Actual location of piles, with variation from plan locations and inclination as
indicated.
 Date and Time of Boring
 Site Weather Condition.
 Ground level before commencement of pile installations
 Pile cut-off level.
 Length Temporary casting.
 Any unusual phenomena encountered.
 Depth and type of soil strata
 Observation of ground water level and ground water in flow.
 Name of inspector for each pile.
4.4.2.12.6 CONCRETE PILE

This work includes work setting out (determining the point of the pile position
in the field in accordance with the plans), mobilization and demobilization
tools, procurement and erection of reinforced concrete piles including load trial
on the pile, local excavation and cutting heads of the pile. The Pile length at
bidding document drawing should treated as only for information, but the
BOOK III
contractor must decide the actual length of the pile needed to achieve erection
requirements. Soil investigation report at nearest location with the site will be
given to the Contractor.
Piles must be designed, casted and treated to obtain the strength needed to
withstand transportation, handling, and pressures resulting erection without
any damage. Reinforcing steel should be provided to withstand the stress
caused by removal, preparation and transport of the stake and tension caused
by the erection and the loads are supported. Concrete covers must not be less
than 40 mm and if the stake is exposed to sea water or other corrosive
influences, concrete covers must not be less than 50 mm.
All materials and workmanship shall comply with the following standards:
 PBI 1971 : Peraturan Beton Indonesia (Indonesian Concrete
Regulation).
 SK SNI T-15-1991-03 : Tata Cara Penghitungan Struktur Beton Untuk
Bangunan Gedung (Tata Cara Penghitungan
Struktur Beton Untuk Bangunan Gedung).
 SII 0192-83 : Mutu dan Cara Uji Elektroda Las Terbungkus Baja
Karbon Rendah (Quality and Test of welding
electrodes Wrapped Low Carbon Steel).
 ASTM A-416 : Standard Specification for Uncoated Seven Wire
Stress Relieved Steel Strand for Prestress
Concrete.
 ASTM A-82 : Standard Specification for Cold Drawn Steel Wire
for Concrete Reinforcement.
 ASTM D-1143.81 : Standard Test Method for Piles Under
(Reapproved 1987) Static Axial Compressive Load.
 ASTM D-3966.90 : Standard Test Method for Piles Under Lateral
Loads.
 ASTM D-3689.90 : Standard Test Method for Individual Piles Under
Static Axial Tensile Load.
4.4.2.12.7 LINES AND GRADES

Contractor shall lay out lines and grades and shall be fully responsible for
correctness of such lines and grades and for proper execution of the Work to
such lines and grades.

BOOK III
4.4.2.12.8 PILE TO PILE CAP CONNECTION

Adequate structural connection between the piles and the pile caps shall be
provided to meet seismic loading design requirements.
4.4.2.12.9 RECORDS OF PILE CONSTRUCTION

During the course of the work, the Contractor shall maintain a complete record
of pile construction and the Contractor shall submit to the Owner, in an
approved format, a record for each pile. Each pile record shall be submitted
immediately after completion of each pile and shall include:
 Type of pile
 Pile number and all principal characteristics of the pile including dimensions
 The depth and rate of penetration, in relation to site datum, for the length
of the pile
 Details of driving and installation sequence progress, including dates, times,
equipment used and personnel (operator, engineer, etc.)
 The equipment hammer model number, weight and rated energy
 Number of hammer blows for each 300 mm of driving/penetration
 Actual location of piles as driven, with variations from plan locations
indicated
 Variations in plumbness or batter
 Set on completion of the initial drive and final test set on completion of the
final redrive
 Any unusual phenomena encountered in driving piles
 Depth and type of soil strata
 Observations of ground water level and ground water flow
 Name of Inspector for each pile
 Cushion material identification when changed, and material added
 Top elevation when driving is complete
 Cutoff Elevation
 Depth of auger and auger size
 The records of pile construction shall be submitted in accordance with the
requirement in Book II
 For cast-in-place concrete top piles, the following additional data shall be
submitted:
 Date and time of “Release for Concreting”
 Date and time of placing concrete fill, including starting and
completion times
 Quantity of concrete fill

BOOK III
4.4.2.12.10 PILE LOAD TESTING
SCOPE OF WORK
Work specified under this section includes furnishing of all labor, materials
and equipment for completion, tension and lateral load testing of the piles.
Piles installed for testing are only pre-production piles.
The permanent structure are production piles. Piles selected for testing are
test piles. All pre-production piles and production piles specifically selected
for testing are test piles.
Drive test pile to the indicated depth and/or indicated resistance.
The pile load testing shall be carried out to the satisfaction of the Owner.
Upon completion of the preliminary pile load testing, Contractor shall cut off
the preliminary test piles, as directed by the Owner and dispose off properly.
METHOD OF TEST
General Test Provisions

Tests shall be performed to the test load indicated on the approved drawings
or as specified herein. Test equipment for the compressive load tests shall be
capable of applying the required test load. Test equipment for lateral and
tensile load tests shall be capable of applying a test load equal to 300 % of the
test design loads shown on the approved drawings.
Care shall be taken to ensure that the load applied by the hydraulic jack is
coaxial with the pile.
Managed test continuously during test period. Should a test be stopped
before completion, and the load shall be wholly or partially removed from the
test pile due to improper or insufficient loading, yield of supports or
connections, malfunction of measurement or measuring and testing
equipment or for other mechanical reasons or for reasons for which the
Contractor is responsible, the Owner shall order the test to be abandoned
and shall be replaced by a new test on another pile at an adjacent location at
no additional cost.
Before commencing with any test the Contractor shall submit for Owner’s
approval full details of his proposals including the datum beam arrangements
and locations of supports. Working piles shall not be used as tension reaction
piles.
Sufficient number of anchor piles shall be driven to prevent excessive
movement of anchor piles.

BOOK III
All devices for measuring the settlement of piles shall be sheltered, and rigidly
attached to a firm and independent support driven at a distance of not less
than 2.5 m from the nearest point of the test pile or anchor piles.
Calibrated load cell shall be used for the load measurement.
Compressive Load Test

Compressive load test shall be performed on individual piles in accordance
with applicable requirements of ASTM D1143.
Hydraulic jack and anchored reaction member method shall be used to apply
the test load. Jacking against production piles acting in tension will not be
permitted.
Prior to the start of production pile driving, compressive tests to failure shall
be performed on individual test pile driven for testing purposes. The location
of the test piles shall be as indicated on the drawings.
Compressive tests shall be performed on individual production piles selected
by the Owner. The approximate location and number of the tests shall be as
indicated on the approved drawings.
Test loads for piles tested to failure shall be applied in accordance with the
procedure for loading in excess of the standard load test, as specified in ASTM
D1143. Test load on production piles shall be applied in accordance with the
standard loading procedure, as specified in ASTM D1143. The preliminary
load tests to failure shall include the cyclical load test of ASTM D1143.
Production pile load tests shall include the cyclic load test only when
For the preliminary compression tests, loading shall be increased as specified
in ASTM D1143 until failure or when 300 % of the test design load is reached.
Loading for the production piling tests shall be increased as specified in ASTM
D1143.
Monitor pile head deflection using a minimum of 3 dial gages, mounted to an
independent frame and located radially about the pile.
Failure shall be defined as the load at which vertical deflection of the pile
head exceeds 50 mm.
Tensile Load Test

Perform tensile load tests on individual piles in accordance with applicable
requirements of ASTM D3689.
Test loads shall be applied in accordance with the procedure for loading in
excess of 200 % of pile design uplift load, as specified in ASTM D3689.
Loading shall be increased until failure occurs.
BOOK III
Tension test shall be performed on individual piles driven for testing

purposes. The location of the test piles shall be as indicated on the approved
drawings.
Monitor pile head deflection using a minimum of 3 dial gages mounted to an
independent frame and located radially about the pile head.
Failure shall be defined as the load at which uplift continues to increase
without any further increase in load.
No concrete shall be placed for pile caps until installation of reinforcement,
tell tales and tension connection is complete. Design of tension connection
shall be Contractor’s responsibility.
Lateral Load Test

Lateral load tests shall be performed on single piles in accordance with the
applicable requirements of ASTM D3966. Test shall be performed for fixed
head and free head conditions.
Test load shall be applied in accordance with the procedure for loading in
excess of the standard load test load, with cyclic loading, as specified in ASTM
D3966.
Loading shall be increased until failure occurs. Failure shall be defined as the
load at which horizontal deflection continues to increase without any further
increase in load, or any lateral movement at design soil top elevation
exceeding 12 mm.
Lateral load tests shall be performed on separate piles driven for testing
purposes. The location of the test piles shall be as indicated on the design
approved drawings.
Monitor pile butt movement and rotation of the head of the test piles.
TEST EQUIPMENT AND MATERIALS

The Contractor shall provide all equipment and materials required for the test
and shall remove all such equipment and materials at the conclusion of test.
The Contractor shall submit drawings of test arrangement, including full data
for equipment and materials, for review and Owner’s approval.
Test Results shall be submitted complete with tabulation of all test data to
the Owner immediately after conclusion of test. Data shall include, as a
minimum, calibration records of all test loading equipment, all dial gauge
readings at each increment and decrement of load, time duration of test with
time started and time completed and any notes on unusual occurrences
during testing.

BOOK III
4.4.2.12.11 NUMBER OF TESTS

Before piling works commences, preliminary pile tests shall be carried out. At
least one pile of each pile type in each specified soil condition shall be tested.
The Owner will select the working piles to be tested. At least one working pile
for each major grouping of piles or at least one working pile for each one
hundred piles shall be tested.
4.4.2.12.12 QUALITY ASSURANCE / QUALITY CONTROL (QA/QC)

Quality assurance/quality control shall be in accordance with the
requirements in Book II, Technical Specification.
4.4.2.13 PC CORRUGATED SHEET PILE ( NOT APPLICABLE )
4.4.2.14 DESIGN AND FABRICATION OF STRUCTURAL STEEL

The scope of work shall be in accordance with Book II Subsection "Summary
Scope of Work".
Design and fabrication of structural steel, as defined in the AISC Code of
Standard Practice, shall conform to the requirements of this Section, and all
applicable requirements of the AISC Manual of Steel Construction, latest edition
unless otherwise indicated.
The Work shall include the following:
 Designing, furnishing, fabricating and delivering structural steel and crane
rails including floor loading signs.
 Designing, furnishing, fabricating and delivering gallery and auxiliary steel.
 Designing and furnishing shop and field connections included in the
structural, steel.
 Verifying field measurements for fabrication as required.
INTENT OF SPECIFICATION
The works covered by this specification shall include full provision for the
following:
All structural steel, columns, girders, beams, bracing, base plates, column
anchor bolts, trolley beams and other materials as required for the support of
the buildings, structures, ducts, equipment, piping and other appurtenances
above the foundations at grade.

BOOK III
With respect to drawings included in the bid of the offer Document, the
following terms shall be clearly understood:
Work indicated on those drawings shall be used only as a guide for the type of
steel work which will be required for the Work; actual sizes, weights, thickness,
relative quantities of various classes etc. shall be based on Contractor's detailed
design drawings.
Cost incurred as a result of changes due to Contractor's design need,
misinterpretation of design intent, miscalculation of connections or other
design, detailing and fabrication errors shall be the Contractor’s responsibility.

The Contractor shall comply with the requirements in this book, Subsection
4.4.3.1.Codes and Standards.
The codes and standards of the following organizations extracted from
Subsection 4.4.3.1.Codes and Standards are specifically applicable to the
design, manufacture and testing of the work included in this Specification:
AISC ………... American Institute of Steel Construction
ANSI ………... American National Standards Institute
AREA ……….. American Railway Engineering Association
ASTM ……….. American Society for Testing and Materials
AWS ……….. American Welding society
SSPC ……..… Steel Structures Painting Council, USA
UBC .………. Uniform Building Code of USA
4.4.2.14.3 REPORTS AND CERTIFICATES

Copies of material certifications, mill test reports, and other reports required by
applicable codes or standards shall be available from the Contractor. Those
reports shall be submitted as requested by the Owner after completion of the
required tests.
All materials for the power plant buildings and other structures shall conform to
the requirements of the Contractor's design drawings, Table 4.4.2.14-1 and
4.4.2.14-2 or approved equal.
Hot rolled steel of wide flange shapes with 600 mm or less depth shall be of
local origin as long as available.
Table 4.4.2.14-1 MATERIAL FOR STRUCTURAL STEEL WORK

BOOK III
ASTM Standards
Item Material
Codes Unless Noted
No.
Hot rolled beams, bars, channels,
1. Plates and angles, bracing, A36
structural tees
2. Plate girders A36
A572 Grade 50
A588 Grade 50
A588 Grade 46
A588 Grade 42
3. Columns A36 or A572 or A588
A36 or
4. Cover plates A572 Grade 50
A588 Grade 50
5. Column base plates and splice plates A36
6. Connection bolts A325F
7. Welding AWS D 1.1

A36 or
8. Column anchor bolt A307 or
A193 Grade B7
9. Round tubular bracing A53
10. Square and rectangular tubing A500, Grade B or A501
A27, Grade 65-35 or

11. Castings
A148, Grade 80-50
12. Forgings A668, Classes C, E and F
13 Crane rails BS 11 or equivalent

Note: For additional requirements for material see Table 4.4.2.14-2

BOOK III
Table 4.4.2.14-2 ADDITIONAL REQUIREMENTS FOR STRUCTURAL STEEL MATERIALS
Material Item Standard Additional Requirements
Use for all structural steel other than specifically

1. Structural ASTM A36
indicated in this specification
2. High-Strength a. ASTM A572 Grade, as required.

Steel b. ASTM A588 Use yield as required.
3. Low-Sulfur ASTM A588 a. The sulfur content of the steel shall be 0.010%
High-Strength Grade A or B maximum, and the sulfides shall be in globular
Steel (for plates A572 Grade 50 forms.
over 12 mm in with special
thickness) process (such as b.The steel shall have the following properties in
vacuum through thickness direction:
degassing) b1. Reduction of area under tensile test shall be
25% minimum.
b2. The yield and tensile strengths shall be not less
than 75% of specified strengths of original
A588 or A572. For plates thicker than 56 mm,
yield tests shall be performed with test
specimens conforming to ASTM A370 Figure 5
for 12 mm dia specimens.
c. The steel shall be 100% ultrasonically
tested, per ASTM A578 Level I for plate thickness of
19 mm and greater, and level 11 for plate thickness
less than 19 mm, except that a 25 mm dia. Circle
shall be used instead of 75 mm dia. Circle, and
scanning shall be continued over 100% of the plate
surface.

BOOK III

(CONT’D)
d. The steel shall be tested for

Charpy V- Notch Impact,
in accordance with ASTM
A370 with frequency (P)
indicated in ASTM A637; and
shall meet the following
requirement:
Direction Charpy Value
(Mils-lateral
expansion) at 0º
C
Logitudinal 70
Transverse 60
Through-Thickness 30
e.Use: Where indicated, especially

for plates loaded or stressed in
through thickness direction.
4. Stainless Steel Hot Plates

a. ASTM A240,
rolled, annealed and Plates for fabrication of welded
b. ASTM A240, conforming to
pickled (HRAP) finish plate piping included in structural
A358, Class 1, Grade 304
steelwork.
5. Stainless-Clad ASTM A240, Type 304 stainless Thickness of cladding shall be

Steel, with finish, cladding steel on backing plate nominal 1.2 mm single clad for
RMS values of 10 to of ASTM A36 steel, Conforming backing plates 6 mm or more in
30 to ASTM thickness.
6.Tubular members ASTM A53 of the following type Use standard, extra strong or
6.1 Round tubular and grade: double extra strong weight.
Bracing a. Type E or S, open hearth or
basic oxygen steel only, with
sculpure Content not
exceeding 0.05%
Grade B only (2,460 kg/cm2
yield)
6.2 Rectangular or ASTM A500 Grade B or A501 For tubular framing
Square Tubing

BOOK III

(CONT’D)
7.High-Strength AISC Specification for a. Bolts and Nuts: Use the following
Bolts Structural Joints Using materials unless otherwise indicated
ASTM A325 - For bolts sizes use A325,type1
- Washer
A325 Bolts : one washer under the
head or nut whichever is the element
turned tightening
8 Shoulder bolts for

slotted sliding
connection.
8.1 Bolts ASTM A325, type 1 22 mm diameter shank; grip length of

bolt shall equal the thickness of the mated
parts plus two 3 mm thick washers plus 3 mm.
Bolt threads shall be 19 mm diameter and the
length shall equal the thickness of two nuts
plus 6 mm.
8.2 Washers ASTM F436 Two 22 mm diameter washers required.
One washer under the bolt head and one
under the nut.
9. Castings a. ASTM A27, Grade Use for all castings unless otherwise
65-35. indicated.
b. ASTM A148, Grade Use only where high strength steel

80-50. castings are required.
10. Forgings ASTM A688, Classes C, E Use for all forgings unless otherwise indicated.
and F
11. Stock Material As specified in Items 1 Mill test reports for applicable material
through 10 shall ordinarily constitute sufficient
record, but separate tests may be
required on pieces selected from any
shipment

BOOK III
Table 4.4.2.14 -2 ADDITIONAL REQUIREMENTS FOR STRUCTURAL STEEL MATERIALS

(CONT’D)
12. Crane Rails- ASTM A1, No. 1, Rails a. Product: Shall be control cooled and
weight 50 Kg/m with carbon content heat treated or end hardened, as made
or more. (Lighter 0.67-0.82% or by one of the following manufactures
rails shall manufactures or approved equal in accordance with
conform to standards meeting the their standard specification for crane
manufacturer same required rails, unless otherwise indicated:
standards).
a.1. Bethlehem Steel Corporation, USA
a.2. United States Steel Corporation
b. Length: Standard 12 m, subject

tolerance of ASTM A1.
c. Size: As indicated on the design

drawings.
d. End Drilling: Three holes each end,

spaced to suit specified joint bars and
as required for tight end joints.
e. Marking: As specified in ASTM A1.
13. Crane Rail As indicated Accessories shall be as made by, or as

Accessories furnished by, one of the rail manufacturers
indicated in item 12 in accordance with their
standard specifications for rail accessories,
for the specified rails and in accordance with
the requirements of this Item 13.
13.2 Bolts and Nuts ASTM B325 and

ANSI B18.2
13.3 Spring Washers AREA Specification

For spring washers

BOOK III
Table 4.4.2.14 -2 ADDITIONAL REQUIREMENT FOR STRUCTURAL STEEL MATERIALS

(CONT'D)
13.4 Rail Clips ASTM A36 or better Shall be "Tight Fit" type, made of pressed steel
plate with reversible steel fillers and 2 holes
each clip.
Also it shall be designed to allow for the
resilient pad and lateral adjustment of the

crane rail of ± 5 mm relative to the crane
girder, during and after installation.
13.5 Resilient Pad The resilient pad under the crane rails shall be
manufactured from synthetic elastomer and
be resistant wear, shear, crushing, oil, grease,
oxygen and ultra violet rays and shall be
reinforced along its length with a steel strip.
4.4.2.14.5 DESIGN
GENERAL PROVISIONS
The design of all structural steel required by this Contract and the design work
for all shop and field connections, including angles, welds, web reinforcement
for coped beams, gusset plates and bolts shall be performed by the Contractor.
The Contractor prior to fabrication shall submit design and shop drawings
including typical calculations for each connection type for review. Such review
shall in no way be interpreted as constituting approval of the adequacy of such
design for their intended use and shall not relieve the Contractor from
correctness and complete design responsibility and from fulfilling all obligations
under the Contract.
All design calculations and drawings shall be prepared under the supervision of
a qualified Engineer and must be approved by Owner.
DESIGN REQUIREMENTS
The design of structural steel shall conform to all applicable requirements of
the AISC Manual of Steel Construction, the latest edition.
The connections shall be designed to resist ultimate moments, shears and axial
forces of connected members.

BOOK III
Prying action shall be considered in the design of bolted connections in

accordance with the AISC Manual of Steel Construction.
The following allowable stresses specified in the AISC Specification for
Structural Joints Using ASTM A325 bolts shall be used in connection bolt design:
Allowable stresses for blast-cleaned surfaces (for shop welded and field bolted
connections).
Allowable stresses for mill scale surfaces (for shop bolted and field bolted
connections).
4.4.2.14.6 FABRICATION
GENERAL PROVISIONS
Conformance
Fabrication of structural steel shall conform to all applicable requirements of
codes and standards specified in this section.
FABRICATION REQUIREMENTS FOR PLUMBING UP AND LEVELLING

The structures shall be plumbed and leveled such that deviations in the
completed work would not exceed the requirements of the AISC Code of
Standard Practice.
Such requirements shall be fully considered in fabrication, and Contractor's
shop erection drawings shall be clearly marked with these restrictions.
MISFITS
Attention is specifically directed to the requirements of the AISC Code of
Standard Practice and Quality Criteria and Inspection Standards, with respect
to correction of fabrication errors. Any errors in shop work which prevent
proper field assembly (and fit up) will be reported, as soon as they are
discovered to the Owner and to the fabricator by the Contractor. The
Contractor shall then make immediate substitutes or arrangement for
correction at no cost to the Owner.
The allowable limits for reaming the connection bolt holes for fit up in the shop
or in the field shall conform to the requirements of the AISC Quality Criteria and
Inspection Standards. If fit up of bolts during erection in the field cannot be
obtained by reaming the fabricated bolt holes within these limits, it is
considered that there are errors in fabrication, and these errors shall be
rectified in accordance with previous paragraph.

BOOK III
CONNECTIONS
All connections shall be welded or high strength bolted, in the shop or field as
follows:
 Shop Connections
All members and details shall be fabricated by welding or high strength
bolting, using FRICTION TYPE connections; and welding may be used in
combination with the high strength bolting completed prior to welding.
 The Contractor shall submit with his bid proposal, a schedule of where he
proposes to use each method of fabrication, and in general the members,
connections, etc. included under each method.
 Field Connections
All connections shall be made with high-strength bolts, using FRICTION TYPE
connections, unless otherwise indicated.
 Welding
Welding, including stud welding, shall conform to the requirements of
Specification refers to "Welding in Steel Structures"
 Welding Drawing
All welding shall be clearly indicated in the shop drawings.
 Field Welding Preparations
Contractor shall provide all end and edge preparations for field welding.
High Strength Bolting, Conformance

High strength bolting shall conform to the applicable requirements of the AISC
Specification for Structural Joints Using ASTM A325 Bolts for friction type
connections, and to the requirements of this Clause. Unless otherwise
indicated.
Bolt Types
Shall be as indicated in Table 4.4.2.14 -2.
Bolt Holes
Shall be 2 mm larger than the nominal diameter of the bolts. Larger or slotted
holes will not be permitted unless otherwise indicated.
Long Grips
Additional high-strength bolts are not required for long grips.
Installations
a. The turn-of-nut tightening or calibrated wrench tightening methods, as
specified in the AISC Specification for Structural Joints Using ASTM A325

BOOK III
Bolts, shall be used. The use of a direct tension indicator for tightening will
not be permitted.
b. The minimum projection of the installed bolt beyond the nut shall be 6 mm.
c. The threaded part of the installed bolt shall not be in the shear plane.
d. Blouse of torque bolts will not be permitted.
Beam Connections
Connection Types
Shall conform to the AISC Specification, Part 4.
Connection Angles
a. Connection angles shall be minimum 10 mm thick.
b. Connection angles for any deep girder shall be continuous from the top to
bottom flanges in all cases.
c. Usual gauge as presented by AISC shall be used. Bolt staggering shall be
used only to maintain the usual gauge.
Knife Connection
Such a connection, consisting of two-connection angles shop assembled to
receive the web of a beam in field erection, shall not be used.
MISCELLANEOUS DETAILS
Welded Cover Plates on Columns and Girders

Cover plates on each flange of columns or girders shall be a single plate in each
thickness.
Bracing
Vertical diagonal bracing members shall be wide flange shapes, double angles,
double channels or tubular. Horizontal bracing shall be single angle.
Tubular Bracing
a. Tubular bracing used for indoor work (not exposed to the elements) shall be
open-ended.
b. Tubular bracing used for exterior work (exposed to the elements) shall have
the top end capped and the bottom end open. Cap plates shall be 6 mm
thick and continuously welded all around the bracing.
Draw for Single-Angle Cross Bracing

BOOK III
Long single angle cross bracing members shall be fabricated with a draw or
reduction in the actual distance center to center of end connection bolt holes
(as compared to the theoretically correct distance) as indicated in the following
Tabel 4.4.2.14.6-1.
No draw shall be provided for double angle, tubular or other shape bracing.
Table 4.4.2.14.6-1
DRAW REQUIREMENTS FOR SINGLE ANGLE BRACING
Length Draw
0 To 3.5 m -
Over 3.5 m to 7 m 1.5 mm
Over 7 m to 10 m 3 mm
Over 10 m 4.5 mm
Double Angle Bracing

All double-angle bracing members have long legs back-to-back unless otherwise
required.
Camber
Built-up girders, trusses and rolled beams shall be fabricated to provide for
camber in accordance with the requirements of the AISC Manual of Steel
Construction.
Column Splice Milled Ends

Such ends shall not be out of square more than 0.75 mm, as specified in ASTM
A6 Table 24. However, only milling techniques shall be used in this fabrication.
Curb Angles and Guard Plates

Curb angles and guard plates shall be connected to the structural steel in the
shop.
Guard plates shall be furnished in as large lengths as possible, with joints not
closer than 90 cm to handrail posts. Cutouts where required to clear indicate
piping, or other equipment, etc., shall be provided.
For adjoining guard in continuous runs or at corners, the ends shall be tack-
welded together at the top.
Hangers
All hangers shall have a minimum of two high-strength bolts at each end.
BOOK III
Trolley Beam Stops

Each trolley beam stop shall consist of two 75 mm x 75 mm x 12 mm angles,
each of which shall be connected to the beam with two 18 mm diameter
machine bolts. Each bolt shall have hexagon head and one heavy hexagon nut.
Girts
Extent
Girt shall include horizontal girt, carrier girt, girt posts, door and window
framing attached to girt, parapet framing, sag rods etc.
Plumb and Level

Girt shall be fabricated to the same plumb and level requirements as specified
in paragraph above at ‘Fabrication Requirements for Plumbing Up and
Leveling’.
Frames Around Openings

Girt around doors, windows, and louver openings shall be fabricated in
accordance with the following requirements:
a. All corners of openings formed by junctions of vertical and horizontal girt
members shall be absolutely square.
b. Vertical and horizontal dimensions of openings shall each be within an
overall tolerance of ± 1,5 mm for doors, ± 6 mm for windows, and + 6 mm,
to 0 mm for louvers.
c. The junctions of vertical and horizontal girt members at the head arid sill of
door openings shall be detailed with end clearances not exceeding 6 mm
nor less than 3 mm, and shall be arranged for field welding closured, of
these junctions.
d. Head angles for windows shall be detailed with end clearances not
exceeding 6 mm nor less than 3 mm; these clearances shall apply for
intermediate joints in continuous runs of head angles, and also for joints of
junctions of the head angle and jamb angle. Also, these joints shall be
detailed for field welding closures.
e. Fill plates at the junction of jamb angles and sill angles shall be provided,
and shall be detailed for field welding closures of these junctions.
f. Steel channel doorframes may be shipped knocked-down for field-welded
assembly or may be completely shop-assembled and shipped as a whole
unit.
Connections
Each connection for a girt shall have a minimum of two 16 mm diameter high-
strength bolts unless otherwise indicated.
BOOK III
Sag Rods
All sag rods shall have two heavy hexagon nuts at each end. Holes for sag rods
shall be 1.5 mm larger than the nominal diameter of the sag rods. Larger holes
up to 4,5 mm larger than the road diameter will be permitted only if a
hardened washer is used with each nut on each side of these holes.
Edge Preparation and Welding

a. Prior to fabrication, The Contractor shall consult with the manufacturer to
ensure the best possible fabrication of the material for the intended
purpose. All joints shall be of welded construction unless otherwise
indicated and the welding shall be done on both the stainless-clad and
backing sides.
b. Only electrodes recommended by the manufacturer for stainless clad steel
shall be used for all welding on the stainless clad side of the material. The
stainless steel side shall be back gauged or ground to bright sound metal
prior to welding. All welding operations shall be performed so as to reduce
to a minimum, or completely eliminate, all weld spatters on the stainless-
clad side. Also use anti spatter compound along both edges of welded
joints, on the stainless-clad side, to permit easier removal of any spatter
that does occur, hard, brittle weld is not acceptable.
c. Grinding of welds will not be required except as necessary to remove sharp
edges; however, all welds shall be made as neatly as possible. Pits, crevices
and other discontinuities shall be corrected by the use of additional weld
metal if required.
Protection
a. The manufacturers shall ship the material in bundles suitable for handling,
with wood laths separating each plate. Each group of plates which are
wrapped to make up a bundle shall be completely wrapped again in heavy
waterproof Kraft paper and steel banded for shipment.
b. Upon receipt of material, the plates shall be left in packaged until they are
required for fabrication.
Special Precautions
a. Any temporary materials, such as handles of lifting lugs etc. shall not be
attached to the stainless-clad side of material.
b. Any scratches, gouges or damages to stainless-clad surfaces shall be cured
satisfactorily by the Contractor at his own expense. Gouges and scratches
0.75 mm deep or less and; those deeper than 0,75 mm shall be filled with
weld metal, as specified for welding of stainless-clad steel, and shall be
ground and hand-buffed smooth. Weld spatter or other deposits on

BOOK III
surfaces shall be carefully removed flush with the surfaces, and these areas
shall be hand-buff smoothly.
Inspection
All stainless-clad material shall be inspected, after completion of fabrication, by
the Contractor, or by a testing laboratory inspector furnished the by Contractor,
for full compliance with all requirements herein specified. Any work not
conforming to the specified requirements shall be satisfactorily repaired, before
the material is shipped.
Crane-Rails
Rail lengths shall be fabricated such that rail joints on opposite sides of the
runway are staggered with respect to each other. Rail joints shall not coincide
with the joints occurring in the runway support girders.
Rail shall be milled or ground to provide tight joint assembly.
Rail clips shall be tight fit type placed in pairs spaced at 60 cm between centers.
SHOP CLEANING AND PAINTING

Shop cleaning and painting including surface preparation of structural steel
shall conform to all applicable requirements of specification refers to ''Prime
Cost and Shop Painting, and Field Painting".
All trolley beam surface shall be painted yellow with one shop prime coat of
paint. The design capacity of each trolley beam shall be stenciled on both sides
of the web at the approximate mid span of each beam, using the notation
“CAPACITY TONS” lettered in 75 mm high block letters, with black paint. The
surface preparation, painting and paint product/manufacturers shall conform
to the applicable requirements of Design and Fabrication of structural steel.
Correction of Painting Work

Painted surfaces of structural steel will be inspected, as specified in
specification refers to “Prime Coat and Shop Finish Painting” in the field after a
reasonable period of weathering. If the condition of any surface indicates
insufficient thickness of paint, or incorrect method of application, etc.
(regardless of prior approval of the work in the shop), the Contractor shall
repaint all such surfaces in the field as requested.
The foregoing requirement shall not apply with respect to surfaces abraded in
shipping, handling etc. for which field touch-up painting shall be performed by
the Contractor.
The quality control procedures specified shall include but not be limited to the
following:
BOOK III
- Material certificates
- Welding
- Non distributive testing
- Shop test and inspection procedures
- Cleaning and painting
- Packaging and shipping
The Quality Control documentation as specified above shall include but not be
limited to the following:
- Welding procedures
- Shop test and inspection reports
4.4.2.14.8 INSPECTION AND TEST AT SHOP
The Contractor shall submit a work inspection and test program covering all
materials and equipment to the Owner. Agreement has to be established on
the degree of inspection and test to be witnessed by the Owner or his
representative before start and during the course of work.

BOOK III
4.4.2.15 ERECTION OF STRUCTURAL STEEL

The scope of structural steel erection shall include the following as applicable to
Contractor's work included in Book II refers to "Summary of Work".
Unloading, storing, protecting, removing from storage and erecting the
following:
 Structural steel
 Gallery and auxiliary steel
 Performs all bolting works for field connections using high strength bolts.
 Furnishing welding electrodes and performing welding for field welded
joints included in the Work.
 Furnishing, and installing anchor bolts and anchor bolt sleeves into concrete
foundations.
 Laying out and verifying lines and grades as previously mentioned.
 Grouting of column base plates.

The Contractor shall comply with the requirements of Book II refers to "Codes
and Standards".
The codes and standards of the following organizations extracted from the
Book II refer to "Codes and Standards" are specifically applicable to the design,
manufacture and testing of the work included in this Specification:
AISC ………… American Institute of Steel Construction
ASTM ………… American Society for Testing and Materials
AWS ………… American Welding Society
ERECTION DRAWINGS
Erection and detail drawings for all parts of the work shall be prepared by the
structural steel fabricator and coordinated with the erector to maximize shop
fabrication and to minimize field fabrication as far as practical.
REPORTS
Copies of welding qualification reports, quality control reports, and other
reports as specified or required, shall be furnished by Contractor to the Owner,
during the course of the work, or upon completion of the work.

BOOK III
4.4.2.15.4 FIELD REPRESENTATIVE

The fabricator shall furnish a full time field representative to assist in the
coordination of the erection work at the site.
WELDING ELECTRODES
Welding electrodes used for the Work shall conform to the applicable
requirements of specification welding in steel structures.
EXPANSION ANCHORS
Expansion anchors shall conform to the requirements of Specification Concrete
Expansion Anchor work and shall receive prior approval of the Owner.
4.4.2.15.6 PERFORMANCE
GENERAL PROVISIONS
Erection of structural steel shall conform to all requirements of the AISC
Manual of Steel Construction (latest edition) and the following:
Lines and Grades

The Contractor shall lay out lines and grades from existing base lines and bench
marks on the property, and shall be fully responsible for the correctness of
these lines and grades and for proper execution of the work.
The Owner reserves the rights to verify the correctness of such lines and grades
during the progress of the work. Such verification by the Owner will not relieve
the Contractor from any responsibilities of the work.
The Contractor shall preserve and maintain all benchmarks and reference
points established. Should the Contractor during execution of the work destroy
or remove any benchmarks and/or reference points established by the Owner,
the cost for reestablishing these benchmarks and/or reference points will be
charged to the Contractor.
Erection Tolerances
Steel work shall be set accurately to the established lines and grades and shall
be plumbed and leveled such that the deviations in all completed work are
within the tolerance limits and meet the requirements, as specified in the AISC
Code of Standard Practice and this specification.
Column base plates shall be set at the specified elevations within the tolerance
of ± 1.5 mm and shall be leveled within the same tolerance.

BOOK III
Fitting
Members and Details

Members and details shall be fitted into place by proper methods which would
not injure the materials. Contractor shall replace any materials unduly injured,
at Contractor's expense. Heating of anchor bolts for bending or other purpose,
and welding of ASTM A193 anchor bolts in the field will not be permitted.
Column Splices
In a column contact joint, the gap between column-milled surfaces not
exceeding 0.8 mm will be accepted. If the gap exceeds 0.8 mm, but is less than
6 mm, it shall be packed out with no tapered steel shims. The shims shall be
mild steel regardless of the column material. Gaps of 6 mm or more shall be
reported to the Owner.
Misfits
Attention is specifically directed to the requirements of the AISC Code of
Standard Practice and Quality Criteria and Inspection Standards, that correction
of minor misfits and a reasonable amount of cutting and reaming shall be
considered as a part of erection.
However, any errors in shop work which prevent proper field assembly and fit
up of parts shall be reported, as soon as they are discovered, to the Owner as
well as to the structural steel fabricator, in order that the fabricator may either
correct the errors or make substitutions.
The allowable limits for reaming the connection bolt holes for fitting in the field
shall conform to the requirements of the AISC Quality Criteria and Inspection
Standards. If, fitting of bolts during erection in the field could not be obtained
by reaming of the fabricated boltholes within these limits, it shall be considered
as errors in fabrication, and such errors shall be duly rectified.
Correction of misaligned boltholes by the use of flame cutting is prohibited.
Field Connections
All other connections shall be made by high strength bolting, unless otherwise
specified.
WELDING
All welding including stud welding shall be performed in accordance with the
Specification Welding in Steel structures.

BOOK III
HIGH STRENGTH BOLTING
Type of Connection
FRICTION TYPE Connection, as specified in the AISC Manual and the
"Specification for Structural Joints Using ASTM A325 Bolts" shall be used for all
bolted connections unless otherwise indicated.
Types of Bolts
The ASTM A325 Type 1 of high strength bolts shall be used unless otherwise
indicated.
Assembly of Joints
Method of Installation
The Turn-of-Nut Tightening or Calibrated Wrench Tightening method, as
specified in the AISC "Specification for Structural Joints Using ASTM A325
Bolts," shall be used.
Bolt and Nut Assembly

All nuts shall be fully engaged with a minimum of 6 mm projection of the
installed bolt beyond the nut. The threaded part of the installed bolt shall not
be in the shear plane. Reuse of bolts as specified in the AISC Specification for
Structural Joints will not be permitted.
Fairing Up
The Contractor shall fair up the holes in each connection with enough pins to
maintain the dimensions and plumbness of the structure. Such pins shall
remain in place until all bolts in the balance of the holes have been tightened.
Washers
a. For an A325 bolt, a hardened flat washer shall be used under the bolt head
or under the nut, whichever is to be turned in tightening.
b. Beveled washers shall be used as specified in the AISC Specification for
Structural Joints Using A325 Bolts.
Location of Bolt Heads

a. Columns: On outside faces of flanges.
b. Beams and Girders: On upper sides of flanges.

BOOK III
INSTALLATION OF EXPANSION ANCHORS

Shall conform to the requirements of Specification Concrete Expansion Anchor
work.
ERECTION DETAILS
Column Stiffener Plates

Column stiffener plates at connection joints with beams and girders may be
shipped loose by fabricator and shall be installed by the Contractor.
Curb Angles and Guard Plates

All curb angles and guard plates shall be connected to structural steel in the
shop.
For adjoining guard plates in continuous runs or at corners, the Contractor shall
tack weld the ends together at the top.
Trolley Beams
The Contractor shall carefully align the splices of bottom flanges of trolley
beams in order to have a smooth travel passage of the trolley passing each
splice.
Girt System
The girt system shall include horizontal girt, door, window and louver framing,
and other vertical members attached to girt, parapet framing, sag rods, etc.
The girt system shall be erected within the tolerances specified.
Sequence of Erection
Girt shall be erected in vertical sequence along with the erection of structural
steel to provide wall bays with girt completed from ground to roof. This would
permit erection of siding in the bays without girt erection being carried on
above siding erection at the same time.
Erection Around Door, Window and Louver Openings

Girt around such openings shall be erected in accordance with the following
requirements:
a. All corners of openings formed by the junctions of horizontal girt and

vertical members of the girt system shall be absolutely square.

BOOK III
b. Vertical and horizontal dimensions of openings shall each be within an

overall tolerance of  1.50 mm for doors,  6 mm for windows, and + 6 mm
to 0 mm for louvers.
c. Junctions of horizontal girt and vertical members at the head and sill of
door openings will be detailed with end clearances not exceeding 6 mm nor
less than 3 mm, and will be arranged for field welding closure of these
junctions by the Contractor.
4.4.2.15.7 INSPECTIONS AND EXAMINATION
GENERAL PROVISIONS
This work is subject to inspection and examination by an independent testing
laboratory at the project site, for full compliance with all requirements of this
specification, the contract and Contractor's design drawings.
The Contractor shall retain and pay for the services of a testing laboratory,
personnel or inspector(s) to perform this inspection and examination work.
The Contractor shall provide, and pay for all rigging required for the work and
for all personnel required to assist the inspector(s).
The Contractor shall furnish and install the tension-calibrating device. The
device furnished shall bear a certification as to the accuracy of the device. Such
certification shall be dated not more than 30 days prior to the first actual use of
the device for inspection of the work.
INSPECTIONS AND EXAMINATION OF WELDING

Shall be as specified in Specification Welding in Steel structures.
INSPECTION ON HIGH STRENGTH BOLTING

This inspection shall be performed in accordance, with the requirements of
Section 5 of the AISC Specification for Structural Joints using ASTM A325 Bolts,
and will include the arbitration inspection specified therein.
In each connection on the structure, approximately 10% of the bolts will be
inspected, but never less than two bolts.

Quality control shall conform to the requirements of Book II.
The quality control procedures shall include but not be limited to the following:
- Welding
- Non destructive testing

BOOK III
- Cleaning and painting
The quality control documentation shall include but not be limited to the
following:
- Welding
- Field test and inspection reports.

BOOK III
4.4.2.16 GALLERY WORK

The Contractor shall design, furnish and install complete system of gallery work
for all buildings, structures, and equipment furnished by the Manufacturer
including all accessories as indicated in Book II, refers to " Summary of Work"
but shall not be limited to the following:
 Framing for steel stairs, galleries and platforms.
 Grating and grating treads, including abrasive nosing.
 Safety floor plate (checkered plate).
 Handrails.
 Ladders.
 Guard plates.
 Banding of all openings in grating occasioned by field run piping.
 All materials necessary, including Type 316 stainless steel studs for grating
hold-down clips to connect the gallery work to structural steel and other
parts of the structure already in place.
 All brackets, hangers and bracing necessary to support the Work rigidly
and keep it in free from vibration and excessive deflection

The Contractor shall comply with the requirements of Book II, refers to "Codes
and Standards".
The codes and standards of the following organizations extracted from Book II
refers to "Codes and Standards" are specifically applicable to the design,
ASTM ............. American Society for Testing and Materials
AISC ............. American Institute of Steel Construction Manual
AWS ............. American Welding Society
SSPC ............ Steel Structures Painting Council, USA
SAE ..........…Society of Automotive Engineers, USA
UBC …………Uniform Building Code of USA
OSHA ……….. Occupational Safety and Health Administration, USA
Code Requirements: All stair riser heights, stair tread depths, stair widths,
ladders, ladder guards, hand railing heights etc. shall conform to the latest UBC
and OSHA code requirements which may apply.
The gallery work shall also conform to the mandatory requirements of all
Indonesian authorities having jurisdiction.

BOOK III
It shall be Contractor's responsibility to investigate such requirements and

determine the applicable provisions. These provisions shall be current to the
date of contract award.
4.4.2.16.3 WORKMANSHIP, SEQUENCE AND FINISH

Workmanship and finish shall be equal to the best shop and field practice. All
material shall have clean surfaces before being worked. Fabricated members
shall be free from twists, bends or open joints. Shearing and clipping shall be
neatly and accurately done. All work shall be neatly finished.
As much of the work as possible, including connections and joints between
members, attachment of clip angles, punching of holes etc. shall be shop
fabricated so as to reduce the amount of field erection work to a minimum.
The Contractor shall be responsible for proper fit of all materials furnished,
including railing and post clearance with other equipment, piping, grating,
checkered plate etc. including field check for clearances.
The Contractor shall fabricate and erect the gallery in the work sequence
desired by the Owner if requested.
4.4.2.16.4 MATERIAL
Grating shall be galvanized steel unless otherwise specified. Steel grating shall
be fabricated from welding quality steel equal to SAE 1015 for bearing bars and
SAE-1010 for cross bars.
Structural steel and all other steel including floor plates, ladders, cages, guard
plates etc. shall conform to applicable requirements of ASTM A36- Standard
Specification for Structural Steel.
Bolts shall be Galvanized high-strength bolts of ASTM A325 type 1
Handrails and posts shall be butt welded steel pipe of standard weight
(Schedule 40) or steel structural tubing of equal or greater weight unless
galvanized pipe is called for in the specification. The pipe shall conform to
ASTM A120 with its steel meeting a minimum tensile strength of 3,000 kg/cm
and a yield point of 1,750 kg/cm on actual physical tests. The structural tubing
shall conform to ASTM A501, F-36 or better material. The Contractor shall
retain final responsibility for spacing of handrail posts. All handrails shall be
shop primed and field finish painted.
Areas which possibly exposed to chemical attack shall have Fiberglass
Reinforced Polyester (FRP) grating with FR gray grit top.

BOOK III
4.4.2.16.5 DESIGN REQUIREMENTS
GRATING
Grating, except where noted otherwise on the approved drawings, shall have a
minimum thickness of 38 mm with 38 mm x 5 mm main bars on 30 mm
center-to-center bar spacing and crossbars on not greater than 100 mm
center-to-center spacing. Deflection of grating shall not exceed L/300.
STAIRS
Channel stringers and grating tread stairs shall be used in all plant areas to
service equipment or to travel from one gallery level to another.
Such type of stairs having : a maximum slope of 400 ; a maximum and a
minimum riser of 190 mm and 165 mm respectively; and a maximum and a
minimum tread of 250 mm and 225 mm respectively is considered gallery
stairs. The stair treads shall be rigidly bolts to stringers with bolt heads on the
outside and nuts on the inside faces of stringers. The stair width shall not be
less than 75 cm.
HANDRAILS
Handrails shall be provided for the following areas and where required:
 Around every stairway floor opening.
 Around every floor opening into which personnel could accidentally trip
or fall, except when provided with an opening cover.
 On all flights of stairs having four or more risers.
 At all open sided floors, walkways and platforms.
 Adjacent to dangerous equipment.
 All temporary openings shall be guarded by temporary handrails.
Handrails shall be placed at 105 cm above the nosing of treads, or above the
top of platform grating or checkered plate. It shall be continuous to the full
length of the stairs. Ends shall be returned or shall terminate in newel posts or
safety terminals.
Handrails shall be standard pipe handrails of 40 mm diameter, welded
construction. The handgrip portion of handrails shall have a continuous smooth
surface with no sharp corners.
Handrails projecting from a wall shall have a space of not less than 40 mm
between the wall and the handrail.

BOOK III
GUARD PLATES
 Guard plates shall be 6 mm thick and shall extend a minimum of 100
mm above the finished floor line, unless otherwise required.
 Guard plates shall be fastened to steel framing members or concreter
slabs.
 All guard plates shall be attached to framing members in the shop,
where possible, in order to minimize the amount of field erection work.
LADDERS
Ladders shall be provided in all pits, manholes, and entrances to tunnels, to all
roofs over 6 m above the ground where there would be no access by any stairs,
or to the floors where no stair system is provided.
The following types of ladders shall be used in the design of the power plant:
 Ladders consist of individual round steel rungs.
 Ladders consist of steel side rails and steel rungs attached to side rails.
 Ladder service platforms or landings 3.6 m or higher above ground shall
have a safety cage.
 Ladders over 6 m high with a cage must have a rest platform at intervals
not exceeding 10 m.
4.4.2.16.6 DETAILED REQUIREMENTS
GRATING
Fabricated galvanized type grating shall be a standard make acceptable to the
Owners however grating of the pressure locked type is not acceptable. The
welding requirements specified hereinafter would not apply to weld grating
which shall be produced in accordance with standard manufacturing practice.
Grating panels shall be of as uniform width as possible. Grating bars on grating
areas adjacent to each other shall run in the same direction, if economically
possible, and grating panels shall in other respects be such fabricated in order
that the design will match when panels are assembled. Ends of panels shall be
cut off neatly. Ends which would have become bent must be straightened
before acceptance. All grating shall be straight and not warped and shall have
full bearing on its supporting steel.
In order to obtain a firm bearing on the supporting steel, each section of grating
shall be fastened near its each corner to the supporting steel. The method of
fastening shall be by either tack welding, fasteners or combination of both.
Fasteners shall be permanently applied to the grating sections to prevent of
being detached and lost when removing or replacing grating sections.

BOOK III
Special care shall be taken to anchor overhung grating sections securely by

means of fasteners. Grating shall be provided with stops to prevent slippage of
any section from the supporting steel when an adjacent panel is removed.
All gallery steel connecting to structural steel shall be continuous fillet welded.
Grating sections shall fit snugly with not more than 3 mm clearance between
adjacent sections of grating, and 8 mm clearance between grating and curb
angles or guard plates.
Holes in grating for pipes, where required by Contractor's design, shall be cut
and banded in the shop, unless otherwise specified.
All other holes which are not specifically located and dimensioned on the
Contractor's design drawings shall be cut and banded in the field in accordance
with field measurements of pipes in place.
When laying out holes in grating for piping, considerations must be given to
clearances required to accommodate pipe covering (if any) and pipe movement
due to thermal expansion.
Gratings shall be splitted around all pipes where possible and shall be made
into easily removable sections. Location of junction lines between grating
sections shall be determined from actual field measurements of pipes insofar as
it is possible. All holes for pipes shall have clearance with the pipe (or pipe
covering as the case may be) of not less than 50 mm or greater than 75 mm.
Furthermore, such arrangement shall be provided to allow for displacement of
pipes due to their expansion or contraction without any contact between
grating and pipe (or pipe covering).
All holes shall be banded with a 5 mm bar projecting 25 mm above top of
grating. The grating bars shall be neatly welded to the band. All bands shall be
divided on the junction line between adjacent panels.
During the installation of a floor grating panel, in case any necessity to cut the
grating at right angles to the bars at a point of support, suitable means shall be
provided to permanently hold the ends of the bar in alignment.
Nosing
Edges of grating at head of stairs shall have a 40 mm wide and not less than 8
mm thick abrasive nosing.
Where grating junction lines occur at head of stairs the nosing shall be cut at
the junction line so as to permit removal of each section of grating.
Manufacturer's standard paint finish shall be provided on metal areas of treads
as nosing. Abrasive areas shall not be painted. Any discolorations, etc., on the
treads and nosing shall be cleaned off with a solvent after erection, and before
completion of the work.
Stair tread nosing shall be installed in the shop but only after the grating treads
have been galvanized.

BOOK III
The projecting edges of longitudinal grating bars at openings which are not
protected by guard plates shall be banded with 6 mm thick bar of the same
depth as the grating.
Outdoor grating and stair treads shall have serrated top. All exterior grating
shall be clipped down with a minimum of two saddle clips per grating section.
STAIRS AND TREADS

Stairs shall be constructed and attached to galleries or concrete work as
indicated on the standard drawings.
Stair treads shall be 32 mm x 5 mm for standard galvanized grating of the same
pattern as the floor grating. Grating treads shall have abrasive noising.
Stair treads shall be rigidly bolted to stringers with bolt heads on outside and
nuts on inside faces of stringers.
CHECKERED STEEL FLOOR PLATES

Checkered steel floor plate shall be rolled steel galvanized plate of a type and
design suitable for the floor loading. Steel floor plates shall have a nominal
thickness of 6 mm unless otherwise required.
The pattern center lines on all checkered steel floor plate sections shall match
and line up in both directions on adjacent sections.
All floor plate sections shall fit snugly into place with not more than 1.5 mm
space between.
All steel floor plates shall be amply reinforced by means of steel angles along all
edges of each plate and in intermediate locations where necessary. Each
stiffener shall be welded on underside of plate along both edges of the
stiffener. Each section shall be provided with two lifting holes located in
opposite corners. Floor plates shall be straight and flush with the surroundings.
Each floor plate section shall be provided with grinding bars, for aligning faces
of plate sections with each other and with adjacent flooring. Grinding bars shall
have bearing over their entire area.
Steel floor plates, where curb angle construction is required shall also be
reinforced with stiffeners except for narrow trenches where stiffeners may not
be required. All openings for pipes shall be neatly cut so as to clear the pipe (or
pipe covering) 12 mm all around. The arrangement shall be such that any
section can be readily removed.
HANDRAILS
All railings and railing post connections shall be in accordance with the details
shown on the approved drawings.

BOOK III
All railing and post intersections shall be welded. Pipe or tubing posts shall be
welded to the top rail, the rail being continuous. The center rail shall be welded
to the posts, the posts being continuous.
The railing and post sections shall be completely fabricated in the shop in as
large sections as practicable which could be conveniently handled and erected.
Field railing splices where required shall be welded and shall in all cases be
located near a pipe post or point of support. No screwed couplings will be
permitted in rails or posts.
After shop and/or field welding is done, all rough weld metal projections shall
be neatly ground off in order to present a smooth appearance joint. Neat
appearing welds without any rough projections will not require grinding. All
sharp corners shall be rounded.
The Contractor shall cut handrails and guard plates and weld them (except
galvanized steel) in field to clear diagonal bracing where required.
Ends of handrails at building columns or other vertical steel may be attached to
the steel by means of a collar welded to the steel.
Where gates are required, swing gates shall be provided. No chain gate shall be
used.
GUARD PLATES
Guard plates shall be furnished in as a long lengths as possible. Ends of
adjoining guard plates shall be welded together. Joints shall not be less than 1
m to handrail post.
Guard plates used at edges of floors and galleries and meeting at angles at
corners shall have corners welded. If necessary, an extra piece of plate shall be
welded to the outside of guard plates to close the gap between plates that do
not join.
Cutouts shall be provided where necessary to clear piping or other equipment.
The Contractor shall provide guard plates around all column penetrations and
moment connections. Gratings shall be coped and fitted with cover plates so as
to prevent openings larger than 25 mm width around such penetrations.
LADDERS
Unless otherwise specified, ladders shall be galvanized and made of steel bar
stringers and round steel bar rungs.
Suitable guards or cages shall be furnished for ladders at locations and
conditions stated in Clause 5.5.3 or where required by OSHA or UBC. Type and
design of guards shall be as required by the codes.

BOOK III
Access from platforms, floors or landings to all ladders going to a lower

elevation shall be provided with a pipe swing gate, as may be indicated, or as
may be required by OSHA or UBC.
4.4.2.16.7 FABRICATIONS AND ERECTION

Fabrication and erection shall be in accordance with the applicable provisions
of the AISC Manual of Steel Construction (latest edition) and the following:
SHOP CONNECTIONS
All shop connections shall be made by welding or with bolts.
Gallery members connecting to existing work or to steel work by others shall be
welded. For welding requirements, aforementioned particular Clause shall be
applicable. All other gallery work shall be bolted. For bolted connection
requirements, previous corresponding Clause shall be applied.
Welded connections shall conform to Tables III and IV, "Framed Beam
Connections", of the AISC Manual, using E70XX electrodes unless otherwise
indicated.
The connection angle length shall be the maximum for each size beam.
Bolted connections shall conform to Table IIA, "Framed Beam Connections", of
the AISC Manual, using double angle connections with minimum 19 mm
diameter bolts of ASTM A325 Type 1 for friction type connections unless
otherwise indicated. Number of bolts and connection angle length shall be the
maximum for each size beam. The minimum projection of the installed bolt
beyond the nut shall be 6 mm.
BEARING PLATES
Beams beared on masonry or concrete work shall be provided with bearing
plates and clip angles.
FABRICATION
Structures shall be plumbed or leveled such that the deviations for the
complete work would not exceed the requirements of the AISC Code of
Standard Practice. Erection drawings shall be marked accordingly.
WELDING
Welding shall be in accordance with the applicable provisions of the AISC
Manual, AWS DIA, "Structural Welding Code” and Specification Welding in Steel
structures.

BOOK III
4.4.2.16.8 CLEANING AND PAINTING

Shop cleaning and painting of gallery steel shall be in accordance with the
Technical Specification for Prime Coat and Shop finish painting.
The field finish coat of paint for surfaces other than grating, ladder stringers
and bar rungs shall be applied per Technical Specification for Field finish
painting.
4.4.2.16.9 GALVANIZING
Grating, stair treads, ladders (except cages), floor plates and stop bars shall be
complete shop fabricated and galvanized after fabrication unless noted
otherwise. The galvanizing shall be compatible to the environmental conditions.
All parts to be galvanized shall be designed for erecting with bolts, pins, and
anchor bolts, clips etc. and shall not require field welding, field riveting, field
drilling or any operation that would damage galvanizing.
All bolts, clips, nuts, washers, anchors, stops, banding and other appurtenances
required for galvanized parts shall also be galvanized or stainless steel and shall
be furnished and installed by Contractor.
Galvanizing shall conform with the applicable requirements set forth in the
latest editions of the ASTIVI Standard Specifications Al 23, Al 5-3, A384, A385
and A386.
Bolts shall be galvanized after threading. Nuts shall be galvanized before
threading. Members shall be galvanized after punching or drilling.
Any warped or bent grating after galvanizing will be rejected and shall not be
used.
Galvanized grating shall be tested in accordance with the requirements set
forth in the latest edition of the ASTM Standard Specification A239.
The Contractor will be requested to regalvanize all gallery work which has its
galvanizing damaged. If it would necessary to alter any galvanized stair treads
or grating in the field, such work shall be implemented before installation at no
cost to the Owner.

Quality assurance/quality control shall conform to the requirements in Book II.
The quality control procedures and documentation shall include but not be
limited to the following
 Welding.
 Nondestructive testing.
 Packaging and shipping.
 Shop test procedures.
 Cleaning, painting and galvanizing.

BOOK III
4.4.2.17 ANCHOR BOLT

The scope of anchor bolts shall include anchor bolts required for structural
steel, gallery steel, auxiliary steel, equipment bases etc. as applicable to
Contractor's work as indicated in Book II, refers to "Summary of Work", and as
specified herein.
The Contractor shall design, manufacture, test, supply and install all anchor
bolts.
All anchor bolts including templates and bolt setting diagrams shall be shipped
to the Site early to meet the Schedule of anchor bolt setting in concrete
foundation.
Anchor bolts, nuts, washers and anchor bolt sleeves shall conform to the
applicable requirements of this specification and the Standard drawings.
Anchor bolts, nuts and washers shall be galvanised in conformance with ASTM
Specification A 153.

The codes and standards of the following organizations extracted from Book II,
refers to "Codes and Standards" are specifically applicable to the design,
ANSI ......… American National Standards Institute
ASTM …..... American Society for Testing and Material

and Documentation the provision of section “Submittals” of this specifications
shall apply.
The quality control procedures and documentation shall be submitted for
owner’s approval include but not be limited to the following:
 Welding
 Non-destructive testing
 Packaging and shipping
 Shop test procedures
 Cleaning and painting

BOOK III
Mill Test Report: Two copies of the mill test report, as required by the
applicable codes standards, shall be submitted by Contractor to the Owner for
his review.
4.4.2.17.5 MATERIAL FOR ANCHOR BOLTS, NUTS AND WASHERS

Nominal: ASTM A36 for threaded rods and ASTM A307 for headed bolts and for
all nuts.
High Strength: ASTM A193, Grade B7 for threaded rods and headed bolts, with
ASTM A194, Grade 2 ANSI Series nuts and ASTM A325 for washers. Hardened
washers shall be provided with high strength anchor bolts.
Bolts and nuts shall be of the coarse-thread series. Bolts shall have 2A
tolerances and nuts shall have 2B tolerances. Bolts shall conform to ANSI B l .1.
Nuts shall be heavy semi finished hexagon nuts conforming to ANSI B18.2.2.
REPORTS AND CERTIFICATION

Mill Test Report: Two copies of the mill test report, as required by the
applicable Codes or Standards, shall be submitted by the Contractor to the
Owner.
4.4.2.17.6 ANCHOR BOLT SLEEVES

Anchor bolt sleeves shall be made of standard weight steel pipe conforming to
ASTM A 120 or made of polyethylene plastic.
Plastic Plugs shall be provided at top of sleeves for anchor bolts with pipe
sleeves. Plugs shall have center opening of 3 mm smaller in diameter than bolt
size to ensure weather tight fit. Openings shall be shop or field punched or
drilled. Plugs shall be maintained until the foundation is prepared for grouting
prior to setting base plates and/or equipment.
4.4.2.17.7 SETTING
Templates shall be provided for all anchor bolts. Templates shall be carefully
designed and constructed with sufficient thickness and material rigidity in order
to hold the bolts to line and elevation as set.
Anchor bolts shall be accurately located and set to line and elevation before
concrete pouring and the its position accuracy shall be maintained throughout
the placing and finishing of concrete.
Column anchor bolts will be erected with the following tolerances:
Vertical Tolerance : 0 – 5 mm
Horizontal Tolerance :

BOOK III
 Individual Anchor Bolts : ± 3 mm

 Anchor Bolt Group : ± 6 mm.
Equipment anchor bolts shall be set to the tolerances under the supervision of
the Contractor. The Contractor shall specify the tolerances required in the
anchor bolt setting along with the bid of the offered equipment.
Heating of any anchor bolt in the field for bending or other purposes will not be
permitted, except that nuts for threaded rods (A36) or headed bolts (A307) may
be tack welded to the plate washers used for embedment in concrete.
Anchor bolt threads shall be protected against any damage. Damaged anchor
bolts shall be repaired or replaced to the satisfaction of the Owner.
Anchor bolt for vibrating equipment and carry uplift force shall not use any
block-outs. At least 150 mm of concrete shall be placed around the block out
used for other foundations.
Non-shrink Groute shall only be used in anchor bolts. Concrete mixes
(regardless of any additives) in lieu of nonshrink grout are unacceptable.
4.4.2.17.8 COATING AND PROTECTION

All anchor bolts shall be coated and protected with antirust compound suitable
for the environmental conditions prior to shipment.

BOOK III
4.4.2.18 CONCRETE EXPANSION ANCHOR WORKS

Electrical panels, motor control centres, control panels, instruments, conduits,
cable tray hangers, minor field routed pipe hangers, tanks, galleries, ladders
stairs and other minor non vibratory equipment, structures and piping
mounted on concrete floors and walls may be fastened with the concrete
expansion anchors suitable for the Site environmental conditions and shall be
designed, furnished and installed by the Contractor. The Contractor's drawings
shall clearly indicate all concrete expansion anchors used in his work. Concrete
expansion anchor will not be permitted for any vibrating equipment.

Contractor shall fully comply with the Project Quality Assurance/Quality
Control Requirements. For submitting Quality Assurance/Quality Control
Procedures and Documentation the provision of clause “Submittals” of this
specification shall apply.
After the contract signed, the contractor shall furnish complete and
comprehensive data or specification regarding the material of his proposed
anchor bolts for the Owner’s approval.
Test data and reports of the quality control procedures and documentation as
specified below.
 Non-destructive testing.
 Packaging and shipping.
 Test procedures.
4.4.2.18.4 DEFINITIONS
For all expansion anchors, the following terms, when used in this specification
or on the Contractor's design drawings, shall have the following meanings:
SLEEVE TYPE EXPANSION ANCHOR

A split expansion shield and a threaded stud bolt with cone expander.
WEDGE TYPE EXPANSION ANCHOR

A split expansion ring (or a separate expansion wedge pair) and a threaded stud
bolt with integral cone expander (or taper expander).

BOOK III
4.4.2.18.5 MATERIAL
TYPE AND FINISH OF MATERIALS

Concrete expansion anchors and accessories shall be made of carbon steel with
zinc plated finish conforming to U.S. Federal Specification QQ-Z-325C or
approved equal. Stainless steel may be used in place of this zinc coated carbon
steel.
STRENGTH OF MATERIALS
The material shall have a minimum yield strength of 4,220 kg per sq. cm for
wedge type anchors, and 3,515 kg per sq. cm for sleeve type anchors. The
material shall have a minimum tensile strength of 5,270 kg per sq. cm for other
anchor types.
CROSS SECTIONAL AREAS

The smallest cross sectional area of the stud bolt of an expansion anchor shall
not be less than the cross sectional area at the thread rod.
SIZE LIMITS
The size limits for expansion anchors shall be as follows: (All sizes of bolt for
sleeve and wedge type anchors shall be shown on The Contractor's drawings).
Sleeve Type: 6 mm through 15-mm diameters of stud bolts.
Wedge Type: 6 mm through 25-mm diameters of stud bolts.
4.4.2.18.6 INSTALLATION
GENERAL PROVISIONS
All concrete expansion anchors shall be installed in accordance with the
manufacturer's specifications and recommendations and the requirements of
this Specification. In case of conflict, the requirements of this specification shall
govern. The locations where expansion anchors will be installed and the sizes of
these anchors shall be as indicated on Contractor's design drawings.
The minimum effective embedded length, spacing and edge distance for
expansion anchors shall conform to the latest code and standard unless
otherwise indicated in the Bid Drawing. The minimum projection of the
threaded part of a bolt beyond the nut shall be 6 mm after complete anchor
installation. The projection over 6 mm shall not be removed without the
consent of The Owner.
The Contractor shall determine the overall anchor length and the hole depth
required such that the specified minimum effective embedded length and bolt
projection can be obtained.

BOOK III
Holes for the anchors may be drilled through hardened grout for finish
concrete, but the effective embedded length shall be determined from the
surface of the rough concrete. Also, such holes may be drilled through surface
repaired concrete, but the effective embedded length, anchor spacing and
edge distance shall be determined in accordance with latest code and standard.
Holes shall not be drilled through grout nor concrete which has not completely
hardened; grout or concrete shall not be placed around untightened anchors.
Reuse of expansion anchors will not be permitted.
Welding on expansion anchors will not be permitted.
For anchors installed in holes drilled through surface repaired concrete, the
dimension (L) given in above clause shall be increased.
Under a certain condition, the minimum effective embedded lengths, spacing
and edge distance shall be adjusted as follows:
When two anchors of different diameters are installed adjacent to each other,
the dimension of minimum spacing ("S") shall be the average of the two "S"
dimensions for each diameters respectively.
If dimensions of minimum edge distance (ED), minimum edge distance to an
embedded sleeve (ES) and the minimum spacing (S) cannot be maintained
between two anchor assemblies, the allowable erection tolerance indicated on
the standard drawings shall be used to resolve the problem. If the problem
involves anchors installed by two different contractors, their erection
tolerances shall be used, or the Owner shall be notified for a resolution.
Minimum distance from an anchor to an embedded steel plate shall equal S.
Unless otherwise indicated, no expansion anchor shall be installed at the
following locations:
At the bottom of a concrete beam; and at the top and sides of the concrete
beam, at each end within a clear distance equal to 1/4 clear span of the beam.
At the bottom of concrete slabs on metal deck, at the ribs of the deck.
4.4.2.19 METAL DECKING WORK
4.4.2.19.1 GENERAL
This specification covers the requirements for metal decking as formwork for
cast-in-place concrete floors and roofs.
Metal decking work shall include Contractor's detail designing, fabricating,
furnishing, installing and inspecting of the Work and shall conform to the
requirements of this specification.
Accessories for metal decking shall include but not limited to the following:
- All fasteners.
- Closures, including the following:

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- End closures
- Side closures
- Column closures
- Reinforcements under metal decking at columns and framed openings,
including miscellaneous structural steel as required for the support of the metal
deck at sleeves and unframed openings shall be cut through the deck prior to
placing of the concrete.
- Other accessories as required

The Contractor shall comply with the requirements of Book II refers to “Codes
and Standards”.
The codes and standards of the following organizations extracted from Book II
refers to “Codes and Standards” are specifically applicable to the design,
AISI ............................................... American Iron and Steel Institute
ANSI ............................................. American National Standards Institute
ASTM ........................................... American Society for Testing and Materials
SDI……..……………………………..……….Steel Deck Institute. U.S.A

The Contractor shall fully comply with the Project Quality Assurance/Quality
Procedures and Documentation the provision of clause “Submittals” of this
specifications shall apply.
comprehensive data on material specification regarding all component and
accessories of his propose system for the Owner’s approval.
Test data and report and the quality control procedures and documentation
shall be submitted to the owner for review.

BOOK III
4.4.2.19.5 DESIGN
DECK TYPES
Deck type and size shall be designed and detailed by the Contractor and shall
be used only for formwork for cast-in-place concrete. The deck shall be suitable
for the span and the construction loads.
The Contractor is allowed to consider the deck as part of reinforcing steel for
the concrete slab.
WELDS, FASTENERS AND OTHER ACCESSORIES

Welds, fasteners and other accessories shall be designed and detailed by the
Contractor in accordance with the applicable requirements of AISI Specification
for the Design of Cold-Formed Steel Structural Members and SDI Design Manual
for Composite Decks, Form Decks and Roof Decks, and the requirements of the
Specification for Welding in Steel Construction, unless otherwise indicated on
the Contractor's design drawings.
CONSTRUCTION LOADS
Decks acting as formwork for cast-in-place concrete shall be designed by the
Contractor for the concrete wet weight plus a minimum 100 kg/m² of
construction live loads.
The Contractor shall be fully responsible for any failure of the decking work
caused by miss conduct of the Contractor.
4.4.2.19.6 STORAGE
All metal decking material, component, fasteners and other accessories shall be
stored dry, off the ground and under cover, in a satisfactory manner.
Contractor shall responsible for storing of the materials in such a manner as to
preclude damages, deterioration, etc. All cost for such protection shall be
included in the contract price.
4.4.2.19.7 MATERIAL
SHEET MATERIAL
ASTM A446, Grade A (minimum yield strength 2320 kg per sq. cm) or 320 MPa.
FINISH
Hot-dip galvanized, ASTM A525, Coating Designation G90 (minimum).
4.4.2.19.8 FABRICATION AND INSTALLATION

BOOK III
GENERAL PROVISIONS
Metal decking, including fasteners and all other accessories, shall be fabricated
and installed in accordance with the requirements of this Clause, applicable AISI
and SDI Specifications and Standards, and in strict accordance with
manufacturer's printed instructions unless otherwise indicated.
DECK POSITION
For cast-in-place concrete slabs, metal decks shall be installed in inverted
position unless otherwise indicated.
OPENING
No openings through deck shall be cut before the concrete is placed and
hardened.
Where the span of metal deck for cast-in-place concrete slabs is parallel to and
directly supported by steel beams, provisions shall be made for full bearing of
the rib bottom on steel beams, or the deck shall be cut and side closures is
provided. If side closures are provided to form a rib bottom, the area of the rib
profile formed shall be at least equal to the area of the deck rib profile.
ALIGNMENT
Metal decking for cast-in-place concrete slabs shall be installed so that the ribs
line up to permit continuity of bottom reinforcing bars.
CLOSURES
Metal decking formwork for cast-in-place concrete roofs or floors shall be
provided with specific closures, with provisions for reinforcing bars to pass
through, and to prevent leakage of concrete during placement at the following
locations:
- Penetrations through metal decking by structural steel or other members.
- Ends or discontinuities of metal decking.
- Perimeters of openings and cants in metal decking.
- All others as indicated on the Contractor's design drawings.
VENTILATION
For metal decking formwork for cast-in-place concrete roofs only, ventilating
clips or suitable openings shall be provided to release the moisture between
the concrete and the metal decking.
FIELD CUTTING FOR OPENINGS

Shall be performed by sawing or nipping; the use of flame cutting, welding
electrodes or chiselling will not be permitted.

BOOK III
FASTENING
All metal decks shall be fastened to every supporting structural steel member.
Where the ribs of the deck are perpendicular to the supporting steel beams
and if the rib spacing of the deck is less than 300 mm, metal deck shall be
fastened at the bottom of every other rib. If the rib spacing is 300 mm or
greater, metal deck shall be fastened at the bottom of every rib.
All ends or butt ends of metal decking shall be fastened to the supporting
structural members.
The side laps of metal decking shall be fastened at not more than 915 mm on
centers.
When fusion welds are used for fastening, they shall have diameters of not
less than 19 mm and shall be free of sharp points or edges.
Where the ribs of metal deck are parallel to and directly supported by steel
beams, the bottom of ribs or side closures shall be fastened to steel beams
with 19 mm diameter fusion welds at a maximum of 915 mm on centers.
TEMPORARY SUPPORTS
The Contractor shall be responsible for designing, furnishing, installing and
removing any temporary supports required for the additional construction
loads resulting from his work.
FIELD TOUCH-UP PAINTING

Field cut edges, scratches etc. in metal decks shall be field touch-up painted
with one coat of zinc-rich paint comparable with shop galvanizing.

BOOK III
4.4.2.20 WELDING IN STEEL STRUCTURES

All welding for steel construction shall conform to the requirements of this
section and shall be applicable to Contractor's work included in Book II,
Subsection "Summary of Work".
Welding covered in this Specification shall include shop and field welding of the
following, as indicated in various technical specifications included with the bid
of offer document or as required for Contractor's work:
Structural steel, galleries, embedded steel, auxiliary steel and miscellaneous
steel, including pile splices.
Welding studs.
All other work as indicated.

The Contractor shall comply with the requirements of Book II, Subsection
"Codes and Standards".
The codes and standards of the following organizations extracted from Book II,
Subsection "Codes and Standards" are specifically applicable to the design,
ASTM ............. American Society for Testing and Materials.
AWS ............... American Welding Society.
GENERAL PROVISIONS
All materials shall conform to the requirements of Book II, Subsection
"Summary of Work" unless otherwise indicated in the Bid of offer Document
STUD WELDING MATERIAL

Materials for stud welding shall conform to the requirements of AWS D1.1.
ELECTRODES
Except as otherwise specified, all welding electrodes shall conform to the
applicable provisions of the AWS Structural Welding Code AWS D1.1 For steels
with special properties, such as resistance to brittle fracture, corrosion-resistant
steels, stainless clad steels and stainless steels, the recommendations of both
the steel and electrode manufacturers shall be secured for each specified steel
and each specific use.

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4.4.2.20.4 DETAILED REQUIREMENTS

Complete penetration welds shall be used for all groove welding unless
otherwise specifically indicated. All double welded joints shall be back gouged
to sound metal before welding the second side.
Fillet welds across flanges of any steel member will not be permitted unless
specific flange area is indicated on Contractor's design drawings; any
undercutting or damage which will reduce the strength will not be permitted.
Preheat and interpass temperatures shall conform to the requirements of AWS
D1.1 and shall be as required for the thickest part of the base metal being
welded.
The maximum preheat and interpass temperature for austenitic stainless steel
shall be 175 OC.
Except for stainless clad steel joints or stainless to carbon steel joints, the
austenitic stainless steel filler metal used shall contain a minimum of 5% ferrite.
The use of wide welds to overcome poor fit-up will not be permitted.
Surfaces and edges to be welded shall be properly prepared according to AWS
1.1, prior to welding. Unless specifically reviewed by the Owner, the only
coating which does not have to be removed before welding is deoxaluminite.
In the welding of stainless clad steel, the carbon steel side shall be welded first.
The following materials shall not be welded unless otherwise indicated:

 Steel reinforcing bar (rebar).
 Nuts and bolts.
 Any carbon or alloy steels containing more than 0.35% carbon.
The filling in by welding of unused boltholes is not permitted
All welding including stud welding shall conform to the requirements of AWS
D1.1 unless otherwise indicated. Welding shall be performed using Shielded
Metal Arc or Submerged Arc Welding Process.
The following welding processes are specifically prohibited:
 Fuel Gas
 Electro slag
 Electro gas - Gas Metal-Arc (short circuiting transfer)
 Flux Cored-Arc (without external gas shielding),

BOOK III
4.4.2.20.6 INSPECTION AND EXAMINATION
GENERAL PROVISIONS
All welding shall be inspected and examined by Contractor's AWS certified
welding inspector in accordance with AWS D1.1 unless otherwise indicated in
the bid or offer document. Inspection and examination reports shall be
submitted to the Owner.
Liquid penetrant for all non destructive examination shall be environmental
friendly and equipped with Corrosion inhibitor.
Each welding operator shall stamp his identification mark or number on all of
his work (except on handrails), as requested by inspector.
In case the inspector believe that a welding operator's work does not meet the
required standards he may prohibit the respective welding operator from
continuing his works, pending results of requalification tests.
Owners may, during the course of the work, review various phases of the work
performed by Contractor, at Contractor's plant and at the site, for compliance
with all requirements of this specification. Owner reserves the right to approve
facilities used for inspection and examination.
Radiographic inspection shall be performed by inspecting laboratory retained
by Contractor. Such inspection will conform to the applicable requirements of
AWS D1.1.
EXTENT AND METHODS OF EXAMINATION

The extent and methods of nondestructive examination for welding required
for all work shall conform to the requirements of Table 4.4.2.20-1, and all welds
shall be 100 % visually inspected.

BOOK III
Table 4.4.2.20 - 1
Extent and Methods of Nondestructive Examination for

Welding in Steel Construction for All Work
Item Extent of Method of Remarks

Examination Examination
1. Structural Steel
1.1 Built-up Girders and 100% Radiograph Welds impractical to be radio

Columns: graphed shall be examined
a. All complete pene- 100% by both Ultrasonic and
tration groove welds. either Magnetic Particle or
Liquid Penetrate methods.
b. Main columns T-joints 100% Ultrasonic
c. All other weld joining
flanges, webs, plates,
stiffeners, 100% Visual
connections, base
plate details etc.
1.2 Rolled Beams and

columns:
a. All complete pene- 100% Radiograph Same as 1.1a

tration groove welds.
b. All other welds 100% Visual

joining cover plates
stiffeners,
connections, base
plate details etc.

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Table 4.4.2.20 – 1 ( continue )


2. Tank, Duct Work etc.
2.1 All complete pene-

tration groove
welds a. 100% for the first Radiograph a.Welds impractical to be radio
3 m. of welds, in graphed shall be examined by
horizontal and both Ultrasonic and either
vertical welds Magnetic Particle or Liquid
respectively, for Penetrate Methods
each welder or
welding operat-
or. (Any weld
fails to meet the
acceptance
standard shall be
replaced and
reexamined
100%)
b. Thereafter, 1%: 1
spot examina-
tion 30 cm long
for each addi-
tional 33 m of
welds (If any
spot fails to
meet the
acceptance
standard, 2
additional spots
shall be
examined at
locations at
least 30 cm on
each side from
failure spot. If
either of the 2
additional

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standard the entire

unit of the 33 m
welds shall be
completely
examined).
2.2 Fillet welds 100% Visual
between plates
and stiffeners
2.3 Welds for

supporting
Same as Item 1 Same as Item 1 Same as Item 1
Structural Steel
3. Welding Studs
3.1 Composite Beam a. The first two studs Additional acceptance

Bend Test
Shear Connectors welded on each beam, standard indicated in AWS
through metal deck D1.1.
where applicable, after
being allowed to cool,
shall be bent to an angle
of 30 from their original
axes by being struck
with a hammer. (If
failure occurs in either
stud, the procedure
shall be Corrected and
welding shall be
continued on separate
plates until two
consecutive studs are
tested and found to be
satisfactory).

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b. 100% of all studs Visual Any stud which does not show a
3600 weld under visual
examination is subject to the bend
test
3.2 All other studs a. Before the start Bend Test AdditionaAdditonal acceptance
of welding
standars indicated in AWS D1.1
operations on
each day for
each welding
gun and associa-
ted power
source two studs
shall be welded
to separate
material in the
same general
position (flat,
vertical,
overhead
sloping) and of
similar thickness
and material.
After being
allowed to cool,
each stud shall
be bent to an
angle of 300 from
its original axis
with a hammer.
(If failure occurs
in either stud,
the procedure
shall be
corrected and
repeated until
two

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consecutive studs
have been
successfully welded
and tested
any studs are welded
to the member).
Any stud which does not
show a 3600 weld under
b. 100 % of all studs Visual visual examination is
subject to the bend or
torque test.
c. At least one stud in Bend Test (Torque Additional acceptance
every 100 shall be bent Test for Threaded standard indicated in AWS
to an angle of 150 from Studs) D1.1
its original axis by being
struck with a hammer.
If threaded, the stud
shall be torque tested
with a calibrated
torque wrench. (If the
stud fails, the
procedure shall be
checked in accordance
with (a) above, and two
more existing studs
shall be bend or torque
tested. If either of
these two studs fails, all
the studs represented
the tests shall be
tested).
Notes: 1. Extent of examination (1%, etc.) shall be applied equally to shop

welding and field welding.
2. Magnetic Particle and liquid penetrate method are for ferrite
materials, and liquid Penetrate method is for austenitic materials.

BOOK III
REQUIREMENTS FOR EXAMINATION

Nondestructive examination for all welding works shall conform to the
following requirements unless otherwise indicated:
Radiographic Examination
Radiographic examination shall conform to the requirements of this section and
to all applicable requirements to the following:
a. AWS : AWS D1.1.
b. ASME : E94 and E142
X-Ray or Gamma Ray shall be used in radiography and the quality level shall be 2-
2T as specified in ASTM E142, unless otherwise indicated.
a. Radiographic Films
a.1 The double film technique shall be used to obtain two films at each
radiographic location. Single film viewing shall be used for interpretation.
a.2 Radiographic films shall be of fine grain, high contrast, Type 1 or 2. Lead
intensifying screens shall be used. Film density shall 2.0 minimums for
single viewing or 2.6 minimums for composite viewing of a double film
exposure. Each film for composite viewing shall have a minimum density
of 1.3 as determined by either film density strips or densitometry. The
maximum density shall be 3.8 for either single or composite viewing. The
quality of film and the steps of processing shall be such as to retain the
best possible definition during storage.
a.3 Any films not acceptable to Owner will be rejected; and Contractor shall
repair and radiograph again these portions of the work covered by these
films until satisfactory results are obtained, at no cost to the Owner.
Ultrasonic Examination
Shall conform to all applicable requirements or the following standard:
AWS : AWS D1.1
ASTM : E164
Magnetic Particle Examination

Shall conform to all applicable requirements or the following standards:
AWS : AWS D1.1
ASTM : E709
Liquid Penetrate Examination

Shall conform to all applicable requirements of the following standards:
AWS : AWS D1.1
ASTM : E165

BOOK III
Visual Examination
Shall conform to all applicable requirements of AWS D1.1.
ACCEPTANCE
Welds meeting the acceptance standards indicated in AWS D1.1 will be
accepted.
Any welds failing to meet the indicated in AWS D1.1 Standard shall be repaired
or replaced and reexamined 100% until they meet the requirements.
Contractor shall perform additional examination in accordance with Table
4.4.2.20 – 1 and AWS D1.1, with no additional cost to Owner.
Acceptance of work by the Owner shall not relieve the Contractor from full
responsibility for the work.
4.4.2.20.7 QUALITY ASSURANCE PROGRAM
GENERAL PROCEDURE
Contractor shall submit, after award of contract, two copies of General
Procedures that he (and his subcontractors, if any) will follow for all welding for
the work.
The procedures shall include, but shall not be limited to, all of the following:
 Selection of welding methods, equipment and materials.
 Control of personnel proposed to be used for this work, and quality control
of workmanship.
 Control of Contractor's welding inspection and examination.
 Types of weld and welded joints.
 Weld profiles and weld sizes.
 Size, classification and material specification for all electrodes proposed for
use
 Methods of groove and edge preparation
 Lengths and spacing of intermittent welds.
 Method and/or sequence of welding to avoid distortion and to minimize
residual shrinkage stresses
 Number and travel speed of passes for each weld
 Procedures for preheating base metals, and minimum preheat and
interpass temperatures required
 Stud welding, including welding shear connector studs to beams through
metal deck.

BOOK III
QUALIFICATION OF WELDERS AND VVELDING OPERATORS

All welders and welding operators employed on any welding work shall be
qualified by an approved testing laboratory in accordance with AWS D1.1.
Laboratories for testing welders and welding operators shall be of
recognized standing. All costs in connection with this qualification shall be
borne by the Contractor.
The qualifications (including requalification, if any) test reports and
certificates shall be available before the start of welding and shall be submitted
for information to Owner upon request.
QUALITY ASSURANCE/QUALITY CONTROL (QA/QC)

Quality assurance/Quality control shall conform to the requirements of Part
Book II refers to ‘Quality Assurance/Quality Control’.
The quality control procedures shall include but not be limited to the following:
- Welding
- Nondestructive testing
- Shop test & inspection procedures
The quality control documentation shall include but not be limited to the
following:
4.4.2.20.8 WELDS IMPRACTICAL TO RADIOGRAPH

Welds which are considered impractical to be radiographed are those where
the joint detail does not permit radiographic examination or the radiography
will not yield meaningful results. The absence of suitable radiographic
equipment shall not be justification for the alternate examination. Examination
by the alternate methods shall require permission of the Owner.
4.4.2.21 PRIME COAT AND SHOP FINISH PAINTING

The Contractor shall paint all structures, equipment, piping and other
accessories provided within the scope of Contract with the prime coat and shop
painting in accordance with the requirements of this specifications.
WORK INCLUDED

BOOK III
Painting for structural steel, gallery steel, miscellaneous steel, equipment and
similar ferrous metals are as follow:
Supply of all material labour and equipment to perform the indicated work
Performing of surface preparation for shop and field painting.
Applying of coating material.
Inspecting each phase of the work.
Painting specified herein for structural steel, Gallery Steel, Miscellaneous Steel,
Auxiliary Steel, equipment piping & ducting, and Similar Ferrous Metals shall
include:
 Surface preparation (shop and field)
 Shop prime coat painting
 Shop or field second coat painting for inaccessible surfaces
 Shop second coat painting
 Field prime coat painting
 Field second painting and field touch up painting
 Field Touch-up for Galvanizing
 Painting of Aluminium Contact Surfaces
The extent of prime coat and related painting shall refer to ‘Field Finish
Painting’ in this Technical Specification unless otherwise indicated.
WORK NOT INCLUDED

Internal linings
Fireproofing
Copper and similar non ferrous metals
Stainless steel
Aluminium (except on contact surfaces to prevent electrolytic attack).
Shall comply with the requirements of the applicable codes and standards
published by the following organizations:
SSPC Steel Structures Painting Council, USA
UBC Uniform Building Code of USA
AISC American Institute of Steel Construction
SII Standard Industri Indonesia
Shall conform especially to the applicable provisions of the following codes and
standards:
SSPC – SP 1 – [63(1971)] Solvent Cleaning
BOOK III
SSPC – SP 2 – [63(1963)] Hand Tool Cleaning

SSPC – SP 3 – [63(1963)] Power Tool Cleaning
SSPC – SP 6 – [63(1963)] Commercial Blast Cleaning
SSPC – SP 10 – [63(1963)] Near - White Blast Cleaning
SPLN 104 – 1993 Colour Standard
SPLN 107 – 1993 Piping and Tank Colour for Power Plant

Requirements. For Submitting Quality Assurance/Quality Control Procedures
and Documentation the provision refers to “Submittals” of this specification
shall apply.
4.4.2.22 SUBMITTALS
PROCEDURES
Contractor shall submit at least:
A List of Coating Materials to be used, each identified by a manufacturer, brand
name, product member and paint manufacturer’s instruction.
Shop cleaning and painting procedures

After award of Contract, but before ordering materials, Contractor shall submit
for review of Owner all of the following samples:
a. Colour Panels: Approximately 30 cm x 30 cm in size. Submit panels for each
finish colour to be used including colours for all undercoats.
b. Colour Chips: Manufacturer’s standard, but not less than approximately 25
cm x 50 cm in size. Submit chips for each finish colour to be used including
colour for all undercoats.
QUALITY CONTROL DOCUMENTATION

Contractor shall keep documentation but not limited to the following:
- Packaging and shipping documents
- Shop cleaning and painting procedures
- Field list and inspection procedures
4.4.2.22.1 GENERAL REQUIREMENT

BOOK III
The intent of the requirement of this specification for prime coat and shop
painting is to ensure thorough and proper surface preparation, and careful and
complete paint application to all exposed areas of surface specified to be prime
coat and shop painted in this specification, and observing strictly the following
procedures:
As the works will be located in a tropical area and near the sea, the paint shall
be of a type, which can best resist tropical conditions and salty air environment.
The contractor shall thoroughly clean, prime coat where required and/or touch
up the entire work, or a substantial portion thereof, before starting the
intermediate coat of paint. However, work shall proceed in a pattern that will
keep to a minimum the necessity for recleaning the touch-up work already
done or the intermediate coat already applied. Cleaning shall be done in such a
manner as not to liberate dust and shall be approved by the Owner. No
intermediate coats shall be applied until the cleaning, prime coating and/or
touch-up work has been approved by the Owner.
DEFINITIONS
CONTACT SURFACES
Surfaces of ferrous metals which are permanently in contact with other
surfaces of the same materials after shop assembly or field erection, such as
contact surfaces at cover plates or connection angles on columns, beams and
girders, etc.
INACCESSIBLE SURFACES
Surface of ferrous metals, which are made inaccessible for painting (other than
contact surfaces) after shop assembly or field erection of the steel or metals,
such as the surfaces in a member composed of two angles back to back with
guessed plates between them, where these surfaces will be exposed to the
weather for their service life.
DFT
Dry film thickness shall be expressed in microns.

BOOK III
GENERAL PROVISIONS
Paints, including types, colours, products and manufacturers shall be as
specified in ‘Field Finish Painting’ or approved equal and shall be suitable for
the environmental conditions. Use of all components of the same
manufacturer's system is mandatory.
However, where the Contractor is unable to comply with this requirement, he
must ensure that the paint to be used is compatible and equal in quality to the
paint already supplied. Details must be supplied to the Owner for approval
before implementing the above.
All operations covered by this section shall be adequately controlled and
supervised by adequately skilled operators.
The Contractor shall submit for approval the method of painting and surface
preparation he proposes to adopt in carrying out the works together with the
list of the type of equipment used and the locations where the proposed
operations would be carried out. The Contractor shall keep the Owner informed
of the proposed programme of operations and if called upon to do so he shall
assist the Owner with inspections at all reasonable time.
Paints shall be delivered to the place of use in unbroken containers bearing the
paint manufacturer's brand name and identification number.
Each coat of paint shall be of a different discernible colour.
Most of the surfaces shall receive the field finish paint.
Mating and contact surfaces except faying surfaces for friction bolting shall be
protected from corrosion by ensuring that the two surfaces brought into
contact with each other are prepared and painted with the full specified
system. Those surfaces which are brought together in the shop shall be
brought together while the last coat of paint is still wet.
Unless otherwise specified, surfaces which are to be friction bolted shall be
prepared as for surfaces would be painted but shall receive no paint coating. All
corrosion and any products which would affect the efficiency of the joint, in
particular, grit, grease, and oil shall be removed from the surfaces prior to
bolting together. The edges of such joints shall be suitably sealed with paint
coatings.
RUST INHIBITING TEMPORARY PROTECTION

Steel surfaces left unpainted in the shop shall be coated with a corrosive-
resistant material.

BOOK III
4.4.2.22.3 DETAILED REQUIREMENTS FOR PAINTING OF STRUCTURES:
SHOP PRIME COAT PAINTING

(Including shop prime, intermediate and a third coat painting for inaccessible
surfaces and girts):
Extent of structural steel and other ferrous metal surfaces to be painted in shop
and to be left unpainted in shop, after completion of the surface preparation
specified above shall be as indicated in Table 4.4.2.21 -1.
Milled surfaces and other machine-finished surfaces shall be protected against
corrosion by using lacquer, unless otherwise indicated.
FIELD PRIME COAT PAINTING

(Including field prime, intermediate and a third coat painting for inaccessible
surfaces):
Field prime coat painting shall consist of one complete coat of paint applied in
the field to all bare structural steel or other ferrous metal surfaces after
specified surface preparation has been completed.
For inaccessible surfaces after field erection, a third coat of paint shall be
provided conforming to Table 4.4.2.21 -1.
FIELD TOUCH-UP PAINTING

Field touch-up painting shall consist of one prime coat and one intermediate
coat of paint applied to the following surfaces after completion of specified
surface preparation.
Surfaces where the shop coat of paint shall be marked, scratched or otherwise
might be damaged, due to shipping, handling, erection, installation, weathering
etc.
Bolt heads, nuts, washers, and adjacent surfaces left unpainted in the shop.
Surfaces of field welds and adjacent surfaces left unpainted in the shop.
Ferrous fasteners which are not otherwise protected.
Exposed fabrication, erection of shipping marks shall be cleaned off and the
areas shall be touch-up painted to match the adjacent surfaces.
For any surfaces which have received two coats, field touch-up painting shall
consist of two coats also as indicated in Table 4.4.2.21 -2.
COLOUR CODE
Colour Code shall be in accordance subject to Owner approval.
FIELD TOUCH-UP FOR GALVANIZING

The following shall be touched-up with one coat of zinc-rich paint:

BOOK III
Areas of galvanized surfaces (furnished and/or installed by Contractor) which

have been marred due to handling, shipping, erection, weathering, etc.
Field welds made on hot-dipped galvanized surfaces.
Paints Systems as indicated in Table 4.4.2.21 -2 shall be used.
PAINTING OF ALUMINUM CONTACT SURFACES

The intent of this requirements is that either the aluminum surfaces to be in
contact with other surfaces, or other surfaces to be in contact with aluminum,
shall have two acceptable complete coats of paint at the time the aluminum is
installed.
Such painting shall be provided as follows:
Aluminium To Be In Contact With Ferrous Metals

To prevent galvanic action between aluminium surfaces and ferrous metals
(other than galvanized steel), the surfaces of the ferrous metals to be in
contact, shall receive one field second coat of paint in addition to the shop or
field prime coat.
Paint Systems 043-C for prime coat, and 043-D for second coat as indicated in
Table 4.4.2.21 -2 shall be used.
Aluminum To Be In Contact With Non-Ferrous Metals

Where aluminium surfaces will be in contact with copper, lead or other non-
ferrous metals incompatible with aluminium, the surfaces of such metals to be
in contact, shall receive two coats of paint.
Non-ferrous metals compatible with aluminium, such as stainless steel, zinc,
white bronze, etc., to be in contact with aluminium, will not require painting.
Paint System 043-C for prime coat, and 043-D for second coat as indicated in
Table 4.4.2.21 -2 shall be used.
Aluminum To Be In Contact With Concrete And Masonry

Where aluminium surfaces would be embedded in concrete or masonry, the
aluminium surfaces shall receive two field coats of paint.
Where aluminium surfaces would be in contact with concrete or masonry the
aluminium surfaces or the surfaces of the concrete or masonry to be in contact,
shall receive two field coats of paint.
Paint System 043-F As Indicated in Table 4.4.2.21 -2, shall be used.
Surfaces may be painted with two coats of specified paints, instead of painting
the surfaces of the other materials to be in contact, where desirable, where
required, or where requested.
Paint System 043-C for prime coat and 043-D for second coat, or 043-F for both
coats, as indicated in Table 4.4.2.21 -2, shall be used.

BOOK III
4.4.2.22.4 CLEANING AND PAINTING OF EQUIPMENT AND PIPING
GENERAL
Equipment shall be divided into three categories:
Equipment except the electrical ones in different colours refers to previously
mentioned specifications which will be installed indoors and therefore would
not be exposed to the weather.
Outdoor Equipment including outdoor transformers and switchgear enclosures
which will be installed outdoor and therefore, would be exposed to the
weather.
All electrical cubicles, panels and indoor enclosures.
CLEANING AND PAINTING OF INDOOR EQUIPMENT (SEE GENERAL

PROVISIONS ABOVE)
All ferrous equipment surfaces shall be cleaned and painted as suggested
below. The Contractor shall design the paint system to be compatible with the
material to be coated, the temperature of the surfaces, service conditions and
which can best resist the tropical conditions and salty air environment.
Surface Preparation: SSPC-SP10, Near White Metal Blast Cleaning.
Shop Primer: Two component rust preventive epoxy primer at 75 to 125
microns DFT.
Equipment which is fully fabricated and assembled prior to shipment to the
construction site, can be completely painted in the shop. However, should any
equipment need to be assembled in the field which then would require major
touch-up, such equipment shall be only prime painted in the shop and the finish
paint shall be applied in the field.
CLEANING AND PAINTING OF OUTDOORS EQUIPMENT

All ferrous surfaces of such equipment shall be treated with the same painting
systems as outlined for structural steel in Table 4.4.2.21-1 and shall be finish
painted as per Technical Specification, refers to Field Finish Painting. The
complete painting system shall be applied on equipment fully fabricated and
assembled prior to shipment to the construction site.
However, should there any equipment need to be assembled in the field which
then would require major touch-up, then such equipment shall only receive
primer and intermediate coats in the shop.
CLEANING AND PAINTING OF ALL ELECTRIC EQUIPMENT CUBICLES, PANELS &

INDOOR ENCLOSURES (SEE GENERAL PROVISIONS.)

BOOK III
All ferrous equipment surfaces of the above electrical equipment unless noted
otherwise shall be cleaned and painted (prime & finish) at the manufacturing
plant per their standards. However, the paint shall be suitable for the Specified
environmental conditions.
The Contractor shall submit a detailed painting procedure for the equipment
for the approval of the Owner.
The procedure shall include description on surface preparation, painting
process and physical characteristics, application and type of paint would be
used.
Type of paint selected shall comply with a recognised International Standard.
The interior of all cubicles, panels and enclosures shall be painted with white
anti-condensation paint.
The Owner will select the colour of the finish paint.
PIPING SURFACES
Insulated Pipe Surfaces:
The surfaces shall only receive manufacturer's suggested painting for
temporary protection prior to insulation.
Un-insulated Pipe Surfaces and Instrumentation:

These surfaces where applicable, should be painted in the same way as the
equipment for indoor and outdoor exposure.
SURFACE PREPARATION
Surface preparation for painting concrete, masonry or wood which would be in
contact with aluminium shall be as specified in the manufacturer's standard.
Surface preparation for painting of all structural steel surfaces as indicated in
Table 4.4.2.21-1 and other metals, including galvanizing, aluminium etc. shall
be as follows, unless otherwise indicated:
For First Coat Painting:

a. Surface shall first be cleaned according to SSPC-SP1 Solvent Cleaning and if
required, SSPC-SP2 Hand Tool Cleaning and SSPC-SP3 Power Tool Cleaning
shall be used prior to blast cleaning.
b. Unless otherwise indicated, surfaces shall then be commercial blast
cleaned, according to requirements of Table 4.4.2.21-2, to produce a
general surface appearance corresponding to SSPC Standard Vis 1, pictorial
surface preparation standards.
c. Where specifically indicated, steel surfaces shall be Near White Blast
Cleaned, according to SSPC-SP10 with a 37.50 to 62.50 microns profile.
BOOK III
d. The blast cleaning equipment shall slightly roughen the surface to provide
an anchor pattern as recommended by the paint/coating manufacturer. The
anchor pattern shall be sharp; a polished surface will not be permitted.
e. Suitable blast cleaning equipment shall be used as recommended by the
paint/coating manufacturer.
f. Only the best quality, dry uncontaminated sand, grit, or shot shall be used
in blast cleaning. Blasting sand shall be dry and of a size recommended by
the paint/coating manufacturer. Blasting grit shall be crushed and made of
cast iron, malleable iron or synthetic grits other than sand, of a size
recommended by the paint/coating manufacturer.
g. After completion of blast cleaning in any area, all traces of sand, grit or
shot and dust shall be removed from the surfaces by using moisture and oil
free compressed air or by vacuum cleaning; brushings shall not be used.
h. Extreme care shall be exercised to avoid contaminating the blast-cleaned
surfaces with fingerprints or with detrimental material from workers'
clothes or from any other sources.
For Second Coat or Touch-Up Painting

a. Before applying the second coat paint, all surfaces shall be cleaned to
remove oil, grease, soil and other contaminants, according to SSPC-SP1
Solvent Cleaning.
b. Before applying touch-up paint, any loose mill scale, rust and paint shall be
removed, according to SSPC-SP2 Hand Tool Cleaning. If required, SSPC-SP3
Power Tool Cleaning shall be used.
Metal Patching
Should there be any requirements to patch or fill scratches or gauges in
equipment base plates, metal housing, etc., a metal putty shall be used. Metal
putty shall be applied in strict accordance with manufacturer's directions, and
shall be level and smooth after application.
PAINT APPLICATION
Conformance
Application of paint shall conform to : the requirements of SSPC Paint
Application Specification No.1 "Shop, Field and Maintenance Painting";
manufacturer's instructions and the requirements of mentioned ‘Painting Work
System’ above.
Time Restrictions
Application of the prime coat painting shall normally be made over a blast
cleaned area within 8 hours after completion of blast cleaning. This time
restriction may be modified to more or less than 8 hours, depending on the

BOOK III
temperature and humidity control exercised. The main criteria is that any rust
bloom shall form on the surface prior to the application of the prime coat. In
case any rust bloom does form, the surface shall be blast cleaned again, before
application of the prime coat.
Temperature Restrictions
Paint shall not be applied when the surrounding air temperature is below 50C,
nor when the temperature is expected to drop to 00C before the paint dries.
Paint shall not be applied to steel which has temperature of more than two
degrees below the surrounding air temperature, or which at a temperature
lower than 30C.
Paint shall not be applied to steel which is at a temperature of over 50 0C unless
the paint is specifically formulated for such application. Whenever necessary
to paint steel in hot weather, precautions shall be taken to ensure that the
specified dry film thickness of paint is achieved.
Moisture and Humidity Restrictions

Paint shall not be applied where exposed to rain, snow, fog, or mist, or when
the relative humidity is such as to cause condensation of paint on metal
surfaces due to variation in metal temperatures and surrounding air
temperatures.
All surfaces shall be perfectly dry before and while being painted and for the
next 24 hours after painting.
Method of Application
Application of paint shall primarily be made by using proper size grade of brushes,
except, where spray equipment or rollers can be used to advantage. Spray
equipment, if used, shall be accurately and fully controlled at all times in order
to prevent damage to adjacent surfaces.
In case two or more coat work is specified, the following shall apply:
a. The second coat of paint shall not be applied until the prime coat has been
completed and checked. If the second coat is applied before the check of
the prime coat, it will be assumed that the prime coat has not been applied,
and at the option of the Owner, the entire painting shall be removed and
such shall be area repainted.
b. Sufficient time for drying shall be allowed between coats.
Minimum Thickness of Paint

The prime and second coats of paint shall be applied to obtain a minimum dry
film thickness as specified in Table 4.4.2.21 -2.

BOOK III
Verification of paint thickness may be made by the Owner at this option; based
on measuring average wet film thickness, using a Wet Film Gauge. Gauges shall
be furnished by the Contractor.
The paint manufacturers shall accordingly be requested by the Contractor to
furnish the wet film thickness required, for each type of paint and method of
application, to obtain the specified dry film thickness. The wet films thickness
shall be based on applying the paint directly from the original containers
without any additional thinners.
In case the Contractor intends to use thinners, he shall inform the Owner and
the paint manufacturer of his intended method of application. The paint
manufacturer shall then re-evaluate the paint and furnish the Owner and the
Contractor with the new wet film thickness required.
Dry film thickness (DFT) may also be verified by the Owner; for verification of
the paint thickness, the dry thickness will be measured using an Elcometer
gauge or a Nordson Micro gauge. SSPC Method PA 2 will be used to determine
the DFT using such gauges.
If the required minimum dry film thickness is not attained, as determined by
the dry-film verification, additional coats of paint shall be applied to obtain the
specification of thickness.
All Work covered by this Specification will be subject to inspection by the
Owner; any work found does not in accordance with the Specification shall be
satisfactorily redone by the Contractor with no cost to the Owner.
The Owner may make random spot checks on materials, equipment etc. which
have been painted, by removing small swatches of paints to bare metal with
acetone and examining the surface with a 5x power magnifying glass to
observe the absence or presence of rust under the prime coat.
The presence of rust or rust stains under such swatches shall be a sufficient
cause for rejecting the work, and the Contractor shall repair and repaint the
work in the field at his own expense.
Each paint application such as primer coat and intermediate coat shall be free
of dry spray, overspray, pinholes, and discontinuities. Areas where such
detrimental conditions occur shall be redone by the Contractor at no cost to
the Owner before applying the next coat.

BOOK III
Table 4.4.2.21 -1 Extent of Prime Coat and Related Painting
Item Surface Painting Paint System

Preparation (see Table
(a) (b) (c) 4.4.2.21 - 2)
(d)
1. Structural and Miscellaneous
Ferrous Steel Members.
a. All surfaces including

columns, Beams, girder girt, Solvent & Near White 1. Shop prime coat 043 – A
hangers, struts, tie rods, Bleats Cleaning. of paint
plates, handrails, posts,
risers, stair stringers, 2. Shop inter-
washers etc unless mediate coat 043 – B
otherwise indicate.
b. Inaccessible Steel Surf and Solvent & Near White 1. Shop prime 043 – A for prime
Girt. Bleats Cleaning. coat and coat and 043-B for
2 .Shop interme- second coats.
diate coats of paint
c. Milled,Embedded Contact None (unless otherwise No painting (Milled
and Welded Surfaces, etc.: indicated herein) surface protected
with lacquer. All
c.1 Milled and Machined Solvent & Near White other surfaces
Surfaces (as on base Blast Cleaning. protected with
plates) antirust Compound
unless otherwise
c.2 Anchor Bolts, bolts, nuts. indicated herein)
043 – A
c.3.Embedded Surfaces. Solvent & Near White
Blast
c.4 Contact Surfaces (as 043 – A
surfaces under column 1. shop prime coat
and beam cover plates) paint.
c.5Top Flanges of Beams

and Girders to support
metal decking or Solvent & Near White 2. shop prime coat
welding studs. Blast Cleaning. paint
043-A

BOOK III
Table 4.4.2.21 -1 Extent of Prime Coat and Related Painting (continued)

(a) (b) (c) 4.4.2.21 - 2)
(d)
c.6 Welding Surfaces (as Solvent & Near 1 or 2 field touch – 043 – H for
75 mm strip on each White Blast Cleaning. up coats of prime coat, and
side of a joint to be matching paint 043 B for
field welded). second coat.
2. Stainless steel, unless None No painting

otherwise indicate.
3. Surfaces to be in contact with

aluminum; or aluminum
surfaces:
a. Surfaces of Ferrous metals Solvent & 1 shop of field 043 – C for

& non ferrous metals not Commercial Blast prime coat & 1 prime coat, and
compatible with Cleaning field second coat 043- D for
aluminium, to be in of paint for ferrous second coat.
contact with aluminium metals, and 2 coats
surfaces to be in contact of paint for non –
ferrous metals.
b. Concrete and masonry As specified in 2 field coats of 043 - F

surfaces to be in contact manufacturers paint.
with aluminium; or standards.
aluminium surfaces to be
in contact with another
structures.
4. Welded Steel Ducts Solvent Cleaning and 1 shop prime coat 043 - A
Near White Blast of paint, on
Cleaning on exterior exterior surfaces of
surfaces of the duct the duct if there is
to be painted unless no lagging outside
otherwise indicated. these surfaces.

BOOK III

(a) (b) (c) 4.4.2.21 - 2)
(d)
5. Metal Doors and Door Channel

Frames
5.1 Channel Frames Solvent & 1 prime coat, 1 043-A and 043-B
Commercial Blast intermediate coat
Cleaning. and field touch up
paint. 043-G and 043-B
5.2 Exterior Doors (Galvanized) Solvent Cleaning. 1 prime coat, 1
intermediate coat
and field touch up
paint 043 - H
5.3 Interior Doors (Sheet Metal) Solvent Cleaning and 1 prime coat
hand Tool Cleaning
6. Exposed Steel Piping for Solvent Hand – 1 prime coat, 1 043-A and 043-B
plumbing Power Tool & intermediate coat
Commercial Blast and touch – up
Cleaning. with paint, on
outside surfaces,
touch – up 75 mm
wide welding
bands.
7. Curb Angel Surfaces in contact Hand Tool Cleaning. 1 field coat. Termastic 100
with concrete (200 microns dry
film thickness).
8. Stainless Steel None No Painting
9. Electrical equipment, including, Commercial blast Prime coat, second 043 C, 043 D and
but not limited to instrument cleaning coat, third coat 043 D
enclosure, switchgear, panel,
motor control centre, trans-
former, motor and bus duct.

BOOK III

(a) (b) (c) 4.4.2.21 - 2)
(d)
10. Control Panel Commercial blast Primer coat, 043 B, 043 I and
cleaning second coat, third 043 J
coat
11. Mechanical equipment Commercial blast Primer coat 043 M

including but not limited to cleaning
pumps valves, external piping
surfaces, and conveyor
machinery
12. Surfaces of equipment and Commercial blast Primer coat 043 M

material to be insulated cleaning
13. Uninsulated equipment and Commercial blast Primer coat 043 O

material having operating or cleaning
service temperature 93C to
230C
14. Uninsulated equipment and Near white metal Primer coat 043 O
material having on service blast cleaning
temperature from 230C to
400C
15. Uninsulated equipment and Near white metal Primer coat 043 Q
material having on service blast cleaning
temperature from 400C to
540C
16. Space conditioning equipment Solvent cleaning Primer coat, 043 R, 043 K,
surface clean and dry Second coat, 043 L
third coat

BOOK III

(a) (b) (c) 4.4.2.21 - 2)
(d)
17. Flash tank :

a) Interior a) Commercial Primer coat 043 L
blast cleaning
b) Exterior b) Commercial Primer coat 043 M
blast cleaning
18. Exchanger and regeneration
Tank
a) Interior a) Commercial Rubber lining
blast cleaning
b) Exterior b) Commercial Primer coat 043 A
blast cleaning
19. Turbine lube oil storage
tank a) White metal Primer coat 043 A
a) Interior blast cleaning
b) Commercial Primer coat 043 A
b) Exterior blast cleaning
20. Closed cooling water
a) Interior a) White metal Primer coat 043 A
blast cleaning
blast cleaning
21. Blow down tank
a) Interior a) Near white Primer coat 043 A
metal blast
b) Exterior cleaning
b) Commercial Primer coat 043 M
blast cleaning
22. Air Receiver

a) Interior a) Near white blast Primer coat 043 A
cleaning
blast cleaning

BOOK III

Paint System
Item Surface Painting (see Table
Preparation 4.4.2.21 - 2)
(a) (b) (c) (d)
23. Water treatment plant caustic
storage tank
a) Interior a) White metal Primer, second 043 U, 043 X
blast cleaning coat
b) Exterior b) White metal Primer, second, 043 Y, 043 Z, 043
blast cleaning third coat Z
24. Acid storage tank
a) Interior a) Commercial Rubber lined
blast cleaning
b) Exterior b) White metal Primer, second, 043 Y, 043Z, 043Z
blast cleaning third coat
25. Desalination Plant Hydrochloric
Acid Solution Tank
a) Interior
a) Commercial Rubber lined
b) Exterior blast cleaning
b) White metal Primer, second, 043Y, 043Z, 043Z
26. Exchanger & Regeneration
blast cleaning
blast cleaning
27. Neutralization Acid measuring
tank
blast cleaning
b) Exterior b) White metal Primer, second, 043Y, 043Z, 043Z
28. Demineralized Water Storage
Tank
a) Interior a) Commercial Primer coat 043S
blast cleaning
b) Exterior b) Commercial Primer coat 043A
blast cleaning

BOOK III

(a) (b) (c) 4.4.2.21 - 2)
(d)
29. Recovery Tank

a) Interior a) Commercial Primer coat 043S
blast cleaning
b) Exterior b) Commercial Primer coat 043A
blast cleaning
30. Portable Water Storage Tank;

Fuel Oil Tank; Reserve Feed
Water Storage Tank; Fresh
Water Storage Tank
c) Interior
c) Commercial - 043A
d) Exterior blast cleaning
d) Commercial
blast cleaning Primer coat

BOOK III
Table 4.4.2.21 - 2 Paint Systems
System
Type / Colour of Paint Use Thickness
Designation
043 - A - Two component Prime coat for 50 to 75 Microns

- Inorganic zinc (85 to 89 % steel dry film thickness
Zinc weight) in dry film
- Green or Grey
043 – B - Two component rust Intermediate 125 to 175 microns

inhibitive polyamide coat for steel dry film thickness
epoxy primer
- 85% solids by volume
- Brown Colour
043 – C - Rust inhibitive alkyd Prime coat for 75 microns dry

primer steel or film thickness each
- 50% solids by volume aluminum coat
043 - D - High glass Second coat, 50 microns dry

- 30% silicon alkyd enamel third coat unless film thickness
- Minimum 50% solids by otherwise
volume indicated
043 - E Zinc-Rich Paint/Grey Touch-up for 75 microns dry

galvanized base film thickness
metal
043 - F Acrylic latex 1 or 2 coat for 100 or 150

Paint/Prime white, aluminum and microns dry film
second coat color selected bare substrate in thickness each
contact coat

BOOK III
Table 4.4.2.21 - 2 Paint Systems (continued)
System Designation Type / Colour of Paint Use Thickness
043 – G Zinc chromate vinyl Wash prime for 10 or 15 microns

Butyral/Green galvanized dry film thickness
surfaces prior to
painting
043 - H Two Component Epoxy Mastic 125 or 175

Primer microns dry film
thickness
System Designation Type / Color of Paint Use Thickness
043 – I - Low Gloss Second coat 38 microns

- Two component smooth
polyurethane
043 – J - Low gloss Third coat 25 – 38 microns

- Two component textured
polyurethane
- 45% tie coat
043 – K - High solids Second coat 100 – 150 microns

- Two component
polyamide epoxy tie coat
043 - L Aliphatic polyurethane Third coat 40 – 50 microns
043 – M - Rust inhibitive epoxy Primer coat 75 microns

primer
043 – O - Inorganic zinc rich primer Primer coat 75 microns

- Minimum 75% zinc by
weight in dry film
043 – P Heat resistant 100% silicone Second coat 30 – 50 microns

aluminum

BOOK III
Table 4.4.2.21 - 2 Paint Systems (continued)

System
Type / Colour of Paint Use Thickness
Designation
043 - Q 100% silicone aluminium Primer coat 25 microns
043 – R Zinc pre-treatment wash First coat 13 microns

primer in accordance with BS
729
043 – S Water Soluble preservative Primer coat 70 microns
043 – T High gloss Third coat 50 microns

30% silicone alkyd enamel
minimum 50% solids by
volume
043 – U - Two component modified Second coat 100 – 150 micron

- Phenolic tank lining
primer white colour
043 – V - High solid two component Primer coat 100 – 150 microns
modified phenolic tank
lining top coat
- light grey color
043 – X Two component modified Second coat 100 – 150 microns

phenolic tank lining finish grey
colour
043 – Y Single package modified vinyl Primer coat 25 – 50 microns

– alkyd primer
043 – Z Single package vinyl chloride Second coat 50 – 100 microns

copolymer Third coat 38 – 50 microns

BOOK III
4.4.2.23 FIELD FINISH PAINTING
The Contractor shall apply field finish paint to all buildings, equipment,
structures, piping and other accessories provided by the Contractor in
accordance with the requirement of this specification and as listed in schedule
FFP herein related to the following:
 Supply of all material, labour, scaffolding and equipment to perform the
indicated work.
 Field surface preparation.
 Field touch-up painting.
 Field touch-up for hot dipped galvanized surfaces.
 Field prime coat painting.
 Field intermediate and finish coat painting.
 Colour coding, identification and marking.
WORK EXCLUDED
This Specification does not include field painting of the following materials and
surfaces:
 Copper and similar non-ferrous metals.
 Stainless steel.
 Aluminum (except contact surfaces - to prevent electrolytic
action).
 Hot dipped galvanized grating.
 Factory pre-finished surfaces except as stated in Schedule FFP
herein.
 Cast iron.
 Plastic or plastic coated conduit.
 Transit conduit.
 Hot dipped galvanized cable trays & conduits.
 Anchor bolts.
 Milled surfaces.
 Concrete Floors, curbs.
 Floor and wall tiles.
 Suspended ceilings.
 Hardware and glazing.

BOOK III
The codes and standards of the following organizations shall be specifically

applicable to the design, application and testing of the work included in this
Specification.
SSPC Steel Structure Painting Council, USA

Contractor shall fully with the Project Quality Assurance/Quality Control
shall apply.
After award of Contract, but before ordering materials, Contractor shall submit
for review and approval of Owner all the following items:
ENGINEERING DOCUMENTS
A list of coating and painting materials to be used, each identified by
manufacturer, brand name, product number and paint manufacturer’s
instruction.
The manufacturer of the paints for the selected system shall submit through
Contractor printed instruction for the use of his materials. Where such
instructions take exceptions to this specification, the exception shall be
submitted to the Owner in the Bid Proposal.
SAMPLES
Colour Panels : Approximately 30 cm x 30 cm in size
Submit panels for each finish colour to be used
including colours for all undercoats.
Colour Chips : Manufacturer’s standard, but not less than
approximately 25 cm x 50 cm in size
Submit chips for each finish colour to be used
including colour for all undercoats.
Self Sticking Tape Samples of each size of self-sticking legend marking tape
proposed for use.

BOOK III

The Contractor shall prepare and provide but would not be limited to the
following quality control documentation.
- Packaging and shipping procedure
- Field cleaning and painting procedures
- Field test and field inspection procedures
4.4.2.23.5 GENERAL REQUIREMENTS
The intent of this specification for field painting is to ensure thorough and
proper surface preparation, and careful and complete paint application to all
exposed areas of surfaces specified to be field painted in this specification, and
observing strictly the following procedure :
As the works will be located in a tropical area and close by the sea, the paint
shall be of such type which can best resist tropical conditions and salty air
environment.
The Contractor shall thoroughly clean, prime coat where required and/or touch
up the entire work, or a substantial portion thereof, before starting the
intermediate coat of paint. However, work shall proceed in a pattern which will
keep to a minimum the necessity for re-cleaning the touch-up work already
done or the intermediate coat already applied. Cleaning shall be done in such a
manner as not to liberate dust and shall be approved by the Owner. No
intermediate coats shall be applied until the cleaning, prime coating and/or
touch-up work has been approved by the Owner.
After intermediate coat has been applied, no finish coat shall be applied until
the intermediate coat is completed, inspected and approved by the Owner. If
any succeeding coat is applied before approval of the undercoat it will be
assumed that such undercoat has not been applied and at the option of the
Owner such undercoat shall be reapplied or the entry coating shall be removed
and such area shall be repainted from the beginning.
DEFINITIONS
Contact Surfaces: Surfaces which are permanently in contact with other
surfaces of the same material after shop assembly or field erection. (i.e.
surfaces under column and beam cover plated, faying surfaces under
connecting angles, splice plates, bolts, nuts and washers).
Inaccessible Surfaces: Surfaces which are made inaccessible for painting (other
than Contact Surfaces) after shop fabrication or field erection such as facing

BOOK III
surfaces in an assembly composed of two angles back to back with a gusset

plate between them.
DFT : Dry film thickness expressed in microns.
Outdoor : Areas of the power plant with or without roofs but
without any wall.
Indoor : Areas of the power plant enclosed with complete roof
and walls.
SAFETY REQUIREMENTS
All necessary safety measures and precautions required by the Owner and
safety recommendations of materials manufacturers, suppliers, etc. shall be
carefully complied with during the entire course of the Work.
PAINT
Paint Manufacturers Instructions: The manufacturer of the paints for the
selected system shall submit through the Contractor printed instructions for the
use of his materials. Where such instructions take exception to this
specification, the exception shall be submitted to the Owner.
Paints shall be delivered to the place of use in unbroken containers bearing
manufacturer's brand name and number.
Paint identification numbers are paint manufacturer's numbers and shall be
used in ordering paint.
Paint shall not be mixed or stored in any contaminated containers.
All paint shall be thoroughly mixed before using and shall be applied in strict
accordance with the manufacturer's printed instructions. The mixture of paint
shall be prepared at the shop or point of use.
PROTECTION AND CLEAN-UP FOR FIELD WORK

The Contractor shall furnish the necessary drop cloths or other protection
required to fully protect all surfaces from paint dropping, mist and other
conditions due to execution of field prime coat, field touch-up, intermediate
and finish paint work by the Contractor.
The Contractor shall exercise particular care to keep clean and unpainted all
valve stems, motor shafts, and other such moving parts in order not to impair
their free movement. Any paint deposited on such parts shall be carefully and
completely removed.

BOOK III
All metal jackets on equipment and piping, cable trays, equipment nameplates,
pressure gauges, instrument glasses, machined surfaces, electrical indicating
devices etc. which are not to be painted shall be protected by masking to keep
them free of paint.
Sufficient care shall be exercised by painters while painting around switches
and controls so as to avoid tripping of circuits. It is imperative that all switches
shall remain unmoved and undisturbed by painters.
All shipping tags, wires, strings and all other means of temporary or shipping
identification on surfaces to be painted shall be removed from such surfaces,
but only after checking with and receiving authorization from the Owner.
The Contractor shall clean all spots from surfaces which have been spotted with
paint such as window glass, floors, walls, equipment etc. leaving the premises
spot clean to the complete satisfaction of the Owner.
Permanent names painted on equipment shall be protected so as to leave the
names free of paint and legible or shall be repainted.
STORAGE OF PAINT AND PROVISION FOR FIRE FIGHTING EQUIPMENT

A temporary building shall be provided by the Contractor for bulk storage of
paint and paint material and for the mixing of paint, thinner etc. as used from
day to day. The building shall be properly ventilated and at all locations where
painting work is in progress shall be adequately protected with fire fighting
equipment satisfactory to the Owner. The floor of this building shall be kept
clean at all times; oily rags, waste etc. shall be removed from this building at
the end of each working day.
HOISTS AND SCAFFOLDS

The Contractor shall provide necessary hoists and scaffoldings to prevent any
interference with the progress of other works or the operation of the station.
Contractor's scaffoldings, walkways etc. shall comply with all applicable
requirements of authorities having jurisdiction. The Contractor shall remove
such scaffolding walkways etc. at the termination of their use.
PIPING WORK
The term piping includes valves, pipelines, traps, strainers and all appurtenances
in a piping system.
MISCELLANEOUS APPURTENANCE
Control and regulating equipment linkages etc. shall be painted to match the
equipment to which they are attached unless directed otherwise.

BOOK III
Small pipe, ducts and other small objects alongside or adjacent to large surfaces
shall be painted to match the background colour.
Brackets, hangers and other accessories shall be painted to match the colour of
supports to which they are attached.
TECHNICAL INFORMATION
Where surfaces of equipment or structures have been prime coat painted in the
shop, the Contractor shall review the compatibility of the field finish paint
system with the shop prime paint prior to performing the work on them.
Wherever the primer is not compatible to field finish paint nor proper primer
has not been used the Contractor shall do the necessary work at no additional
cost.
Field Touch-up Painting

Field touch-up painting where required shall consist of one coat of paint
applied to the following surfaces after they have been properly cleaned as
herein specified:
a. Surfaces where the shop coat of paint has been marred scratched or
otherwise damaged due to shipping, handling, erection, installation,
weathering etc.
b. Heads of field bolts and nuts and adjacent surfaces left unpainted in
the shop.
c. Surfaces of field welds and adjacent surfaces left unpainted in the
shop.
d. Surfaces of any ferrous fasteners which are not otherwise protected.
Exposed fabrication, erection of shipping marks shall be cleaned off and the
such areas shall be touch-up painted to match the adjacent surfaces.
Provided further, that field touch-up painting should consist of two coats for
any of the above mentioned surfaces, which have received two coats either in
the shop or in the field of prime coat painting.
For surfaces where blast cleaning and wash primer are specified, touch-up
painting shall include blast cleaning and application of the wash primer before
the touch-up coat, or coats, are applied.
Touch-up painting shall overlap the prime coat by not less than 25 mm all
around to ensure continuity of coating.
Equipment and piping insulation and aluminum jacketing finishes shall not be
painted. However, the colour bands, flow direction arrows, names of the fluids
for the piping and names of the equipment shall be indicated on the piping and
equipment. Exposed hangers, rods, supports and accessories shall be painted.

BOOK III
All indoor and outdoor bare (uninsulated) pipings shall be painted, including
piping in pits and trenches.
All hangers and supports shall be painted except sliding surfaces, springs and
adjustable or movable parts.
All indoor and indoor bare (uninsulated) equipment use shall be painted,
including motor base plate, stop valves and others.
Underground piping which is asphalt coated for corrosion protection parts of
asphalt coated pipe exposed above ground or above floors shall be painted.
In general, asphalt coating shall not be removed but shall be thoroughly
cleaned by brushing, washing and/or chipping as necessary. Compatible primer
and paints shall be used.
Surfaces of all structures for piping, equipment etc. included in this Contract
which will be made inaccessible for future painting after the erection of such
items due to contact with other pipings, equipment, walls, roofs, ceilings etc.,
shall be field finish painted completely prior to such surfaces becoming
inaccessible.
4.4.2.23.6 SPECIFIED SURFACE CLASSES
GENERAL
The Specified Surface Classes and the general nature of the specified surfaces
included in each class, shall conform to the requirements specified herein.
CLASSES
The specified surfaces included in the Work consist of the following four
classes:
Class SSS (Specified Structural Surfaces): Includes all exposed surfaces of
structural steel, miscellaneous steel, auxiliary steel, galleries, handrails, surge
bins, exterior doors etc. as indicated in Schedule FFP.
Class SES (Specified Equipment Surfaces): Includes all exposed surfaces of the
following, including all auxiliaries and accessories, as applicable:
a. Mechanical equipment including tanks.
b. Electrical equipment excluding electrical cubicles and indoor panels.
b. Electrical fittings, junction boxes, outlet boxes, fasteners and all
appurtenances.
d. All other items of similar nature to the foregoing as indicated in Schedule
FFP or as required to properly complete the Work.
Class SPS (Specified Piping Surfaces): Includes all exposed surfaces of the
following, including valves, traps, strainers and all appurtenances, accessories,
hangers, supports etc. as applicable
a. Mechanical piping.
BOOK III
b. All other items of similar nature to the foregoing as indicated in Schedule

FFP or as required to properly complete the Work.
Class SBS (Specified Building Surfaces): Includes all exposed surfaces of the
following as applicable :
a. Plastered surfaces
b. Interior doors, rolling doors
c. Wood work
d. All other items of similar nature to the foregoing as indicated in Schedule
FFP or as required to properly complete the work.

BOOK III
Schedule FFP
Schedule FFP lists the specified areas and surfaces, finish applied in the shop,
field surface preparation system, field paint system and colours.
SCHEDULE FFP
COLORS
PAINT (BY OWNER)
SURFACE
SYSTEM INTER
PRESENT PREPARATION
ITEM SPECIFIED AREAS AND FILL IN BY MEDIA FINISH
FINISH REQUIRES
No. SPECIFIED SURFACE CONTRACTOR TE COAT
(MINIMUM)
(NOTE-1) COAT
(NOTE–2)
1. CLASS SSS
Specified structural
surfaces :
1.1 All structural steel,

auxiliary steel,
miscellaneous steel,
conveyors steel, galleries,
trolleys, stairs, ladders,
cages,
handrails, exterior doors
etc. as furnished by the
Contractor
1.1.1 Indoor Shop Prime Clean and dry as 043K, 043L Later Later
Painted recommended
by paint
manufacturing
SSPC – SP3
1.1.2 Indoor Bare Metal Clean and dry as 043K, 043L Later Later
recommended
by paint
manufacturing
SSPC – SP3
1.1.3 Outdoor Shop Prime Clean and dry as

Painted recommended 043K, 043L Later Later
by paint
manufacturing
SSPC – SP3

BOOK III
SCHEDULE FFP ( continue )
COLORS
PAINT
(BY OWNER)
SURFACE SYSTEM
INTER
ITEM SPECIFIED AREAS AND PRESENT PREPARATION FILL IN BY
MEDIA FINISH
No. SPECIFIED SURFACE FINISH REQUIRES CONTRACTO
TE COAT
(MINIMUM) R
COAT
(NOTE-1)
(NOTE–2)
1.1.4 Outdoor Bare Metal Clean and dry as 043K, 043L Later Later
recommended by
paint manufacturer
SSPC – SP3
1.2 All other exposed steel Shop Prime Clean and dry as 043K, 043L Later Later
surfaces, supports etc. Painted recommended by
integral part of item 2 paint manufacturer
below including elevator SSPC – SP4
CLASS SES
2. Specified Equipment
surfaces :
2.1 Mechanical /equipment

including but not limited
to pump valves, external
piping surfaces and
conveyor machinery
2.1.1 Internal Clean, dry and free

Shop Prime contaminant SSPC 043K, 043L Later
Painted – SP3
Clean, dry and free

2.1.2 External Shop Prime contaminant SSPC 043K, 043L Later Later
Painted – SP#

BOOK III
COLORS
PAINT (BY OWNER)
SURFACE
SYSTEM INTER
ITEM SPECIFIED AREAS AND PRESENT PREPARATION
FILL IN BY MEDIA FINISH
No. SPECIFIED SURFACE FINISH REQUIRES
CONTRACTOR TE COAT
(MINIMUM)
(NOTE-1) COAT
(NOTE–2)
2.2 All jacketed mechanical Shop Prime None None None None
equip-ment, pumps etc. Painted
included with the
Contract.
2.3 Uninsulated equipment Shop Prime

and material having Painted Clean, dry and free 043 P Later Later
operating or services contaminant as
temperature from 93C recommended by
to 230C paint manufacturer
SSPC-SP3
2.4 Uninsulated equipment Shop Prime Clean, dry and free

and material having Painted contamonant as
operating or services recommended by 043 P Later
temperature from 230C paint manufacturer
to 400C SSPC-SP3
2.5. Uninsulated equipment Prime coat Clean and dry as

and material having painted recommended by
operating or services paint manufacturer
temperature from 400C SSPC – SP3 043P Later
to 540C
2.6 Space conditioning Prime coat Clean dry 043K, 043L Later Later
equipment painted SSPC – SP1

BOOK III
COLORS
PAINT (BY OWNER)
SURFACE
SYSTEM INTER
CONTRACTOR TE COAT
(MINIMUM)
(NOTE-1) COAT
(NOTE–2)
2.7 Flash Tank
2.7.1 External Primer coat Clean and dry as 043K, 043T Later Later
painted recommended by
paint manufacturer
SSPC – SP3
2.8 Exchanger and regenera-

tion tank
paint manufacturer
SSPC – SP3
2.9 Turbine Lube Oil Storage

Tank
2.9.1. External Primer coat Clean and dry as 043K, 043T Later Later
paint manufacturer
SSPC – SP3

BOOK III
COLORS
PAINT (BY OWNER)
SURFACE
SYSTEM INTER
CONTRACTOR TE COAT
(MINIMUM)
(NOTE-1) COAT
(NOTE–2)
2.10 Closed Cooling Water
Head Tank
2.10.1 Internal Primer coat Clean and dry as 043V Later Later
paint manufacturer
SSPC – SP3
paint manufacturer
SSPC – SP3
2.11. Blow Down Tank
2.11.1. External Primer coat Clean and dry as 043K, 043T Later Later
paint manufacturer
SSPC – SP3
2.12. Air Receiver
paint
manufacturing
SSPC – SP3

BOOK III
COLORS
PAINT (BY OWNER)
SURFACE
SYSTEM INTER
CONTRACTOR TE COAT
(MINIMUM)
(NOTE-1) COAT
(NOTE–2)
2.13. Exchanger and
Regeneration
2.13.1. External Prime coat Clean and dry as 043K, 043T Later Later
paint manufacturer
SSPC – SP3
2.14. Demineralized Water

Storage Tank
2.14.1 External Prime coat Clean and dry as 043K, 043T Later Later
paint manufacturer
SSPC – SP3
2.15. Recovery Tank
paint manufacturer
SSPC – SP3

BOOK III
COLORS
PAINT (BY OWNER)
SURFACE
SYSTEM INTER
CONTRACTOR TE COAT
(MINIMUM)
(NOTE-1) COAT
(NOTE–2)
2.16. Potable Water Storage
Tank ; Fuel Oil Tank;
Reserve Feed Water
Storage Tank; Fresh
Water Storage Tank.
paint manufacturer
SSPC – SP3
3. CLASS SPS (Specified

Piping Surface )
3.1 All bare steel piping

included with the
Contract
3.1.1 Indoor Bare Metal SSPC – SP4 Later Later
3.1.2 Outdoor Bare Metal SSPC – SP4 Later Later
3.2 All insulated and Bare Metal None None None None
jacketed steel piping
both indoor or outdoor
included with the
Contract

BOOK III
COLORS
PAINT (BY OWNER)
SURFACE
SYSTEM INTER
CONTRACTOR TE COAT
(MINIMUM)
(NOTE-1) COAT
(NOTE–2)
3.3 All valves including hand-
wheel and connection
bolts included with the
Contract
3.3.1 Indoor Bare Metal SSPC – SP4 Later Later
3.3.2 Indoor Shop Prime SSPC – SP3 Later Later

Painted
3.3.3 Outdoor Bare Metal SSPC – SP4 Later Later
3.3.4 Outdoor Shop Prime SSPC SP3 Later Later

Painted
3.4. All pipe hangers, duct

hangers, included with
the Contract
3.4.1 Indoor Shop Prime SSPC – SP3 Later Later

Painted
3.4.2 Outdoor Shop Prime SSPC – SP3 Later Later

Painted

BOOK III
COLORS
PAINT (BY OWNER)
SURFACE
SYSTEM INTER
CONTRACTOR TE COAT
(MINIMUM)
(NOTE-1) COAT
(NOTE–2)
4. CLASS SBS (Specified
Building Surface)
4.1 All plastered surfaces Bare Per Paint Manu- Later Later
facturer’s
standard
4.2 All interior doors and Shop Per Paint Manu- Later Later
rolling doors Primed facturer’s
standard Varnish
4.3 All wood work Bare Per Paint Manu- Later Later
facturer’s
standard
4.4 Aluminum windows Anodized None None None
Notes:
1. Contractor shall fill up paint system in this column based on the paints
systems indicated in Table 4.4.2.22-1 (Paint System for Steel Surfaces)
and Table 4.4.2.22-2 (Paint System for Building Surfaces) as applicable.
2. Owner will select the finish coat after the award of the contract at no
extra cost to the Owner.
3. Bare metal surfaces shall receive both shop and field coat paints as
indicated in Table 4.4.2.22-1 (item 1, 2, 3, & 4).
4. Field touch up of primed metal surfaces shall be applied using field coat
paints as indicated in Table 4.4.2.22-1 (item 3 & 4).
5. Field touch up of galvanized steel surfaces shall be applied using paint
system in Table 4.4.2.22-2, Specification refers to “Prime Coat and Shop
Finish Painting”.
6. Thiokol based or silicone based rubber sealant caulking shall not be
painted. All other caulkings shall be painted with same paint as adjacent
to or surrounding areas.
7. For safety colour painting see the standard bid of the offer Drawings.

BOOK III
4.4.2.23.7 PAINTING WORK SYSTEM

Tables 4.4.2.22-1 and 4.4.2.22-2 of this specification show Owner's suggested
Paint Systems, for steel and building surfaces respectively.
The Contractor shall design the paint system to be compatible with the material
to be coated, the temperature of the structures/equipment/piping surfaces,
service conditions and which can best resist the tropical conditions and salty air
environmental.
The Contractor shall submit with his bid proposal details of painting system and
additional surface preparation requirements complete on schedule FFP herein
for the Owner's review.
The Contractor shall provide a minimum of 5 years after plant commercial
operating date, of paint performance guarantee against any potential failure of
the paint system and discoloration. The guarantee shall be properly signed and
sealed by the Contractor.
4.4.2.23.8 DETAILS OF PAINTING WORK SYSTEMS
SURFACE PREPARATION SYSTEM SL-SP3

Shop primed metal or galvanized metal to be coated or painted shall be as
follows:
System Description
It shall include preparation of all specified ferrous metal, surfaces which have
been shop prime painted, or galvanized, and which would receive field touch-
up and/or field finish coats.
Surface Preparation
All surfaces shall be cleaned free of rust, dirt, dust or other foreign material.
The Systems SSPC-SP1, Solvent Cleaning; SSPC- SP2, Hand tool cleaning; and if
required SSPC-SP3, Power Tool Cleaning shall be implemented.
Surface Appearance After Surface Preparation

Shall be at least as good as indicated by preparation grade photo BSt3 and CSt3.
SURFACE PREPARATION SYSTEM SL-SP4

Bare metal to be coated or painted shall be as follows:
System Description
This shall include preparation of any specified ferrous metal surfaces which
have not been shop prime painted but shall be field prime coated or painted.
BOOK III
Surface Preparation
Methods SSPC-SP1, Solvent Cleaning, SSPC-SP2, Hand Tool Cleaning, and SSPC-
SP3, Power Tool Cleaning, SSPC-SP10, Near White Metal Blast cleaning, shall be
implemented where required.
Surface Appearance after Surface Preparation

Shall be at least as good as indicated by preparation grade photo BSa2 1/2 and
CSa2 1/2 of SSPC-Vis-1.
SURFACE PREPARATION FOR CONCRETE AND PLASTER SURFACES

Concrete and plaster surfaces shall have aged at least 60 days prior to starting
preparation for painting.
Surfaces shall be completely free of oil, grease, free lime or other
contaminants.
Cracks, voids, etc shall be filled with speckling compound and sanded or rubbed
smooth.
All rough spots shall be sanded smooth.
SURFACE PREPARATION FOR WOOD SURFACES

Surfaces shall be sanded smooth.
All knots and sappy streaks shall be carefully coated with shellac before
painting.
Suitable primer shall be used.
Holes, splits, scratches etc. shall be filled with speckling compound after primer
has been applied and the affected areas shall be again sanded smooth.
SURFACE PREPARATION FOR GALVANIZED SURFACES

Surface shall first be prepared by Solvent Cleaning.
Following the solvent cleaning, the surface shall receive one (1) wash coat pre-
treatment in accordance with the applicable requirements of SSPC Pre-
treatment Specification No. 3, "Basic Zinc Chromate-Vinyl Butyral Wash coat",
or shall receive a prime coat as specified.
METAL PATCHING

BOOK III
Should it be found necessary to patch or fill scratches or gouges in equipment

metal housing or motors, etc., a metal putty shall be used.
Metal putty shall be applied in strict accordance with manufacturer's directions,
and shall be leveled and sanded smooth after application.
4.4.2.23.9 COLOR CODING AND/OR IDENTIFICATION AND MARKING

Colour band for jacketed pipes, flow direction arrows and names of fluids shall
be located on piping system immediately adjacent to all operating accessories
such as valves, regulators, strainers and other devices, including points where
pipes branch or pass through walls, floors or partitions.
Colours of bare and jacketed pipes shall be as indicated in Table 4.4.2.22-3 as
applicable.
The final location of colour bands, arrow marks and names shall be adjusted at
site according to the direction of the Owner, taking the actual service operation
into consideration.
Major equipment and auxiliaries shall be indicated on the surface of tank, pump
or motor bodies etc.
Identification Names (Legends) and Arrows

Legends and arrows shall be painted on using stencils unless self-sticking legend
marking tape is used.
Legends and arrows shall be stencilled at the following locations :
- At all valves
- At intermediate points, approximately 8 m apart, on long pipe runs.
Legends shall be in letters of style as approved, and arrows shall be of adequate
size and shape for pipe lines of 75 mm diameter or larger (this shall include
insulation where used). For smaller pipe lines the legends and arrows shall be
sized as large as each line will permit.
Paint for legends and arrows shall be Black Pipe Enamel unless otherwise
indicated.
4.4.2.23.10 RESTRICTIONS DURING PAINTING

Application of paint shall conform to the applicable requirements of SSPC Paint
Application Specification No. 1, "Shop, Field and Maintenance Painting" and to
the requirements herein specified.
Paint shall not be applied to surfaces which are operated at a temperature of
over 500C unless the paint is specifically formulated for application at the
proposed temperature. When a surface is painted in hot weather, precautions

BOOK III
shall be taken to ensure that the specified dry micron thickness of paint is
obtained.
MOISTURE AND HUMIDITY RESTRICTIONS

Paints shall not be applied in rain, fog or mist or when the relative humidity is
as such to cause condensation on metal surfaces due to variation in metal
temperatures and surrounding air temperatures.
All surfaces shall be perfectly dry before and while being painted.
4.4.2.23.11 METHOD OF APPLICATION

Application of the paint shall primarily be made with proper size and grade of
brushes except where spray equipment or rollers can be used to advantage.
Spray equipment, if used, shall be accurately and fully controlled at all times to
prevent damage to adjacent surfaces. If, in the opinion of the Owner, the over
spray during paint spraying operations may causing damage to plant equipment
the use of spray equipment would be restricted to those areas (if any) where, in
the opinion of the Owner, damage to plant equipment would not occur.
The Contractor shall solvent clean or sand and smooth touch-up, prime coats
and undercoat paint on all equipment and on other readily visible surfaces to
secure a smooth workmanlike finish coat.
All work covered by this specification will be subjected to inspection by the
Owner, and any work found out to be non conformance with the Specification
shall be redone to the satisfaction of the Owner.
The Owner may make random spot checks of materials, equipment etc. which
have been painted by removing small swatches of paint to bare metal using
acetone and examining the surface with a 10x power magnifying glass to
observe the absence or presence of rust under the prime coat. The presence of
rust or rust stains under such swatches shall be a sufficient cause for rejecting
the Work, and The Contractor shall prepare and recoat the work in the field at
his own expense.
Dry and wet film thicknesses may be determined by the use of gauges. The
gauges and procedure shall be in accordance with SSPC PA-2.
To check the amount of thinner added the viscosity of paints in the cans may be
determined by viscosity cups and compared with such values obtained from the
manufacturer.
The continuity of paint film on metal surfaces may be checked by a low voltage
detector. Inadequately coated areas will be marked with chalk. The Owner may

BOOK III
consider the entire area defective if five or more deficiencies are found in an
area of 10 m2.
The surface temperature may be determined by the use of a surface
thermometer.
Paint shall have sufficient adhesion to prevent hardened coats being lifted as a
layer when the blade of a putty knife is inserted under it; intercoat adhesion
shall be such that two or more hardened coats shall not be delaminated when
tested with a sharp knife.
All equipment necessary for quality control testing shall be provided by the
Contractor when requested by the Owner.
4.4.2.23.13 SAMPLES
After award of Contract, but before ordering materials, the Contractor shall
submit for review of the Owner all of the following samples:
Colour Panels: Approximately 30 cm x 30 cm in size. Panels shall be submitted
for each finish colour to be used, including colours for all undercoats.
Colour Chips: Manufacturer's standard, but not less than approximately 25 mm
x 50 mm in size. Chips shall be submitted for each finish colour to be used,
including colours for all undercoats.
Self-Sticking Tape: Samples of each size of self-sticking legend marking tape
proposed for use.

BOOK III
TABLE Part 4.4.2.22-1

PAINT SYSTEM FOR STEEL SURFACES
PS-3 PS-4
PS-1 PS-2
ITEM COAT-TYPE-DFT VALSPAR SHER- PS-5
AMERON CABOLINE
CORP. WILLIAMS
S
H 1 Shop-prime Coat : Dimetcoat 9 Carbo-Zinc Mobilzinc 7 Zinc clad
O (inorganic zinc 85 to 80 % zinc 11 13-F-12 B69VI/B69D2
P by weight) 50 to 75 microns
P
A 2 Shop-Intermediate Coat : Amercoat 190HB Val-Chem HS Epoxy
I (two-component polyamide 383HS Epoxy 89 B62
N epoxy)125 to 175 microns Series Series/B60V20
T
F 3 Prime-Intermediate Coat : Amerlock Carbomastic Alumepoxy Epoxy Mastic

I (Touch Up and Total Coating) 400AL 15 75A2 B62SW1/B60V
E (Aluminum-Epoxy-mastic) 125 W1
L to 175 microns
D
P 4 Field Finish Coat : Amercoat 134 Mobilthane Polane F63

A (Apliphatic polyurethane) 50 450 GL 40 Series Series F63
I to 75 microns Series/V66V
N 29
T
1. Contractor may use an approved equal paint system and shall fill in PS-5
or any additional column as required.
2. All paints shall meet the performance requirements.
3. The use of all components of the same manufacturer’s paint system is

mandatory.
4. Owner will select the colour scheme of field finish painting work to
complement the building colour at a later date after the award of the
Contract at no extra cost to Owner.

BOOK III

PAINT SYSTEM FOR BUILDING SURFACES
(FOR CLASS SBS)
PS-10 PS-12
PS-11
ITEM COAT-TYPE-DFT DETROIT E.1 DU PS-13
KEELER LONG
GRAPHITE POINT
1. One Latex Sealer Coat 59402 4100 389 Y – 187

12.5 to 25 microns Sealer
2. Intermediate Coat 59404 Kolor Tex Acrylic

Latex Flat Finish (25 to Acrylic Latex
50 microns) Latex
3. Finish Coat Latex Flat 59404 Kolor Tex Acrylic

Finish (25 to 50 Acrylic Latex
microns) Latex
1. Contractor may use an approved equal paint system and shall fill in PS-
13 or any additional column as required.
2. All paints shall meet the performance requirements.
3. The use of all components of the same manufacturer’s paint system is

mandatory.
4. Owner will select the colour scheme of field finish painting work to
complement the building colour at a later date after the award of the
Contract at no extra cost to Owner.

BOOK III

COLOR SYSTEM FOR PIPING
NO. FLUID NAME COLOR FOR PIPE
I STEAM : RED :
a. Wet Steam Silver with red and green band

b. Super Heated Steam Silver with red and white band
c. Exhaust Steam Silver with red and black band
II WATER : GREEN :
a. Feed Water Green with red band

b. Condensate Water Green with yellow band
c. Sea Water Cooling Green with orange band
d. Fire Fighting Red
III FUEL & LUBE OIL : BROWN :
a. HSD & IDO Brown with yellow band

b. Residual Brown with black band
c. Gas Yellow
d. Lube Oil :
d.1 Inlet Brown with white band
d.2 Outlet Brown with red band
IV AIR : BLUE :
a. Atomizing Air Blue with brown band

b. Control Air Blue
V WATER TREATMENT :
a. Acid (HCL) Orange

b. Alkali (NaOH) White
VI VACUUM GREY

BOOK III
4.4.2.24 METAL SIDING, ROOF AND INTERIOR WALLS
4.4.2.24.1 SCOPE
This specification covers the requirements for metal siding, roofing and interior
wall and shall include contractor's designing, detailing, fabricating, furnishing,
installing, inspecting and testing of the work and shall conform to the
requirements of this specification and as shown on the drawing.
WORK INCLUDED
Designing detailing, fabricating, furnishing and installing metal siding and
roofing, with all penetration through the siding, walls and roofing.
Interior metal wall works.
Louvers, sunshades, and other appurtenances.
Detailing, fabricating, furnishing and installing all Rain Water Gutters, Flashing,
fasteners and other material necessary to ensure a watertight construction.
Furnishing and insulation for siding and roofing and wall as required.
Surface protection and painting.

Comply with the requirements of the applicable codes and standards published
by the following organizations:
AISI American Iron Metal Institute
ANSI American National Standards Institute
NBS National Bureau of Standards, USA
SAE Society of Automotive Engineers,
UL Underwriters' Laboratories, Inc,
Conform especially to the applicable provisions of the following codes and
standards :
ASTM A525 Galvanized Metal
ASTM B 1 17 Salt Spray
ASTM C423 Noise Reduction Coef
ASTM D3363 Pencil Hardness
ASTM D2247 Humidity
ASTM 623 Wentherometer
ASTM D1737 Flexibility
ASTM D523 Gloss
ANSI A58.1 Design Load

BOOK III

and Documentation the provision of “Submittals” of this specification shall be
applied.
comprehensive data on materials specification regarding a component and
accessories of his proposed system for the Owner's approval.
Test data and report and the quality control procedures and documentation
shall be submitted to the Owner for review.
Written Warranty on siding & roofing coating for a minimum period of 10 (ten)
years shall be submitted to the Owner's after acceptance of works.
Engineering calculation shall support the design in conformance with this
specification.
4.4.2.24.5 DEFINITIONS
Metal Siding: Exterior enclosure of one or more sides of a structure, insulated
or uninsulated. Insulated siding shall consist of exterior metal sheets, insulation,
subgirts and interior metal sheets (which are the siding components).
Uninsulated siding shall consist of the single exterior metal sheets only. Both
types of the siding shall also include all related fasteners and other accessories.
Metal Roofing: Exterior enclosure of the roof of a structure, insulated or
uninsulated, constructed of the same components, fasteners and other
accessories as for Metal siding (in contrast to metal decking covered with
concrete and/or built-up roofing).
Insulated roof shall consist of exterior metal sheets with insulation underneath,
and with interior metal sheets.
Uninsulated roof shall consist of the single exterior metal sheets only.
Metal Interior Wall: Enclosure of one or more sides of a space within a
structure, insulated or uninsulated, constructed of the same components,
fasteners and other accessories for metal siding (in contrast to prefabricated
metal partitions or similar constructions). Insulated walls shall consist of two
metal sheets enclosing an insulation core, and with or without subgirts
depending on the method of construction. Uninsulated walls shall consist of an
assembly of single metal sheets.

BOOK III
Fire Rated Insulated Fluted metal Siding: Shall be used where indicated and
approved by the Owner and shall have its exterior fire rated which shall consist
of field assembled panels utilizing a liner panel insulation, subgirts, gypsum
board and fluted extension metal sheet.
4.4.2.24.6 DESIGN REQUIREMENTS
STRUCTURAL REQUIREMENTS
The Contractor shall be fully responsible for the design of siding, roofs and
interior walls to withstand the specified loads, without exceeding the maximum
allowable unit stresses according to AISI, and without exceeding the allowable
deflections as specified in the following paragraph. Subgirts shall be used for all
insulated siding. Panels may be designed as continuous over two or more
spans, according to the girt or purlin spacings covered.
The Contractor shall have qualified engineers to perform or supervise the
design work.
Fasteners for attaching siding, roof and interior wall component to each other
and to grits and other structural supports shall be designed to withstand the
specified loads without exceeding maximum allowable unit stresses for such
fasteners.
The Maximum allowable deflection for insulated or uninsulated siding, roofs or
interior walls subjected to the design loads shall not exceed 1/180 of the clear
span between grits or purlins, in the direction normal to the plane of the siding,
roof or interior wall.
Design wind loads shall conform to all applicable requirement of ANSI A58.1,
based on a basic wind speed of 120 km/hr, and the minimum design live load
for the roof deck shall be 100 kg/m2.
The maximum fibre stress shall not exceed the foregoing specified deflection of
14 kg/m² for steel panels.
THERMAL REQUIREMENTS
The overall coefficient of thermal transmission U for insulated siding, roofs and
interior walls shall not exceed 0.75 watt/m2 C in still air.
Test data shall be submitted to Owner if requested to substantiate Contractors
claims as to the thermal properties of his materials used for construction.
ACOUSTIC REQUIREMENTS
If acoustically treated areas are required, they shall have a Noise Reduction
Coefficient (NRC), in conformance with ASTM C423, of not less than 0.85 and
the Contractor shall submit a test report to the Owner if requested to support
his claims for the NRC value of his materials used for construction.

BOOK III
WEATHERTIGHTNESS
All completed siding and roofs shall be weather watertight and dust tight.
Provision shall be made, in the design of insulated siding, to drain to the
exterior of siding of any condensation forming within the assemblies.
4.4.2.24.7 STORAGE
All siding materials, components, fasteners and other accessories shall be
stored dry, off the ground and under protective cover, in a satisfactory manner.
The Contractor shall arrange with the Owner for temporary storage of materials
not erected, and shall be responsible for storing these materials in such a
manner as to preclude damage, deterioration, etc. All costs for such protection
shall be included in the Contract Price.
4.4.2.24.8 MATERIALS AND DETAILS
METAL SHEETS
Metal sheets shall be of steel and be compatible with the coat finish system.
Cold rolled steel sheets of structural quality shall conform to the requirement of
ASTM A446, Grade B, G 90 “Zinc Coated Steel Sheets”. European Norm EN
10142 : 1990, EN. 10147: 1992 with galvanize Z 275 gr/m². Two side at three
point test according to EN 10142: 1990.
The metal thickness shall comply with one of the following requirements.
a) Metal thickness shall be determined from the defined loading
requirements, but shall be not less than that determined from the
width-of-flat surface in accordance with the following table. Beads may
be incorporated into flat surface to reduce the width-of-flat.
3-inch flat 4-inch flat 6-inch flat
US Std. 22 ga US Std. 20 ga US Std. 18 ga
b) The thickness shall be minimum 0.72 mm nominal thickness (TCT) up to
maximum 0.85 mm TCT regardless of loading and span when sheets are
fluted as required for loading and span.
METAL SHEET FINISHING

Finishing of siding, roofing, trim, flashing and gutter shall be one of the
following specified coatings, coil coated on the sheets metal prior to forming,
and modified as necessary to comply with the requirements defined in section
“Coating Test”.

BOOK III
Finish coating shall comprise of PVF2 Plus, a double-two layer polyvinylidene

fluoride applied on primer for both exterior and interior surface on insulated or
uninsulated roof and wall panels.
The “PVF2 Plus” acting as top coat, is a double coated “PVF2 Kynar 500”, a 80 %
or 80/20 fluorocarbon (polyvinylidene fluoride) applied to the special steel
substrate in accordance with the requirements of the metal siding and roofing
fabricator but conform with the metal sheet requirement as stipulated on
previous section.
Total dry film thikness of min. 46 microns composed of both an epoxy corrosion
inhibitive premier and the top coat PVF2 plus Kynar 500.
The color of reverse side shall be light gray or standard manufacturer’s light
gray. The final colour coat of steel cladding shall be submitted to the Owner for
approval.
ACOUSTIC TREATMENT
Where an acoustic treatment is required for insulated siding, or roofing, the
interior sheet shall be fully perforated with 3.0 mm diameter holes and 5 mm
triangle spacing which will provide NRC value of not less than 0.85 as specified
above.
INSULATION
Where insulated siding & roofing (external wall & electrical room) is indicated,
the insulation shall conform to the following requirements:
Material: shall be fibrous glass, rock or slag with minimum density of 60 kg/m 3.
The roof insulation shall be reinforced on down face with vinyl or aluminum
foil. The thickness of vinyl shall not be less than 0.01 mm and the thickness of
aluminum shall not be less than 0.0025 mm.
The wall insulation shall be completely enclosed with 150-micron thick
polyethylene protective cover.
Thickness of insulation: shall be a minimum of 3.75 cm if not otherwise stated.
FIRE HAZARD CLASSIFICATION RATING

The layer of insulation, including aluminum foil facing, shall meet the following
Fire Hazard Classification Rating of Underwriter’s Laboratories, such as:
Flame Spread = 10- 15
Fuel Contributed =0-5
Smoke Developed =0
FIRE RATED EXTERIOR WALLS

BOOK III
The material shall be the same as insulated exterior metal siding with the
addition of gypsum boards, the thickness and number of which shall be
determined for a two-hour fire rating.
Panel thickness shall be 3.75 cm nominal overall.
Interior panel sheets shall be galvanized interior type sheets as refers to section
‘Metal Sheet Finishing’.
INSULATED INTERIOR WALLS

Panel thickness shall be 3.75 cm nominal overall.
Panel sheets shall be galvanized interior type sheets, prime coated similar to
the interior metal sheets in section ‘Metal Sheet Finishing’.
FLASHING
Exterior flashing material, Pattern and finish shall be the same with exterior
sheet of siding and roofs with minimum thickness of 0.70 mm.
Interior flashing material shall be galvanized metal with the same thickness and
finish with interior sheet of insulated siding and roofs.
Flashing shall be provided wherever required but not limited to the following:
Corners, roofs, ridges, caps, etc.
Beam penetrations, wall or roof sleeves, duct openings and miscellaneous
openings etc.
FASTENERS
Type of Fasteners
One of the following three types of screw Fasteners shall be used as indicated
for the fastening of metal siding, roofs and interior walls:
Type A: Type A sheet metal screws are those having pointed ends and wide
pitch threads. This type of screw shall be used for connecting gauge metal to
gauge metal.
Type B: Type B self-tapping screws are those having flat ends and close pitch
threads. This type of screw shall be used for connecting gauge metal to a
structural member.
Type AB: Type AB self-tapping screws are those having pointed ends and close
pitch threads. This type of screw shall be used for connecting gauge metal to a
structural member.
Material

BOOK III
Shall be of type 305 or approved stainless steel with cadmium-plated finish and
the heads painted to match colour of siding.
Size of Fasteners: No. 12 or larger.
Length of Fasteners
The length of type A screw shall be sufficient to engage gauge metal sheets
together with a minimum projection of 1.0 cm beyond the sheet surface.
The length of the type B or type AB screws shall be such as to engage a
sufficient thickness of supports to which they attached, to develop the full
capacity of fasteners.
PARAPET CAP
Same as exterior flashing
CAULKING & SEALING TAPE

Manufacturer's standard
LAPS
Lap fines for siding shall line up all around the building.
End laps at walls and roofs shall be 15 cm minimum and 25 cm minimum
respectively.
Side laps shall not be less than 1/2 rib.
Side and end laps in the exterior roof shall be sealed with mastic tape.
COATING FOR METAL SIDING AND ROOFS

Shall be organic coating and meet the detail requirement specified on Table in
section ’Metal Sheets’.
RAINWATER GUTTERS AND ROOF SHEET METAL ITEMS

Rainwater Gutters and Supports shall comprise of steel sheet plate and must be
protected by beam hot dip galvanized with minimum weight of zinc coating of
0.250 kg/m².
The outlet surface shall be finished with protective colour as same as exterior
flashing to match the siding.
The lay out and sizing of gutters and roof drains shall be designed for the
maximum anticipated rain fill intensity at the site, but not less than 3 mm in 1
minute.
Each dewatering section shall be provided with at least 2 roof drains and 1
overflow pipe.
All sheet metal items shall be rigid, true to line and neat in appearance. They
shall be designed and manufactured in such a way that both soldering work on

BOOK III
site can be reduced to a minimum, and neat and easy installation shall be
allowed.
Provision shall be needed for separating sheet metal items from wood boards
and/or concrete or plaster surface by mean of adequate roofing felt.
Longitudinal slope of gutter bottoms shall not be less than 0.5 %.
Box gutters shall be adequately supported and designed to support rigidly the
loads and will allow permanent flow of water.
Gutter outlets of diameter between 15cm to 20cm shall be provided for

connection to rain water down pipes.
Basket strainers of non corrosive wire
Overflow pipes of 10 cm diameters and of lengths between 50cm and 80 cm

shall be provided. The projecting part from the outer alignment of exterior
walls and/or siding shall not be less than 25 cm. Overflow pipes to be routed
through concrete and/or masonry parapet walls shall be wrapped by means of
adequate roofing felt.
Provision shall be made for expansion joints in box gutters, wall flashings and
cap strips etc. The expansion joints shall be adequate for the type of works
specified. They shall not be spaced more than 10.00 m.
Flashings shall be provided where required to reach full water tightness. The
thickness of steel shall not be less than 0.7 mm. Cap strips, if required shall
have a girth comprised between 15 cm and 25 cm.
PENETRATIONS, WALL OR ROOF SLEEVES

Penetrations, sleeves, duct openings, etc, in siding, roofs, and interior walls
shall be shown on Contractors drawings and shall be soundly designed for
weather tightness.
LOUVERS
Louver shall comply with the requirement defined in the general technical
specifications refers to sub section ‘Metal Sheets’ and ‘Metal Sheet Finishes’.
The Material, fasteners and finishing shall be the same as the siding material
defined in this general technical specification.
4.4.2.24.9 ERECTION
Erection shall be in strict accordance with manufacturers’ procedure for such
type of work. Care shall be taken to ensure that Metal and aluminium are at all
times separated such that a galvanic reaction cannot take place.

BOOK III
4.4.2.24.10 PROTECTION OF INSULATION DURING ERECTION

For all insulating constructions all insulation material shall be satisfactorily
protected from the weather during erection to eliminate soaking of insulation
by water, or other moisture contaminants.
4.4.2.24.11 CLEANING OF SIDING, ROOFS AND INTERIOR WALLS

All exposed faces of siding, metal roofs and interior walls shall be cleaned free
of labels, dirt, streaks, caulking or sealing materials, undue discoloration etc.
and as a minimum a dry wipe down shall be provided at the time of erection.
All exposed faces of siding, metal roofs and interior walls, prior to acceptance
by Owner shall be completely satisfactory to the Owner in appearance.
4.4.2.24.12 REMEDY OF DEFECTS IN APPEARANCE

Defects in appearance which include nicking, scratching, gouging, dimpling,
denting, abrasions, and marring of any nature due to shipping, storing,
handling, erection, weathering etc. shall be remedied at Contractors expense as
follows:
Touch up the baked enamel organic coating finish with one or more coats of the
same coating material used for the original finish. Thickness, appearance and
colour of the touch-up shall match adjacent surfaces. If touch-up is not
satisfactory to Owner, damaged sheets or accessories shall be replaced.
4.4.2.24.13 INSPECTION AND TESTING

The Contractor shall be responsible for all inspection and testing required by
this specification unless otherwise specified. The Owner may during the course
of the work, observe various phases of the work performed by Contractor, at
the Contractor’s plant and at the site.
Coating Tests
General
The coating system of the external steel sheet for roof and wall shall meet the
following performance criteria and test results and shall be substantiated and
certified by a recognized independent testing organization.
Results of the following tests shall be submitted to the Owner, proving the
compliance with the following requirements.
Colour Change and Fade Resistance

A sample with a minimum of two raw-cut edges shall withstand a minimum of
60 days emmaqua weathering test exposure (exterior equatorial mount with
mirrors and water spray) and/or 200.000 Langley’s of ultra violet radiation
without cracking, peeling, blistering or loss of adhesion. Maximum colour

BOOK III
change, including all exterior surface deposits such as dirt or chalk, shall not
exceed 2 nbs units.
Abrasion – Resistance Test for Coating System

A flat specimen shall be subjected to abrasion-resistance test. The test shall be
conducted in accordance with ASTM D-968-51 (falling sand) which specifies that
the end point shall be the first appearance of the base metal. Coating system
shall resist abrasion to the extent indicated by the use of not less than 200 liters
of sand to produce a first appearance of base metal.
Coating System Integrity Test

A sample shall withstand a salt-fog test for a minimum of 1,000 hours in
accordance with ASTM B – 117 – 64, including the scribe requirement in the
test. Immediately upon removal of the specimen from the test, the coating
system shall show no signs of cracking, peeling, blistering or loss of adhesion.
Pollution-Resistance Test
A flat specimen, with no protected edge, shall be subjected to the 30 cycles of
Kesternich testing without blistering, peeling or loss of adhesion. The
Kesternich test consist of eight hours of exposures at 40 ºC.
With 100% relative humidity (condensation) in a controlled sulphur dioxide
(SO2), carbon dioxide (CO2) atmosphere. Atmospheric concentrations of
pollutant gases shall be in accordance with Kesternich test standards DIN
50018. It shall be followed by 16 hours of dry time, which concludes one cycle
of testing.
Humidity-Resistance Test
A sample shall be tested for 1,000 hours at 100 deg F in accordance with ASTM
D – 2247 – 68 with no blistering, peeling or loss of adhesion.
Glare-Resistance Test
A flat sample shall be tested at 60 deg in accordance with ASTM D – 523 – 67.
The rating shall fall in the 10 to 15 range.
Pencil Hardness (ASTM D3363) : Shall be F minimum
Weatherometer (ASTM G23): after 5,000 hours exposure in sunshine Arc.

Weatherometer or Atlas Twin Arc Weatherometer, no chalk in excess of No. 8
per ASTM D 659 and no colour fade more than 5 NBS units perSTM D2244, as
operated under Dew Cycle conditions using 60/60 cycle.
Flexibility (ASTM D 1737) : Withstand 1T – 2T bends

BOOK III
Gloss (ASTM D 523) : 25-35 % reflectivity measured on 60 ºC gloss meter.
Impact : no removal of finish when tested as follows :

Using as sharp knife, make 6 or more parallel cuts at 1.5 mm intervals through
finish to bare metal.
Cross hatch similarly.

Reserve impact to at least 92 cm – kg or to point of metal rupture.
Apply Scotch cellophane tape firmly to scribe impacted are. Remove tape with
sharp pull, there shall be no loss of adhesion.
WATER TESTING
The completed roofing and siding installation shall be such that absolutely no
water will leak through. The Owner reserves the right to conduct water leakage
tests on installed roofing and siding at any time during the installation.
Should any leakage be discovered during such leakage test. The roofing and/or
siding shall be disassembled to the extent directed by the Owner and all joints
shall be resealed with specified sealant or tape, and the roofing and/or siding
shall be reinstalled. Joints shall be sealed as directed by the Owner on all
subsequent panels.
Warranty
The Contractor shall furnish the Owner, upon acceptance installation, a written
warranty that fluorocarbon organic coating has been applied in accordance
with licensee manufacturer’s process instructions and under normal conditions;
and it shall meet the following standards for a minimum period of 10 years (the
Contractor shall state the number of years warranty and also the number of
times he will replace any defective panels without charges of any kind):
- Will not chalk in excess of ASTM D659 No. 8 rating. Chalk rating shall be
determined by the procedure outlined in ASTM D659.
- Will not change colour more than 5 NBS units as determined in accordance
with procedures set forth in ASTM D 2244, after removal of external deposits
and chalk.
- Will not crack, check or peel (lose adhesion).

BOOK III
4.4.2.25 MISCELLANEOUS ARCHITECTURAL WORK

Miscellaneous Architectural Work shall include Contractor's designing,
detailing, furnishing, installing, inspection and testing of the following work
covered by this specification and as applicable to Contractor's building work
included in Book II refers to "Summary of Work" and Book IIIA, Section 4.4.1
Technical Specification refers to "General Civil and Architectural Design
Requirements". All materials and workmanship shall be neat and in accordance
with the best modern practice and subject to prior approval of the Owner.
DOORS
- Hollow metal doors.
- Rolling steel doors.
- Aluminum doors.
WINDOWS
- Aluminum top hung.
- Aluminum horizontal projected.
- Aluminum fixed windows.
LOUVERS
- Fixed louvers.
FLOOR FINISH
- Monolithic finish.
- Separate concrete floor finish.
- Ceramic.
MASONRY
- Brick work.
- Thin set tiles.
CEILING WORK
- Louvered grid ceiling.
- Acoustic ceiling.
PLUMBING
- Floor drains.
- Roof drains
- Plumbing fixtures

BOOK III
BUILT-UP ROOFING
CARPENTRY WORK
BUILDING APPLIANCES
- Kitchen unit.
- Steel lockers

The codes and standards of the following organizations are extracted from
Book II refers to "Codes and Standards" specifically applicable to the design,
AA Aluminum Association, U.S.A
AAMA Architectural Aluminum Manufacturers Association, U.S.A.
AMCA Air Movement and Control Association, Inc. U.S.A.
ANSI American National Standards Institute Inc.
AWWA American Water Works Association
LIA Lead Industries Association, Inc. U.S.A
JIS Japan Industrial Standard
NAAMM National Association of Architectural Metal Manufacturers,
U.S.A
NEMA National Electrical Manufacturers Association, U.S.A
NFPA National Fire Protection Association, U.S.A
SSPC Steel Structures Painting Council, U.S.A.
UL Underwriters Laboratories, U.S.A
N.1.5. Peraturan Konstruksi Kayu Indonesia (Indonesian Regulation
for Wooden Structure)
N.J.10. Bata Merah sebagai BahanBangunan (Indonesian Standard
for Bricks)
IEC International Electrotechnical Commission
4.4.2.25.3 DOORS
GENERAL
All doors shall be designed and provided by Contractor and shall meet the
following minimum requirements:

BOOK III
DESIGN LOAD
Wind Load
Exterior doors shall be designed to withstand a minimum wind pressure of 150
kg/m2 while interior doors shall withstand such pressure of 100 kg/m 2,
uniformly applied over the entire area of the door. The maximum deflection of
the door under wind pressure loading shall be 1/120 of the width span.
Operating Load
All exterior doors shall be designed to operate under a minimum of 50-kg/m2
load uniformly applied over the entire area of the door.
SWING HOLLOW METAL DOORS
HOLLOW METAL DOOR USAGE

Class I Doors
Seamless hollow steel construction, with 1,58 mm face sheets and additional
tubular reinforcement at head, hinged jamb and locksets or push-pulls and
prepared for surface hinges and thorough bolted to door, unless otherwise
indicated.
Class I doors shall be used for all exterior door locations. Class I doors shall also
be used for interior doors which are exposed to heavy traffic areas, abusive
usage or extreme difference in room pressure.
Class II Doors
Seamless hollow steel construction, with 1.27 mm face sheets and additional
channel reinforcement at head and prepared for mortise hinges, unless
otherwise indicated. Class II doors shall be used for all interior door locations.
HOLLOW METAL DOOR TYPE

The doors shall be flush type. Vision light shall be used when desired for a
safety reason or required for a plant operating reason i.e. to view any condition
on the opposite side of the door when the door is in the closed position.
Materials
Face sheets shall be roller-leveled or stretcher-leveled prime quality cold-rolled
carbon steel.
Stiffeners, reinforcing and other accessories shall be prime quality carbon steel.
Glazing
a. Glazing shall conform to the applicable requirements of ANSI Z97.1.

BOOK III
b. Normal door glass shall consist of minimum 6 mm thick clear polished wire
reinforced glass.
c. Glazing compound shall be in accordance with the manufacturer's
recommendations.
d. Setting blocks and spacer shims shall be made of neoprene rubber and shall
be provided as recommended by the glass manufacturer.
Door Frames
The frames of hollow metal doors shall be steel channel frame (ASTM A36) or
pressed metal frames (prime quality cold rolled carbon steel). Where a fire
rated frame is required, the frame construction shall be used.
Hardware
Hardware for the door shall include locks, butts, closers, holders, panic devices
etc. The fasteners shall be Type 304 stainless steel for exterior doors and brass
type for interior doors. All hardware shall meet the Owner's prior approval.
DOOR CONSTRUCTION DETAILS
General Provision
a. All doors shall be seamless hollow steel construction conforming to ANSI
A123.1, with each door formed from two face sheets of steel. No seam shall
occur on the door faces or sides. The top and bottom of the door shall be
closed and the internal construction shall consist of steel rib stiffeners.
b. All doors provided in the air conditioned room shall be insulated with
fibrous glass or mineral wool of 48.00 kg per cubic meter density, having
Underwriters Laboratories certification for the service.
Door Details
a. Bottom clearance :
Shall be maximum 3 mm between
bottom of door and finish floor.
b. For doors with full mortise butts : Doors and frames shall be mortised
to receive butts.
c. Bottom drips : Shall be provided on all exterior doors
d. Astragals : Shall be provided on the active leaf of all
double doors.
e. Door stop seals : Shall be provided on all doors.
f. Glazing details : Shall be provided with fixed glass stop on the
exterior side and removable glazing bead on
the interior side of a door.
DOOR TREATMENT

BOOK III
Exterior Doors
a. Both sides of face sheets, all surfaces of internal stiffeners, reinforcing,
etc. and all other steel accessories forming an integral part of the door
shall be hot dip galvanized in accordance with applicable requirements
of ASTM A123, A153, A385, A386 and other applicable ASTM Standard
Specifications for hot dip galvanizing of materials. The minimum weight
of galvanizing shall be that for G90. Poorly galvanized work will be
rejected.
b. After fabrication of the door is completed, all exposed surfaces shall be
properly cleaned and shall receive primer paint baked at 1500C for not
less than one half hour.
Interior Doors
a. Inside surfaces of doors shall be treated, before fabrication, with a rust
inhibitor, as approved by the Owner.
b. Exposed surfaces of doors shall be treated with Bonderite after
fabrication.
c. Primer paint shall be applied and baked at 1500C for not less than one
half hour.
ROLLING STEEL DOORS
CURTAIN
Exterior Doors
Curtain for exterior doors shall be of interlocking slats, roll formed (not drawn)
from not lighter than 1.27 mm hot-dip galvanized steel sheets of structural
quality, conforming to the applicable requirements of ASTM A446 for Grade A
steel, or better, with not less than G90 galvanizing. Galvanized surfaces shall be
provided with phosphate coating for good paint adhesion (painting shall be also
done by this Contractor).
Interior Doors
Curtain for interior doors shall meet the same requirements as for exterior
doors, except that slats shall be of manufacturer's standard gauge required for
such doors.
Slats
Slats of flat exterior design shall be formed in easy curves without sharp bends,
and shall be of the proper size and cross section to maintain the deflection
within safe allowable limits. Assembly of slats shall be such that damaged slats
can be removed and replaced easily.

BOOK III
Coiling
Curtain shall be coiled on a steel pipe of sufficient size to carry the door load
with vertical deflection not to exceed 0.80 mm per 300 mm of opening width,
and evenly balanced with helical springs contained in the pipe. All springs shall
be anchored to the tension rod, and held in position by the same adjusting
wheel, which shall be accessible from the outside.
Weather Stripping
a. Weather stripping shall be provided for all exterior doors, essentially
continuous around each door, for an airtight and weather tight seal.
b. Rubber weather stripping shall be provided on both sides of guides to
reduce the infiltration of air around the ends of curtain. Rubber shall be
not less than 1.60 mm thick. Weather stripping shall be attached to guides
with continuous flat bars arranged to permit replacement of worn
weather stripping.
c. Weather stripping at door head shall be sheet rubber, not less than 1.60
mm thick and shall be attached to head with a continuous flat plate to
permit replacement of worn weather stripping.
Bottom Bar
The curtain bottom bar shall be made of two structural steel angles, ASTM A36
or better, with hot dip galvanized finish.
Combination Safety Device and Weather Seal

a. This combination of safety device and weather seal at the bottom of
curtain shall be the manufacturer's standard, with electrical control to
stop and reverse curtain travel automatically. Weather seal shall be
extended full length of the door to provide an airtight and weather tight
seal.
b. If any rolling steel door in closed position rests on the top of railroad track
rails which project above floor level, the combination safety device and
weather seal shall be in three separate sections (from jambs to rails on
both sides, and between rails) and shall extend to floor level. A cutout in
door at each rail shall be provided, with the width of cutout equal to rail
head width plus 50 mm and the height of cutout equal to rail height above
floor plus 75 mm. Reinforcement of door shall be made horizontally
across cutout sections, and loop type rubber astragals shall be provided
projecting 75 mm below top of cutouts when door is in open position.

BOOK III
ACCESSORIES
Coil Brackets
Coil brackets shall be high-test gray iron castings of uniform texture, or
fabricated from steel plate not less than 6.35 mm thick. All surfaces shall be
smooth and even.
Hood
Curtain coil shall be housed within a sheet metal hood formed from not lighter
than 0.635 mm hot dip galvanized steel sheets, conforming to the applicable
requirements of ASTM A525 for G90 coating class, or better. Galvanizing shall
be treated for good paint adhesion as herein before specified for the curtain.
Separate galvanized steel sheet metal with baked enamel finish closure pieces
shall be provided as indicated or as required, to close the top of the hood tight
against the adjacent wall or structure to provide a weather tight seal.
Guides
Shall be formed from structural steel shapes, ASTNA A36 or better, to provide
slots of sufficient depth for retaining the curtain in guides. Continuous locking
bar shall be provided at each guide for anchoring wind locks. Guides shall be
hot dip galvanized.
End locks
Malleable iron end locks shall be provided on each slat for interior doors.
Wind locks
Wind locks on each slat shall be provided regardless of width, for all exterior
doors, and for interior doors where required. Wind lock capacity shall be as
required for the wind load specified in ‘Wind Load’ as mentioned before.
Electric motor operated rolling steel doors shall be used for large access
openings. Rolling doors shall bear the appropriate U.L. label or approved equal
when occurring in fire rated walls.
OPERATORS
Mounting
Operators shall be bracket mounted on hood except operators for exterior
mounted doors which shall be wall mounted inside the building.
Gearing
Operator gearing shall be high efficiency worm gear, running in an oil bath,
complete with spring-set of 380 or 220 Volt AC solenoid operated brake,
completely housed in an enclosure with IP53 degree of protection for indoor
location and IPW55 degree of protection for outdoor location.

BOOK III
Motors and Controls

a. Motors
Shall be designed for outdoor operation, high starting torque, hoist type, 380
volt, three-phase, 50 Hz, squirrel-cage, of sufficient power to operate doors at
an approximate speed of 0.3 m per second. For detailed electrical requirements
please refer to Book IIIC.
b. Pushbutton Stations
Unless otherwise indicated, each operator shall be equipped with a momentary
contact heavy duty three-button pushbutton station, marked "OPEN" -
"CLOSE" - "STOP" and with limit switches, of type acceptable to the Owner,
which will stop motor at limits of travel. Reversing magnetic contactor
complete with 380/220-volt control transformer and thermal overload
elements which will be furnished by others. Pushbutton stations shall be for
wall mounting, unless otherwise indicated.
c. Limit Switches
Shall be heavy-duty type, in IPW55 as defined by IEC 60529 or NEMA Type 4
enclosures for outdoor operation, with provisions for terminating Owner's
conduit and conductor wires. Limit switches shall be rated for 0.5A inductive at
220 V DC.
d. Control Circuits
Shall be suitable for 110 Volt AC operations.
e. Emergency Chain Operation
Emergency hand chain operator, which will not affect the timing of the limit
switch, shall be provided to operate each door in case of power failure or
removal of motor for inspection and servicing.
INSTALLATION
Rolling overhead steel doors and doorframes shall be installed by an installer
approved by manufacturer, in strict accordance with manufacturer's printed
instructions.
ALUMINUM DOORS
GENERAL
Aluminum wide stile entrance doors shall be fully glazed and the aluminum
doorframes are only used as indicated in the approved drawings.

BOOK III
MATERIALS
Doors, Frames and Trims
a. All doors, frames and trims shall be extruded aluminum; alloy 6063 with
anodized finish and the color will be selected later by the Owner without
any additional cost.
b. Thickness of any component of framing shall be minimum 3 mm.
Fasteners
All fasteners shall be 245 aluminum alloys and cadmium plated brass or bronze
and shall closely match the finish of the aluminum.
Glazing
All glazing shall be of minimum 12 mm thick tempered safety glass
Hardware
Hardware for the door shall include locks, butts, closers, holders etc. of
premium quality.
ERECTION
All doors and door frame shall be set plumb, level square and shall be
continuously caulked to provide weather tight seal at all joints between frames
and masonry or concrete with silicone rubber sealant per manufacturer's
recommendation.
4.4.2.25.4 WINDOWS
GENERAL
All exterior windows shall be aluminum top hung windows having float glass
glazing material and operated by a hand wheel except for the office areas
which shall be anodized aluminum, horizontal projected with insulating glass,
commonly known as "Thermo pane".
DESIGN LOADS
Wind Loads
Design wind loads shall be 150 kg/m2.
Wind Load Design
Unless otherwise indicated, all windows and window frames in exterior walls,
including mullions, connections, fasteners and other accessories shall be
designed to withstand the specified wind loads over the entire area of each
window without permanent distortion and without exceeding allowable unit
stresses and allowable deflections. Allowable unit stresses shall conform to the
applicable requirements of AA Specifications for Aluminum Structures.
Allowable deflections shall be 20 mm maximum.

BOOK III
DESIGN REQUIREMENTS
Height and Length
Height and length of any top hung window section shall be determined by
lighting and ventilating requirements, but shall not exceed 1.25 m in height and
8 m in length for a single continuous window unless otherwise indicated.
Mullions
All mullions shall be of fixed type, unless otherwise indicated.
Maximum Horizontal Spacing of Window Maintains: 60 cm nominal.
Vents
Entire area of each window shall be operable and shall open out to an angle of
45 degrees to provide a free air opening of approximately 75%, except where
windows are indicated to be fixed.
WINDOW COMPONENTS
The minimum thickness of any structural component of the window framing,
vents etc. shall be not less than 3 mm.
MATERIAL
Window framing and hinge members
Extruded aluminum, Alloy 6063, with T-temper as required for the service and
with anodized finish.
Flashing
Aluminum alloy Alcad 3004 and not less than 3 mm thick.
Weather stripping
Vinyl rubber bulb seal.
Fasteners
Shall be # 14 self-tapping screws made of Type 305 stainless steel, cadmium
plated, with bonded combination stainless steel and neoprene washers.
Spacing of fasteners shall be 30 cm O.C. maximum.
GLAZING
General Provision
a. Seal
All glazing shall be sealed with vinyl rubber bulb seal all around, between
the glazing and the sash, to obtain weather tightness.
b. Fastening
Fastening of glazing sheets shall be by continuous clamping action around
the edges of each sheet and no holes shall pierce the sheets.

BOOK III
Clamping action shall maintain the sheets in place under a load equal to at
least twice the design load, but shall also permit for proper expansion of
the sheet.
For fastening panels to supports, fasten to vertical mullions of windows
with aluminum cap mullion strip designed to permit expansion of panels
and fasten to horizontal members of windows with Type 305 stainless
steel self-tapping screws, cadmium plated, with bonded combination
aluminum or stainless steel and neoprene washers.
c. Cleaning
All glazing sheets shall be cleaned of all labels, dirt, paint etc. and washed
cleanly inside and outside, just prior to hanging of sash in window
openings.
d. Broken Glass
Contractor shall replace all glass broken during construction at no cost to
Owner.
Type
a. Glass Glazing
Shall be minimum 6 mm thick blue tinted polished float glass with heat
reflective coating.
b. Insulating glass glazing
Shall be minimum 25 mm overall thickness which consist of 6 mm blue
tinted polished float glass with heat reflective coating outboard and 6 mm
clear polished float glass inboard with 13 mm air space between.
Insulating glass glazing shall be used for windows in air-conditioned
offices control rooms etc.
ERECTION
All windows shall be set plumb, level, square and shall be continuously caulked
to provide weather tight seal at all joints between frames and siding, masonry,
concrete or girt with silicone rubber sealant per manufacturer's
recommendation.
4.4.2.25.5 LOUVERS
GENERAL
The location and the area of the louvers shall be determined by ventilation
requirements.
LOUVER TYPE
All louvers shall be fixed type.

BOOK III
DESIGN LOAD
Wind load
All exterior louvers shall be designed for a wind load of 150 kg/m2
Wind load design
Unless otherwise indicated, all louvers and louvers frames in exterior walls,
including connections, fasteners arid other accessories, shall be designed to
withstand the specified wind loads over the entire area of each louvers, without
permanent distortion and without exceeding allowable unit stresses and
allowable deflections. Allowable deflections shall be 20 mm maximum.
DESIGN REQUIREMENTS
Free area
The free area shall be 45% minimum as determined by using the equation in
AMCA Standard 500.
Pressure drop
Both intake and exhaust static pressure drops through a louver with an interior
screen shall not exceed 3.8 mm wg (water gauge) at a velocity of 240 m/min
through the free area when tested according to AMCA Standard 500, Figures
5.4 and 5.5 (wall mounted).
Water penetration
Water penetration of a louver shall not exceed 60 and 250 cc of water per m 2 of
free area in 15 minutes, at free area velocities of 240 and 300 m/min,
respectively. The water flow rates and length of time for each test shall be the
minimum values specified in AMCA Standard 500.
Louver size
Louvers and louvers frames shall be 15 cm in depth. The maximum louvers
width shall be limited to 1.75 m and the maximum louvers height shall be
limited to 5 m for a single louvers.
Screens
All louvers shall be provided with aluminum insect screens.
Assembly
Louvers shall be assembled by welding and/or mechanical fasteners.
Louver blades
Louvers shall have drainable blades.
Louver mullions
Horizontal and vertical louvers mullions shall be provided as required.
Mounting angles

BOOK III
Shall be continuous aluminum mounting angles as required. When using vinyl

gaskets for sealing, the mounting angles shall be grooved for permanent
insertion of seals.
MATERIAL
Louver Frames and Blades
Louvers frames and blades shall be extruded 6063-TS aluminum alloy. The
minimum thickness of louvers frames and blades shall be 3 mm.
Screens
Screen frames shall be 6063-TS extruded aluminum with a minimum thickness
of 2 mm, and shall be rewirable. The screens mounted on the interior or
exterior faces of louvers shall be 19 mm mesh. Wire shall be aluminum with 2.3
mm diameter intercropped at 6 mm intervals.
Seals
Blade and jamb seals shall be vinyl.
Fasteners
Fasteners used in the assembly of louvers shall be stainless steel.
FINISHING
General Provisions
a. Each louver shall have a fluoropolymer finish, with color matching the
adjacent wall.
b. Louvers mullions and exterior screens shall have the same finish and color as
the louvers.
c. Screen assembly shall be painted price to installation to louvers frames.
d. Mounted angles and interior screens shall be mill finished.
Fluoropolymer Finish
This finish shall be a polyvinylidene fluoride coating containing a minimum of
75% Kynar 500 resin. The coating shall be oven baked in accordance with the
manufacturer's printed procedures.
INSTALLATION
The installation of louvers shall be in strict accordance with the louvers
manufacturer's printed instructions.
Louvers frames shall be continuously caulked externally and internally. An
acceptable alternate to interior caulking is either extruded vinyl bulb
gaskets or sealing tape.

BOOK III
4.4.2.24.6 FLOOR FINISH
General
Floor finishes shall be applied in the various locations based on this
criteria.
Separate concrete floor finishes shall not be applied until all machinery
and equipment is in place.
Where floor drains are required in monolithic or separate finish a 3 mm
slope per 30 cm in the finish floor from high point of floor-to-floor drain
shall be used.
TYPES OF FLOOR FINISH

Monolithic Finish
Requirements
a. Monolithic finish is one produced on structural concrete slabs which
are poured all at one time with one concrete mix. Concrete for
structural slabs with monolithic finish shall be of the driest consistency
possible to work with a sawing motion of screed.
b. Surface shall first be screeded and then be floated to a smooth,
compact surface. Any excess water shall be removed during floating
operation by covering surface with burlap or similar material and
spreading cement or a cement-sand mixture, directly on top of burlap.
Spreading of cement or cement-sand mixture directly on top of
concrete will not be permitted.
c. After floating, the surface of concrete shall be covered by floor
hardener and shall be steel troweled to a smooth, slate like surface.
Final troweling shall be done after concrete is hard enough in order no
mortar accumulates on trowel and a ringing sound would be produced
as trowel drawn over the surface. Finish surface shall not be marked off
in areas or scored in any manner. A floor surface hardener colorcorn
shall be applied in accordance with the manufacturer's instructions for
permanently exposed floors.
Uses
a. Structural concrete floor slabs where monolithic finish is indicated on
the approved drawings.
b. Floor areas where resilient tile finishes (asphalt, rubber, vinyl etc.) are
indicated or as required.

BOOK III
Separate Concrete Floor Finish (Topping Slab)

Requirements
a. A separate concrete finish for the following areas shall be applied over
the rough slab finish.
The separate finish shall be reinforced and steel troweled similar to
monolithic finish and shall have minimum 225-kg/cm 2 compressive
strength at 28 days.
b. Provide bonding adhesive for separate concrete floor finishes up
through 10 cm thick.
c. Material of aggregate, cement, reinforcing bar and water shall conform
to the requirements of concrete work.
d. Field control test shall cover all material and concrete test required and
shall be done in accordance with the requirements of concrete work.
e. Cure, seal and dustproof surfaces of monolithic and separate concrete
floor finishes immediately after finishing by applying one coat of
membrane curing compound, resin base type (wax base will not
permitted) at the rate of approximately 7 mm 3 per liter, conforming to
applicable requirements of ASTM C 309, type 1.
Uses
a. Areas of the switchgear installation shall be provided with 75 mm
separate concrete finish reinforced with welded wire fabric to permit
accurate setting of the base channels and to provide a true level
surface in such areas. The top of the rough concrete shall be set 75 mm
below the nominal floor elevation.
b. Where specifically required for setting of contractor's other equipment.
Raised Floor
Requirements
a. The raised floor shall be self-supporting with adjustable height.
b. The raised floor shall be of adequate strength to withstand uniform live
load of 1,500 kg/m2 and 500 kg individual load measured in the center
of a panel.
c. The raised floor shall be of prime quality and unless otherwise required
by the Owner, the size shall be 600 x 600 mm.
Ceramic Tile
Requirements
a. Ceramic tiles shall be of prime quality and the tile color, size and
pattern shall be approved by the Owner.

BOOK III
b. The tiles shall be soaked and bedded on a prepared screed, in a 1: 3 by

volume cement/sand mortar with thickness of 10 mm. The tiles shall be
laid square and true with 3 mm wide joints grouted in matching
cement mortar.
c. Bonding adhesive shall be provided as specified in requirements of
‘Separate Concrete Floor Finish’ mentioned in previous paragraph.
d. The Contractor work shall include all cutting and fitting tiles to
abutments and protecting floor tiles after lying. The tiles shall be
polished, washed and left clean upon completion.
Uses
a. Office areas
b. Kitchen and dining areas
c. Hallways and stair landings
d. Other areas unless otherwise indicated.
Glazed Tiles
Requirements
a. Glazed tiles shall be prime quality and the tile color, size and pattern
shall be approved by the Owner.
b. The tiles shall be installed as refers to clause ‘Ceramic Tile’ in the
previous paragraph.
Uses
a. Toilet
b. Shower rooms
c. Locker areas
CHEMICAL RESISTANT SPECIAL COATING WORK

Scope
a. The Contractor shall arrange for the services of a qualified special
coating manufacturer to provide coating system(s) for the areas and
under the conditions specified. Such systems(s) shall be guaranteed by
the Contractor for the period of time and to the extent herein
specified.
b. The areas involved shall be indicated on the approved drawings
including concrete surfaces of floors, trenches, curbs and embedded
steel items etc. in the following structures:
b.1 Water Treatment Plant.
b.2 Waste Water Treatment Plant.
b.3 Electro Chemical Plant.

BOOK III
c. The work shall include the selection of the total coating systems,
preparation of substrate surfaces, priming, coating application,
preparation of each coating to accept next coating, for a multi-coating
application and treatment of the finish surface. The Contractor shall
propose the coating material for the approval.
Epoxy coating similar to Master-top is recommended for b.1 and b.2
and flak line or approved equal shall be used for b.3. The Owner will
select the color of the coating.
Documentation to be Submitted
The Contractor shall submit the following minimal documents for the
Owner's review before selection of a coating:
a.Generic description and identification numbers of proposed materials,
recommended dry film thickness of each coating, application and
specific color for each different area.
b. Preparation procedures for concrete and steel, application procedures
including, but not limited to sketches of corner, concrete crack, drain,
curb, equipment base, joint treatment and curing methods.
c. Ambient environmental and safety conditions required, prior to, during
and after application until curing is completed.
d. Test and experience data indicating proposed system's past success in
performing under similar conditions.
e. Detailed repair procedures.
Warranty
a. The Contractor shall guarantee the coating system(s) provided, for a
period of five years following the commercial operation.
b. This guarantee shall cover any failure of the coating system(s) relative
to abrasion, cracking, blistering, delaminating and discontinuities which
occur during exposure to the service conditions specified in ‘Chemical
resistant Special Coating Work’ paragraph above.
c. Upon notice by the Owner of any failures the Contractor shall promptly
visit the site, examine the failure and advise the methods of repairs,
time when repair can be made and environmental conditions required
for repairing the failure.
d. Repairs under the guarantee shall be at no cost to the Owner and shall
be performed promptly at the Owner's convenience.
e. Such repair or removal and replacement shall be guaranteed for the
remaining time of the original guarantee.
f. If desired the Contractor will be allowed to periodically inspect the
coating system as to continuation of specified service conditions and
possible signs of imminent failure.

BOOK III
Service and Surface Conditions

a. Chemical exposures
a.1 Floor surfaces shall be considered as subject to "splash and
spillage", trenches shall be considered as totally immersible areas,
with trenches immersed 50 percent of the time. These conditions
will prevail throughout the estimated service life of the coating
system(s).
a.2 Coated areas may be exposed to either acidic or caustic conditions
based on the worst possible combinations of the fluids as
determined by the Contractor.
b. Abrasion exposure
b.1 Floor Surfaces: Constant foot traffic, occasional rubber wheeled
fork lift traffic both empty and loaded.
b.2 Trenches: Slow flow of effluent.
c. Temperature
c.1 Floor Surface: Operating temperature range varies from 20 0C to
500C.
c.2 Trenches and Sump Surfaces: Operating temperature range, 200C
to 500C; temperature shock as determined by the Contractor for
the effluent.
d. Existing Conditions of Surfaces.

d.1 Concrete Cracks: Concrete surfaces may have shrinkage cracks, the
coating system shall accommodate, without cracking (failure) a
0.2-5 mm in width movement of the existing cracks and the
occurrence of new cracks in the concrete.
d.2 Concrete finish shall have a minimum age of 30 days prior to the
application of the coating. Concrete shall be made using type II
cement and shall have minimum of 250-kg/cm2 compressive
strength at 28 days.
d.3 Steel Surfaces may or may not have shop applied prime coats.
Working Conditions
a. The Contractor shall protect existing equipment and surfaces which are
not to be lined against coating deposits, dust and other detrimental
factors associated with coating work.
b. Coating shall be applied after the completion of the equipment
erection or as directed by the Owner.

BOOK III
Quality Control and Assurance

a. Application of the coating system materials shall conform to the
printed instructions of the coatings manufacturer regarding
environmental, preparation of surfaces, material mixing, material
application, curing and repair.
b. Material Information.
c. Documentation indicating that the coating system(s) have been
applied, cured and inspected per coating manufacturer's requirements
shall be submitted to the Owner.
d. Documentation indicating that coated surfaces in trenches have been
spark-tested by the Contractor with voltage(s) required by the
Contractor by criteria submitted to the Owner.
Acceptance Criteria
The surface coating system(s) shall meet the following criteria before
acceptance by the Owner.
a. Floors shall have an evenly distributed nonskid surface.
b. Trenches shall have smooth surfaces.
c. The surfaces shall be free from blistering, delamination, cracks and
discontinuities.
d. The coating system shall be of the required minimum and maximum
dry film thickness accepted by the Owner.
e. Surfaces shall be uniform in texture, color and appearance.

BOOK III
4.4.2.24.7 MASONRY WORK
GENERAL
Masonry work shall include brick or concrete hollow blocks masonry work as
required with all associated reinforced bracing, anchors, ties and damp proof
course.
MATERIAL
Bricks
Bricks shall be Indonesian Type I, 125 mm x 75 mm x 250 mm size and obtained
from an approved local manufacturer and shall comply in all respects with
Indonesian Standard N.I.10 “Bata Merah sebagai Bahan Bangunan”.
Bricks shall be well fired and free from deep or extensive cracks, damage to
edges and corners, pebbles and expansive particles of lime. They shall also,
when a cut surface is examined, show uniform texture.
Glazed Ceramic Tile
The size of ceramic tile shall be approximately 100 mm x 200 mm x 6 mm,
standard quality, self-spacing and glazed ceramic tile.
Color and pattern shall be approved by the Owner.
Uses
a. Toilet room : full height of the wall
b. Shower room : full height of the wall
c. Kitchen : 1.75 m height of the wall
Mortar for Masonry
Mortar shall conform to the applicable requirements of ASTM C270 with a
minimum compressive strength of 176 kg/cm2, at 28 days and consist of the
following materials:
a. Sand : ASTM C144, use washed natural sand only
b. Lime:
b1 Quick lime : ASTM C5
b2 Hydrated lime : ASTM C207, Type S
c. Portland cement : ASTM C150, Type I
d. Mixing water : ASTM C270
Use either of following mixes (by volume) as best fits work and as required to
produce best quality workmanship
a. Portland cement-lime-sand mix
a.1 Portland cement or approved equal
Type I one part
a.2 Hydrated lime, Type S, or lime putty Not less than 1/2 part nor
more than 1-1/3 parts

BOOK III
a.3 Masonry sand 2-1/4 to 3 times sum of volume of cement and lime.
b. Masonry-cement-sand mix
b.1 Masonry cement …….. One part
b.2 Masonry sand ……..… 3 to 4 times volume of masonry cement.
MIXING
Shall be Mechanical batch mixer, in accordance with ASTM C270.
REINFORCING, TIES AND ANCHORS

Continuous Reinforcing Ties (For double wythe wall)
a. Steel, heavy duty or extra heavy continuous truss type, hot dip galvanized
after fabrication, shall conform to ASTM A82.
b. Width of ties: 5 cm less than overall thickness of masonry construction.
Tie bar Anchors

a. Type
Adjustable bar ties, sliding in bar anchors welded to supporting steel or
sliding in bar or dovetails anchor slots securely fastened or anchored to
concrete or masonry backing.
b. Material for Tie bars and Bar Anchors
Steel, hot dip galvanized with minimum size of 5 mm diameter unless larger
size is required.
c. Shape and Make
Triangular, rectangular or oval ties bars, as required. Provide complete with
manufacturer's standard anchors for the construction.
Corrugated Metal Ties (For double wythe wall)

Steel, hot dip galvanized, 79 mm thick, 2.5 cm wide by 17.5 cm long, corrugated.
Bar Reinforcing
Steel, ASTM A615, Grade 60, intermediate grade, deformed (except 6 mm
diameter bars may be smooth).
MEMBRANE DAMP PROOFING FOR BRICK WORK

2 plies of 0.67 kg/m2 coal tar saturated felt.

BOOK III
CONSTRUCTION OF BRICK WORK

Masonry work shall be plumb and straight about doors, windows, louvers and
other openings, etc. The Contractor shall verify correct size and location of
openings before masonry work is started.
The masonry wall shall be reinforced as follows:
a. Where total area exceeds 12 m2, the wall shall be reinforced with reinforced
concrete column and beam.
b. When the height of brick wall: exceeds 30 times the wall thickness,
reinforced concrete bond beam shall be provided at interval not exceeding
15 times the wall thickness.
Built in all concealed work as required for conduits, bushings, appliance and other
built in work and for all openings, chases, recesses and slots.
All embedded portions of structural steel columns and beams shall be covered
with at least 13 mm thickness of sand cement mortar unless otherwise required.
Special precautions shall be taken in the erection of the masonry surfaces to
maintain the necessary plumpness and alignment of masonry as required for thin
set ceramic tile.
Membrane damp proofing shall be provided for all exterior masonry resting on
concrete foundations, floors, beams, curbs etc.
All masonry wall surfaces shall be plastered with 15 mm thick mortar consisting
of minimum 1 part of cement to 4 parts of sand by volume and shall be smooth
finished.
The toilet and shower room walls shall be plastered with minimum 1 part cement
to 3 parts of sand by volume and shall include an approved water proof
admixture.
Plaster wall shall be protected from draughts and from drying unevenly before it
has set.
INSTALLATION OF CERAMIC TILE

Tiles shall be installed with the thin-set bed method using water resistant organic
adhesives. Installation shall also conform to the applicable requirements of ANSI
A108, “Standard Specifications for Installation of Ceramic Tile with Water
Resistant Organic Adhesives”.
Grout to be used for installation of tile work shall be subject to Owner’s approval.
Cutting : All cutting of glazed tile shall be performed on the job with a
power driven saw in such a manner as to provide true and even
edges.
Grout Joints : Grouts shall be slightly concave tooled.
Cove Bases : Cove bases shall be provided for glazed side or sides of all walls.

BOOK III
Cleaning : All tile surfaces shall be cleaned with burlap as work progresses.
4.4.2.24.8 CEILING WORK
GENERAL
This section covers acoustical ceiling and louvered grid ceiling, including
supports and accessories.
Louvered grid ceiling shall be only used for control room area and other area
required by the Owner.
Exposed tee suspended moisture resistant acoustic tile ceiling shall be used for
in high moisture areas such as toilet and shower rooms.
Exposed tee suspended acoustic tile ceiling shall be used for the other area
such as office, kitchen, dining room etc.
MATERIALS
Louvered Grid Ceiling
Louvered grid ceiling shall be aluminum with aluminum lacquer finish and shall
be square or rectangular with removable core.
Exposed Tee Suspended Moisture Resistant Acoustical Tile Ceiling.
The following type and make with lay in panels, installed in exposed mill finish
aluminum grid suspension system.
Suspension System: Exposed tee type, direct hung.
Tile : Ceramic Acoustical Lay in Panel, 60 cm x 60 cm x 1.58 cm; Travertine
Design, washable matte white finish.
Exposed Tee Suspended Acoustical Tile Ceiling
One of the following types an makes with lay in units, installed in exposed
painted metal grid suspension system.
A. Suspension System:
A.1. Exposed tee system, direct hung, with interlocking crossties and all
required accessories.
A.2. Exposed tee system, snap lock, direct hung, with interlocking beam
crossties and all required accessories.
B. Tiles
B.1. Incombustible mineral fiber, 60 cm x 60 cm x 1.90 cm, shadow line panel,
glacier pattern, non-directional with aluminum foil back.
B.2. Incombustible mineral fiber, 60 cm x 60 cm x 1.90 cm, reveal edge, texture-
tone pattern, non-directional with aluminum foil back.

BOOK III
ANCHORAGE OF HANGER
Steel sub framing: Continuous hanger support steel sub framing, spaced 1.20 m
on centers for acoustical tile ceiling are welded in place to the structural
supports.
Anchorage of hanger to concrete with sleeve type or self drilling anchors, will
not be permitted.
TIE WIRE
Soft monel or 18-8 stainless steel, 1,587 mm.
HANGER
All hangers shall be galvanized. Minimum size of galvanized annealed wire
hanger shall be 2,778 mm for acoustical tile ceilings. The hanger size for each
location shall be as required by the weight of the suspended ceiling and spacing
of the hangers. Extra hangers shall be provided at each corner of the light
fixture and as required for the work, in order there are at least two additional
hangers for each 1.20 m length of light in addition to the regular grid system
hangers.
ERECTION
GENERAL PROVISION
Erection of all acoustical ceilings shall conform to the applicable requirements
of ANSI Standard Specifications and to the requirements herein specified.
The ceiling grid and fixing system shall be designed and installed in a manner
that will allow ready access for ease of maintenance.
SUSPENSION SYSTEM
Acoustical lay in type ceilings shall be unrestrained perimeter construction,
providing freedom of movement at intersections with walls.
Hangers
Hangers shall be of ample length and shall be attached to the overhead
construction in such a way that the ceiling is securely and rigidly braced and
supported to prevent any sag or displacement as a result of either downward
load or upward pressure. Attachments shall develop the full strength of each
hanger.
Main Tees
Main tees shall be spaced not more than 60 cm apart with outer lines not more
than 20 cm from walls and parallel thereto. Tees shall extend to within 25 mm
of walls at ends and shall be continuous for their full length. Splices shall be
made with manufacturer’s standard splices.

BOOK III
Furring
Cross tees shall be erected at right angles to main tees and spaced as required
by the ceiling layouts. Cross tees shall be securely attached to the main tees at
each crossing by special clips or by saddle tying.
CLEAN UP
After ceiling work has been completed, all rubbish shall be removed, surfaces of
ceiling panels and trim shall be cleaned and floors shall be left clean.
4.4.2.24.9 PLUMBING
GENERAL
Plumbing work shall include Contractor designing, furnishing, installing,
cleaning, painting, coating, inspection and testing of the following work
specified hereinafter:
a. Floor drains
b. Roof drains
c. Water supply and sanitary equipment work
d. Plumbing Fixtures and Accessories
Piping from drainage and supply system shall not be routed over electrical
equipment. Pipings which must be routed over the electrical equipment shall
be insulated.
DRAIN SYSTEM CRITERIA

FLOOR DRAINS
Floor drains shall be provided at all concrete floors for normal washdown,
drainage of any water accumulation from equipment drain or to drain water
used in fire protection system.
All drain piping shall have a minimum slope of 3 mm per 300 mm with an
accessible cleanout in each change of direction.
Sleeves are not required for floor drain piping.
All floor and equipment drainage shall flow through an oil separator before
discharging to a sump, tank or exterior drain system.
In a monolithic finish, the top of drain shall be placed 10 mm below finished
floor elevation with a drainage area of 40 to 50 m2 per drain.
All floor drain grates shall be cast iron.
ROOF DRAINS
Rainfall intensity data used shall be the maximum recorded in the area.

BOOK III
Roof drains for all major roofs shall be located in the center of every other
column bay to a maximum of 15 m centers, or 800 m2 of drainage area with a
minimum size of 15 cm diameter. On smaller roofs 10 cm diameter drains may
be used. Penthouse roofs and canopies may have 7 cm diameter drains.
The roof drainage down comers shall discharge on splash blocks located at
grade.
All roof drain grates shall be cast iron.
MATERIAL
Floor Drains
a. Base Slabs (except as noted otherwise).
a1.All piping shall be service weight cast iron coil pipes and fittings.
a2.Floor drains shall have cast iron body and strainers with caulked
outlet and extensions as required. Strainers to meet finished floor
level.
b. Above Base Slabs (except as noted otherwise).
b1.Use "Victaulic type" couplings and fittings with galvanized steel
pipe.
b2.If floor drain system must be connected to sanitary system use cast
iron screwed drainage fittings with galvanized steel pipe.
b3.Floor drain shall be cast iron body and grate with screwed bottom
outlet.
Roof Drains
Hot dip galvanized butt-welded steel pipe with "Victaulic type" conforming to
the following ASTM specifications.
a. 250 mm dia or smaller: ASTM 120 Schedule 40
b. 300 mm dia and larger: ASTM A53 Schedule 30
WATER SUPPLY AND SANITARY EQUIPMENT WORK
GENERAL
Water supply, sewage and sanitary work shall include Contractor's designing,
furnishing, cleaning, painting, coating, inspection and testing of the following
work specified herein after:
1. Water supply equipment work
2. Sanitary equipment work
The Contractor shall submit shop drawings of the fabricated items to the owner
for approval. The shop drawings shall clearly show the details of fabrication,
installation, dimensions, sizes, operation, methods of anchoring and any other
pertinent details required for satisfactory installation.

BOOK III
EQUIPMENT AND MATERIALS

Elevated Water Tank
a. Type of elevated water tank
Elevated water tank shall be of windpressureproof and earth quake proof
construction and consist of a sandwich construction panel with facing
materials comprising fiberglass-reinforced polyester (F.R.P) made from
unsaturated polyester resin and glass fiber of with foam plastic core.
b. Materials
Unsaturated polyester resin shall be used for the facing material and shall
be waterproof, weatherproof, and harmless to human health.
The fiberglass shall be made from non-alkali fiberglass as stipulated in JIS
RJ411-3417.
The foam plastic core material shall be rigid and closed-cell.
Any filters and coloring agents shall be harmless to human health.
c. Accessories
The elevated water tank shall be provided with adequate amount of the
following accessories:
c.1 Water inlet pipe connection (F.R.P)
c.2 Water outlet pipe connection (F.R.P)
c.3 Drainage pipe connection (F.R.P)
c.4 Connections for overflow hole and overflow pipe with insect
screens (The insect screens shall be made of plastic and the
connections shall be made of F.R.P)
c.5 Air passage and air vent with insect screens (The insecticide nets
shall be made of plastic and the passage and vent shall be made
of F.R.P)
c.6 Covered inspection opening (plastic)
c.7 Reinforcing materials, supports and stands for elevated water
tank
c.8 Steel ladder
c.9 Electrode mount
c.10 Breakwater cover
d. Shape, Dimensions and Performance

The shapes, dimension and performance of the elevated water tank shall
be designed by the Contractor in accordance with the manufacturer’s
specifications and submitted to the Owner for approval.
Sanitary Equipment and Accessories

a. All sanitary ware plumbing fixtures shall be of high quality and of
Indonesian manufacture, specified in table refers to or approved equal.

BOOK III
b. All fittings for sanitary wares shall be in accordance with JIS A 5514.
c. All accessories and visible sanitary wares such as faucets, flush valves and
flushing pipes shall be nickel chromium plated.
Piping Materials and Pipe Fittings

a. Pipe
a1. Water supply pipes
The water supply pipe shall be the steel pipe lined with rigid PVC in
accordance with JWWA-K116.
a2. Drainage and air vent pipes
The drainage and air vent pipes shall be galvanized steel pipe in
accordance with JIS G3442, rubber joint type cast iron pipe in
accordance with JIS G5525 and HASS-210, rigid PVC pipe type VP in
accordance with JIS K6741 and/or the centrifugal reinforced
concrete pipe as specified in JIS A5303. The above pipes shall be
applied for the drainage and air vent pipes.
b. Pipe Joints
b1. Water supply pipe joints
The water supply pipe shall be joined using malleable cast iron
flanged fittings coated with plastic in accordance with JIS B2301. The
flange type pipe joints shall be made by welding the flange to the
end surface of the steel made joints as stipulated in JIS B2211 or JIS
B2212, and further by lining the internal surface with rigid PVC of
the same specification as that used for lining of the steel pipe.
b2. Drainage and air vent pipe joints
The drainage and air vent pipe shall be joined using malleable cast
iron fittings in accordance with JIS B2301. Screwed type drainage
pipe joint shall be in accordance with JIS B2303. Rigid PVC pipe joint
shall be in accordance with JIS K6739.
c. Gate Valves
c1. Gate valves with a nominal diameter of 50 mm or less shall be
bronze with threaded ends as stipulated in JIS B2023 and rated at 10
kg/cm2.
c2. Gate valves with a nominal diameter of 65 mm or above shall be cast
iron outside screw type with flanged ends as stipulated in JIS B2044
and rated at 10 kg/cm2.

BOOK III
d. Check Valves
Check valves with a nominal diameter of 50 mm or less shall be bronze,
swing type with threaded ends as stipulated in JIS B2025 and rated at 10
kg /cm2.
Check valves with a nominal diameter of 65 mm or over shall be cast iron,
swing type with flanged ends as stipulated in JIS B2045.
e. Automatic Air Release Valves (Air Vent Valve)
Automatic air vent valve shall be float type with a function to
automatically release air, and shall be actuated precisely. This valve shall
be so designed that it withstands the maximum service pressure.
f. Ball Taps
The main parts of the ball taps shall be made of bronze, and the ball shall
be brazed to a copper plate. In case the nominal diameter of ball is 50 mm
or less, the ball tap shall be of a screwed type, but in case the diameter of
the ball is 65 mm or over, the ball tap shall be of a flanged type.
The ball tap shall be so designed that it will actuated precisely without
causing water hammer due to rapid opening or closing.
g. Flexible Joints
Flexible joint shall be of a bellows type, and shall have sufficient flexibility
and resistance against pressure. The bellows and protective steel band
shall be made of cold rolled stainless steel plate/sheet (SUS-304) as
stipulated in JIS G4305.
The length of one flexible section shall be 400 mm.
h. Strainers
The strainers shall be of Y-type. In case the nominal diameter is 50 mm or
less, the strainer shall be of a screwed type made of bronze, but in case
the diameter is 65 mm or over, the strainer shall he of a flanged type
made of cast iron.
i. Pipe Washers
Pipe washer shall be made of nickel chromium coated brass or stainless
steel.
j. Pipe Sleeves
Pipe sleeve shall be made of steel pipe or steel plate with a thickness of
0.4 mm or greater (0.7 mm or greater in case the nominal diameter
exceeds 200 mm). However, non-water proofed floor pipe sleeve to be
used indoors shall be made of laminated cardboard.
k. Pipe Support Fittings

BOOK III
k1. Pipe supports shall be resistant to contraction and expansion,

rolling, etc. of pipe, and be of a construction having sufficient
bearing strength against load of pipe when liquid is contained inside.
The materials to be used shall be in accordance with JIS G3101
(Rolled Steel for General Structure).
All steel fittings shall be finished by galvanizing.
k2. The inserts shall have sufficient strength for supporting the pipe
and shall have a construction suitable for connecting hangers,
etc. All inserts shall be made of cast iron, press formed malleable
cast iron or steel plate.
l. Cementing/Bonding Materials
l1. Thread sealing material
Thread sealing tapes shall be in accordance with JIS K6885
(Unsintered Polytetrafluoroethylene Tapes for Thread Sealing (Raw
Tapes)), and shall be non-hazardous to human health.
Paste sealing agent shall not be affected by the liquid in pipe and
shall consist of contents suitable for the intended purpose. In case
the agent is used for sealing of piping for drinking water, it shall not
be hazardous to health.
l2. Packing
Packing shall be in accordance with JIS K6353 (Rubber Goods for
Water Works Service), JIS R3453 (Compressed Asbestos Sheets), etc.
and be suitable for the quality of water, water pressure,
temperature, etc.
l3. Caulking lead
Caulking lead shall, in principle, be the 5th Class of those stipulated
in JIS H21 10 (Pig Lead).
l4. Caulking hemp
Caulking hemp shall, in principle, be jute of # 130 single threads
which, when tied in a bundle, has a diameter or about 25 mm.
Drainage Pipe Fittings

a. General
a1. Water sealing depth for traps shall be 50 mm or more, and the
total effective area of the drainage hole for strainer shall not be
less that the sectional area of the drainage pipe.
a2. The materials for drainage pipefittings shall be Grade 2 or higher
as stipulated in JIS G5501 (Grey Iron Castings) in case of cast iron
materials. For brass casting, the materials shall be Grade 2 or
higher as stipulated in JIS H5101 (Brass Castings).

BOOK III
a3. All iron castings shall be cold-painted having a synthetic resin finish
containing refined bituminous material.
a4. The nickel chromium plated section of the drainage pipefittings
shall be equivalent to or higher than Class 1 of Grade 2 in JIS
H8617 (Electroplated Coatings of Nickel and Chromium).
b. Floor Drain Trap
Floor drain trap shall be made of cast iron, and the strainer shall be
nickel chromium plated brass. The floor drain trap for asphalt-
waterproofed floors shall be of a waterproofing type and for other type
of floors shall be of an ordinary type.
c. Sink Trap
Sink traps shall be made of cast iron and shall be furnished with an
inside basket made of brass or stainless steel (SUS 304). The strainer
shall be made of brass having a nickel chromium plating finish.
d. Floor Clean-Out
Floor clean-out shall be of screwed type made of brass having a nickel
chromium plating finish. Floor clean-outs for asphalt-waterproofed
floor shall be of a waterproofing type and for other types of floors shall
be of an ordinary type.
e. Under floor Clean-Out
Under floor clean-out shall be of screwed type made of brass.
f. Drainage Pipe Fittings
Drainage pipefittings shall be made of brass having a nickel chromium
plating finish, and the chain and stopper shall be made of stainless
steel.
Pit and Pit Cover

a. General
a1.The materials for iron castings shall be equivalent to or higher than
Grade 3 as stipulated in JIS G5501 (Grey Iron Castings).
a2.Iron castings shall be baked with refined tars in accordance with JIS
K2473 (Processed Tars) to which more than 2 % linseed oil or
drying oil is mixed, or shall be cold-painted with refined
bituminous materials to which synthetic resin finish is added.
b. Invert Pit
b1. Invert pits shall be of concrete construction and all visible portions
shall be finished by mortar coating. Moreover, the pit shall be
furnished with a cover, and an invert applicable to the pipe
diameter shall be provided on the bottom of the pit.

BOOK III
b2.The cover shall be made of cast iron with chain, and shall be of an
odor proof type able to withstand the weight of 2,500 kg.
c. Storage Pit
c1. Storage pit shall be of concrete construction and all visible
portions shall be finished by mortar coating. Moreover, the pit
shall be furnished with a cover.
c2. The cover shall be made of cast iron with chain, and shall be of an
odor proof type able to withstand the weight of 2,500 kg.
d. Valve Box
Valve boxes shall be of a circular type made of cast iron with a cover.
e. Garden House Valve Box

Garden house valve boxes shall be of a box type made of cast iron and
furnished with a cover. The bottom of the box shall be so designed as
to facilitate drainage of water.
f. Trench Covers and Frames

Frames and anchors shall be of all welded construction and of
structural steel angles, covers shall be checkered plates.
Frame construction shall be such that tops of frames and cover plates
are finished flush with the floor.
Slots shall be provided for lifting. All sharp edges and buss shall be
removed from cover plates and exposed edges of frames.
Size of cover plates shall be designed to facilitate easy removal.
The thickness of checkered plate shall 6 mm, with stiffeners it
required to limit deflection.
The material shall conform to JIS G3101-SS41, or equivalent.
g. Watertight Manhole Frames and Covers

Watertight manhole frames and covers shall be installed where
indicated in the drawings. The frames and covers shall be of heavy
type designed water pressure is 3 kg /cm2 or more and of 700 mm
diameter. Frames shall have flanges at base and top, rubber gaskets,
and stainless steel cap with air vent valve.

BOOK III
EXECUTION
Erection Works
a. Elevated Water Tank
a.1 The location of the elevated water tank shall be arranged by the
Contractor approval by the Owner.
The elevated water tank shall be firmly fixed with anchor bolts
having sufficient strength so that the tank will not slide laterally
nor move in any way due to horizontal seismic or wind loads.
a.2 The elevated water tank shall be installed on a horizontal plane
on the foundation having a steel base, and the foundation shall
have an even bearing surface against the load. The elevated
water tank and the steel base shall be fixed firmly with anchor
bolts to withstand wind pressure and other loads.
a.3 After installation, the elevated water tank shall be cleaned and
washed with water. Following that the tank shall be sterilized by
using sodium hypochlorite solution, etc.
a.4 The piping related to the elevated water tank shall be supported
in order that the tank would not be weighed down by the pipe.
Flexible joints shall be provided for all respective connecting
pipes to the water tank except for the drainpipe and air vent
pipe.
b. Sanitary Ware, Accessories and Fittings
b.1 General
- In case wall hanging fittings are fixed on a concrete wall or
brick wall, expansion bolts shall be used.
- In case a metal panel or lightweight steel framed board wall is
set, steel plate and worked angle materials or hard wood patch
shall be fixed to the sanitary ware in advance.
- In case a part o the sanitary ware is embedded in concrete, the
portion of the sanitary ware that comes into contact with
concrete or mortar shall be covered with asphalt having a
minimum thickness of 3 mm.
However, the bottom contact surface of sanitary ware, such as
that for standing type urinals, shall be filled with sand.
b.2 Stool
- The upper end of the stool be set horizontally in place after
deciding the precise setting position.
- Prior to connecting the stool to the drain lead pipe, the
connecting end of the lead pipe shall be flared up to the
diameter of the flange, and after inserting the non drying
sealing materials between the external surface of the flange

BOOK III
and connecting end, the stool shall be connected to the drain

lead pipe by nuts fastened from above. The plate thickness of
the external end of the flared lead pipe shall not be less than 2
mm. Moreover, the end of the flange for the lead pipe to be
connected to the stool shall be supported sufficiently with
hangers, etc. so that no load of drain pipe, etc, will act directly
on the stool.
b.3 Urinal
- Urinals shall be set precisely in place without any
misalignment.
- Connection of urinal with drainpipe shall be carried out in
accordance with the procedures for connecting the stool in
(d2).
- The setting height of urinal shall be 530 mm from the floor
surface to the upper front end of the urinal.
b.4 Wash basin and hand wash basin
- The bracket or back hangers shall be firmly set in place, and
the washbasins shall be fixed carefully so that the upper
surface of the basins will be kept horizontal. In order to
eliminate leakage of water, heat-resistant non-drying sealing
materials shall be filled around drain holes of the basins and
around openings between the drainpipe fittings.
- The setting height of the basins shall be 800 mm (approximate)
from the floor surface to the upper front end of the basins.
b.5 Slop Sink
The trap shall be set in place without any misalignment, and the
connection of slop sink to the drainpipe shall be carried out in
accordance with the procedures for the above washbasins in
(d4).
b.6 Water Cock
Water cocks shall be fixed firmly after precise centering by fully
taking into account the convenience of use and harmony with
the surrounding facilities.
A sufficient space for the spout shall be provided between the
end of the spout of water cock and the flood level rim of the
drain receptacle.
b.7 Mirror
The setting height of the upper end of the mirror shall be 1,800
mm from he floor surface.

BOOK III
Connection of Pipes
a. General
a1. All pipes shall be carefully cut at a right angle against the axial center
of the pipes so as to avoid any deformation of the sections, and the
cut end shall be finished smoothly.
a2. All pipes shall be connected after removing any chips, dust and other
foreign matter and after confirming that all such foreign matter has
been completely removed from inside the pipes.
a3. In case piping work is temporarily suspended, all pipes shall be
sufficiently protected to avoid the entry of foreign matter.
b. Water Supply Piping
b1. No water supply piping shall be connected according to an insertion
system unless specified otherwise.
b2. Epoxy resin synthetic rubber rust inhibitors shall be-sufficiently
coated over the end face of threaded portions and the bottom of
threaded portions of joints. All rust inhibitors to be applied to any
drinking water piping shall not be hazardous to human health and
shall not have any adverse effect on drinking water.
c. Drainage and Air Vent Piping
c1. Prior to connecting the galvanized steel pipes, the pipes shall be
correctly threaded in order that a slight clearance is provided
between the end face of pipes and the recess of joints in order to
obtain the tapered threaded pipe portion.
The steel pipes shall be screwed tightly into the joints
c2. All cast iron pipes shall be connected by using rubber rings. In this
case, the pipes shall be inserted into the rubber rings until the end of
spigot comes into contact with inserted into a position near the end
of spigot in advance shall be inserted into the pipes carefully in order
that no twisting will occur in the opening between the socket and
spigot. The, the rubber rings shall be set in close contact with the
pipes while uniformly fastening the tap bolts and nuts using a junk
ring.
c3. All rigid PVC pipe shall be carefully connected by a cold working
method in order that no ridges or abrupt diameter changes will occur
between the connected pipes. The flow of water in the piping shall be
smooth and uninterrupted.
c4. All centrifugal reinforced concrete pipes shall be connected by using
collars.
After both ends of the joined pipes have achieved tight contact with
each other at the central part of the collar and are carefully set in
place to ensure proper alignment in the surrounding opening, stiff
-consistency mortar shall be placed into the opening. In this case, all

BOOK III
cement and water inside the pipes shall be completely removed. In

case one end of a pipe is made into a socket from after connecting a
collar to the end with mortar, mortar shall be placed about 10 mm
away from the pipe end.
Piping
a. Water Supply Piping
a1. General
- Prior to execution of piping work, detailed study shall be made on
the relationship between other piping and equipment, and all
positions for pipe laying shall be decided by taking into account
the precise slope of the respective piping.
In the case where piping is laid inside a building, setting of the pipe
support fittings and embedding of pipe sleeves shall be carried our
without any delay and in accordance with progress of the work.
- Flange joints shall be inserted for all main piping at appropriate
intervals in order to ensure easy removal of such piping.
- In the case where piping is branched from the main piping, T-joints
shall be used.
- Air release valves shall be provided at the dead air space portion in
piping, and a mud discharge valve shall be provided at the portion
where mud is collected. The size of the mud discharge valve shall
be the diameter of the related pipe, however, the size of the valve
shall be 25 mm minimum.
- In case anti-sweat covering is not provided for piping, pipe
washers shall be fixed to all portions of piping that penetrate
through ceilings, floors, walls, etc. and is visible from the outside.
- Any openings between the piping that penetrates through fire
service areas, etc., shall be filled with rock-wool heat insulation
and other noncombustible approved material to maintenance the
fire rating of the wall.
- In case where a pipe sleeve is used at a place requiring water
tightness, lead caulking shall be provided in the opening between
the sleeve and pipe.
- In the case where any steel pipe and similar materials are laid
under the ground, such pipe shall be protected against corrosion
by either a double coating of coal tars or a double winding of
corrosion proof vinyl tapes (JIS Z1901 "Protective Polyvinyl
Chloride Tapes").
- Any repair of steel pipe, cast iron pipe and lead pipe with caulking
shall be prohibited.

BOOK III
- After completion of pipirrig work, the inside of the piping shall be

cleaned by water pressure during of hydrostatic testing of the
piping. In the case of piping for drinking water, the piping shall be
sterilized until free residual chlorine of 0.2 ppm or over has been
detected at the end of the piping.
a2. Gradient
In the case of horizontally running pipe, the up feed pipe shall have
an upward slope and the down feed pipe shall have a downward
slope. In principle, the gradient shall be 1/250.
a3. Support Pitch
- The support pitch of the horizontally running pipes shall, in
principle, be in accordance with the values in the following table
and, wherever necessary, all bent sections and branching sections
shall be supported. In the case where steel pipes or similar pipes
are supported with hangers, a steady rest shall be provided for
each horizontally running pipe in order to avoid looseness of the
pipe due to movement at the time of earthquake.
- A steady rest shall be provided for indoor vertical pipe at least at
one spot on every floor.
MAXIMUM SUPPORT PITCH OF WATER SUPPLY PIPE

(Unit: m)
Nominal Pipe 20 or less 25-40 50-80 100-80 200 or more

Diameter
Maximum 1.8 2.0 3.0 4.0 5.0

Pitch
b. Drainage and Air Vent Pipe

b1. General
- All horizontally branched drainage pipes, etc. shall be combined
nearly horizontally at an acute angle of less than 45 0.
- In case bent lead pipe is used, the pipe shall be carefully fabricated
so as not to Impair its roundness, and no branch drainage pipe
shall be connected to the bent section of the pipe.
- No wastewater shall be discharged directly from the following
equipment.
• Cooling tower/s
BOOK III
• Air conditioners
• Elevated water tanks
• Pumps
- Indirect drainage pipe shall be opened while maintaining a space
of over twice the diameter or the pipe from the drain receptable
and flood level rim.
- In case an obstacle is foreseen in providing the above opening,
appropriate measures shall be taken for protection.
- The lowest portion of the vertical drainage pipe shall be fixed with
a support stand where necessary.
- Air vent pipes shall run out vertically or at an angle of less than
450C from the horizontally branched drainage pipe, and in no case
shall the pipe be run out horizontally.
- In the case where air vent pipes on floors are connected to vertical
air vent pipes, the said pipes shall be connected at the place over
150 mm from the flood level rim of the related equipment.
Vertical air vent valves shall be connected to the stack vents in
accordance with the above procedures.
- In case a pipe is buried, a pit shall be excavated from the lower
end of the pipe to a depth of about 100 mm in case the nominal
diameter of the pipe is 300 mm or less, and about 150 mm in case
the nominal diameter exceeds 300 mm. After unscreened crushed
stone, unscreened gravel or pit sand has been laid and compacted,
the pipe shall be laid. However, the portions where joints are
provided shall be excavated further if necessary.
Initial back filling of pipe shall be carried out up to the centerline
of the pipe to ensure immovability, and after sufficient
compaction, the pipe shall finally be buried.
b2. Gradient
The gradient of horizontally running drainage pipes laid inside a
building shall be at least 1/100. All air vent pipes shall have an
upward slope facing the vertical pipes and shall be free from reverse
slope and unevenness.
b3. Support Pitch
a. Horizontal cast iron pipes shall be supported at a pitch of less
than 1.6 m, and the deformed fittings to be connected shall be
supported at a pit of less than 0.6 m, respectively.
In case pipes are connected with rubber, each straight pipe and
deformed fitting shall be supported at the connected portion.
Vertical pipes shall be supported at least one spot on each floor.

BOOK III
b. The support pitch of non-metallic pipe (PVC pipes) shall, in

principle, be as shown in the table below, and vertical pipes shall
be supported at more than one spot on each floor.
SUPPORT PITCH OF VINYL PVC PIPE

(Unit: mm)
Nominal diameter 40 or less 50 or more
Maximum pitch 1.2 1.5
MATERIALS
Plumbing fixtures and accessories shall conform to the requirement specified in
Table 4.4.2.24 - 1 or approved equal.
All supply piping for plumbing fixtures shall be copper piping with solder or
threaded Fittings.
All sewer piping shall vitrified salt glazed extra strength clay pipe per ASTM C700
and standard strength cast iron pipe per ASTM A74 with bell and spigot joints.
All supply piping for water shall be hot-dip galvanized butt-welded steel pipe with
threaded fittings.
INSTALLATION
All plumbing fixtures and accessories shall be installed in strict accordance with
manufacturer's printed instructions.
After installation is completed, the Contractor shall thoroughly clean all plumbing
fixtures and accessories. Surface of ail fixtures and accessories shall be free of
stains, markings, scratches and debris.
INSPECTION AND TESTING

The Contractor shall test all drainage systems and plumbing fixtures and
accessories after installation to ensure the proper operation as follows:
a. Water Supply Pipes
A hydrostatic test of water supply pipes shall be carried out prior to
coating and prior to shielding and backfilling, or after completion of
piping. The minimum pressure retention time shall be 30 minutes.
The test pressure of piping below elevated water tanks shall be twice
the pressure equivalent to the static head.

BOOK III
b. Drainage Pipes
The water-filling test of the drainage pipes shall be carried out prior to
coating and prior to shielding and backfilling, or after completion of
piping.
The water passage test of sanitary drainpipes shall be carried out after
sanitary wares, etc. have been attached.
The minimum water retention time in case of water filling test shall be
30 minutes or more and that in case of the water passage test shall be
15 minutes or more.
Any adjustments or repairs needed, shall be made by Contractor at his
own expense and shall be completed to the satisfaction of the Owner.

BOOK III
TABLE 4.4.24-1 PLUMBING FIXTURES

Manufacturers / Model
Items Type / Description Numbers
TOTO Indonesia
Lavatory One piece white vitreous L511 V3

china lavatory
Supply & Drain Fitting Combination fitting with TGL511 – MPAN

aerator and pop up drain
Supply pipe 9 mm wall supply, loose key STANDARD

stop, escutcheon, reducing
coupling, chromium plated
P-Trap 31 mm adjustable P -Trap, TGP

cleanout plug, tubing drain to
wall, chromium
Mirrors One over each lavatory TS 119 AS5

Mirrors for lavatories and
wash-fountains. Stainless steel
angle frame, satin finish with
concealed and theft proof
locking device (size as
required)
Towel Rail One at each lavatory, stainless TS113W

steel rod and fitting
Water Closet Indonesia Style C97V/A – 97 KL & TV

150NWV 12
Water Closet Floor mounted, siphon jet C72/3/710 BRTL

action, white vitreous china,
elongated bowl, 37 mm top
spud, 2 bolt caps
Flush Valve Chromium plated, with STANDARD

vacuum breaker, 2,5 cm screw
driver angle stop and quiet
flush collections

BOOK III
TABLE 4.4.24-1 PLUMBING FIXTURES ( CONTINUE )

Manufacturers / Model
Items Type / Description Numbers
TOTO Indonesia
Paper Holder One each water closet, forged S-20
brass chromium plated, metal
roller
Coat Hook One each water closet, forged TS 118 WS

brass chromium plated
Wall Hung Urinal 45 cm white vitreous china U57M

washout urinal with integral
extended shields, flushing rim,
strainer and trap with
cleanout, and 5 cm back outlet
Flush Valve Chromium plated, with STANDARD

vacuum breakers, 18 mm
screw driver angle stop and
quiet flush action
Strainer Beehive grid STANDARD
4.4.2.24.10 BUILT-UP ROOFING
GENERAL
The built-up roofing over concrete/precast concrete slabs shall comprise of
alternate four layers of felt and four layers of bitumen to form a flexible roof
cover with sufficient strength to resist normal expansion and contraction
forces, and a top aggregate layer.
MATERIALS
CANT STRIPS
Fiberboard material, 10 cm high by 10 cm wide, beveled at 45 0.
CONCRETE PRIMER
Solution of petroleum residual asphalt in petroleum solvent, per ASTM D41.
VAPOR RETARDER
Asphalt coated base sheet 1.8 kg /m2 per ASTM D2626. For use only on
concrete and precast roofs.

BOOK III
BITUMEN
Coal Tar (Type III, per ASTM D450).
PERMANENT ROOF SYSTEM

Coal-Tar-Saturated organic felts (0.65 kg /m2) per ASTM D227.
AGGREGATE SURFACING
Peagravel per ASTM D1863.
ROOF WALKWAY TRAFFIC PADS

Shall be 1 m x 1 m x 25 mm thick precast concrete pads.
Reglets, Metal Flashing and Counter Flashing: Shall be 0.47 mm thick stainless
steel conforming to ASTM A240, Type 304.
PERMANENT ROOFING SYSTEM

CONCRETE PRIMER
The existing concrete /precast concrete channel roof slabs shall be sealed
with an asphalt primer. Apply the primer at a rate of 0.2 liter to 0.4 liter per
m 2.
Application and curing shall be in accordance with manufacturer's printed
instructions.
VAPOR RETARDER
Provide single-ply asphalt coated base sheet on the roof area using asphalt
bitumen by solid mopping at a minimum rate of 1.12 kg/m 2.
The vapor retarder shall be lapped 10 cm over the preceding sheet and 15 cm
at the end laps. Extend the vapor retarder 15 cm up all vertical surfaces.
The vapor retarder (coated base sheet) shall be manually broomed into the
hot asphalt and laid without wrinkles, buckles or kinks and free from pockets
and blisters.
The vapor retarder shall be applied so that the direction of water flow is not
against the laps.
APPLICATION OF FELTS
Coal-tar bitumen shall be uniformly applied over the vapor retarder at a rate
of 1.22 kg/m2. Into this coating of pitch, while hot, lay four layers of coal-tar
saturated felts lapping each sheet 0.7 m over the preceding one and lapping
the ends of the felts not less than 15 cm. End stripping or tapping of these
laps will not be permitted. Each ply shall be uniformly mapped, using not less
than 1.22 kg/m2 of bitumen so that in no place shall felt touch felt. At no time
shall the mopping extend more than 2.5 m ahead of th6 felt roll.
When beginning the membrane roofing installation, install the appropriate
width starting strips of felt to achieve the required four-ply system.

BOOK III
Lay plies of felt in single fashion. Apply felts so that the direction of water
flow is not against the laps of the plies.
Felts shall be manually broomed into the hot bitumen and laid without
wrinkles, buckles or fish-mouths so that the felts are free from pockets and
blisters.
At ail vertical surfaces extend the felts up 50 mm above the cant strip and
mop.
APPLICATION OF AGGREGATE SURFACING

The final finishing of the roofing shall be a triple weight application of coal-tar
bitumen at a rate of 3.66 kg/m2. Aggregate shall be distributed into the hot
bitumen at a rate not less than 20 kg/m2 of gravel.
Application of the coal-tar bitumen and aggregate shall be performed at the
same time as lying of the roofing felts, except that in periods of hot and dry
weather, the top surfacing may be delayed overnight. For work not
completed on the same working day, Contractor shall glaze felts left exposed.
4.4.2.24.11 CARPENTRY WORK
GENERAL
Carpentry work shall include the supply, installation and finishing of all
wooden doors, cabinets and other timber work as required and/or as
MATERIAL
Lumber
a.All carpentry work shall comply with the requirement of P.K.K.I. “Peraturan
Konstruksi Kayu Indonesia” 1961 – N.I.5.
b. Lumber for doors and frames shall be teak class I and shall be well
seasoned with moisture content not to exceed 15% before preservative
treatment.
c. Lumber shall be free treated of knots, shakes, cracks and not or other
defects which could affect its strength and durability.
d. All lumber shall be treated with approved preservative solution to
preserve against moisture penetration, fungal decay, insect and vermin
attack and to improve the dimensional stability of the wood.
e. All lumber shall be varnish finished.

BOOK III
Nails, Screws, Bolts and Nuts

All nails, screw, bolts and nuts shall be of sufficient size and strength and shall
be adequately spaced to ensure that all lumber work and joinery work is
constructed in the best possible manner.
DOORS
All interior doors shall be flush teak veneered on both sides of the doors as
indicated and varnish finished except in the toilet area where the doors shall
have plastic vinyl lamination on the toilet side of the door.
All doors shall have 4 cm minimum overall thickness.
The Contractor shall supply and install all fixtures including door closers that
shall meet prior approval of the Owner.
WORKMANSHIP
DELIVERY AND STORAGE
Contractor shall be responsible for seeing that finish materials are not
delivered until the building and/or storage area is sufficiently dry so that
woodwork will not be damaged by excessive changes in moisture content.
PROTECTION
All finish materials shall be protected from weather and from damage of any
sort during transit. After delivery at the Site, all such materials shall be
protected, as approved, to prevent damage from excessive changes in
moisture content, or from any other damage. Any material which is damaged
shall be replaced to the complete satisfaction of the Owner at Contractor’s
expense.
JOINING FOR JOINERY
All joints shall be tongue and groove, mortise and tenon or rabbet and shall
be glued, unless otherwise indicated, using glue suitable for the purpose of
the complete work. Nails shall not be used in joints. Dowels shall be
hardwood and at least two dowels shall be used in each joint. Complete joints
shall be tight and so formed as to conceal shrinkage.
Glued joints shall be used where provisions need not be made for shrinkage
or other movements in the connections. All glued joints shall be cross-
tongued or otherwise reinforced. Surfaces to be glued shall have a good sawn
or planed finish and be kept clean, free from grease, dirt, sawdust and any
other contamination.
Adhesive for joints shall be resin of a type approved by the Owner, with
adequate pressure applied to ensure intimate contact whilst the adhesive is
setting.
All joinery work should be left well sanded and finished smooth and ready to
receive a final varnish finish.

BOOK III
NAILING
Nailing shall be blind nailed wherever possible, where not possible, nailing
shall be so located and driven as not to be conspicuous on the surface. All
exposed nails shall be carefully countersunk, the holes filled and the surface
finished to match surrounding wood finish.
FINISH WORK
Finish woodwork shall be installed plumb and level, straight and true and shall
be carefully fitted and scribed (so as not to mar or damage wood surfaces to
adjacent materials.
All exposed surfaces shall have a fine smooth finish and shall be free from
machine or tool marks, abrasions, raised gain or other imperfections. Any
imperfections found on completion of work shall be corrected, at the
Contractor’s expense, to the complete satisfaction of the Owner.
4.4.2.24.12 BUILDING APPLIANCES & SPECIALTIES

GENERAL
This shall include Contractor’s furnishing and installing complete kitchen units
and lockers as indicated on the general arrangement drawings.
KITCHEN UNIT
The unit shall include but not be limited to the following including all
accessories:
 Electric range with two burners.
 Electric refrigerator.
 Double stainless steel sinks and countertop.
 Upper cabinets.
Kitchen unit shall be installed complete with all plumbing connections, all
electrical wiring, switches etc. integral with equipment and ready for plug in
to electrical outlets and all conduit and outlet boxes as required. All electric
appliances shall be suitable for operation on 220 VAC, single phase, 2 wires,
50 Hertz.
The color of the appliances cabinets and counters will be selected by the
Owner.
STEEL LOCKERS
Metal lockers for locker rooms shall be 46 cm wide by 53 cm deep by 65 cm
high, double tiers with sloping top.
The shelves of all lockers shall be perforated and the upper and lower part of
each locker door shall be fully louvered for proper ventilation.

BOOK III
Each locker shall have standard equipment including metal shelf, chrome
plated handle, bolts and nuts and a combination pad lock for each locker.
Doors shall be of heavy construction to resist warp or bending. Each door
shall be provided with a number plate, a nametag plate and means for
padlock attachment.
Locker doors shall be equipped with rubber bumpers.
Each locker shall be cleaned of all scale after fabrication, primed with a baked
on primer and finished with baked on enamel of the color approved by the
Owner.
4.4.2.26 MISCELLANEOUS AND EMBEDDED METAL WORKS
4.4.2.26.1 SCOPE
This specification covers design, detailing, furnishing, fabricating, delivering
and erecting miscellaneous and embedded metal components.
WORK INCLUDED
Design, detailing, furnishing, fabricating, delivering, unloading/handling,
sorting, storing, protecting, removing from storage and erecting
miscellaneous and embedded metal components. Scope includes but not
necessarily limited to the following items.
- Welded grating
- Checkered steel floor plates.
- Stairs and treads
- Handrails
- Ladders
- Guard plates
- Embedded steel members, including steel door frames
- Banding of all openings in grating occasioned by field run
piping.
- All materials necessary, including Type 316 stainless steel studs for
grating hold-down clips to connect miscellaneous metal components to
structural steel and to other parts of the structure already in place.
WORK NOT INLCUDED

Design, furnishing and installation of the following items are not included in
this specification.
- Anchor bolts and anchor bolt sleeves into concrete foundations
- Ductwork

BOOK III
- Metal doors and pressed steel frames

- Pipe hangers, electrical equipment and duct supports
- Structural steel framing for buildings.

Contractor shall fully comply with the Project Quality Assurance/Quality
Procedures and Documentation the provision “Submittals” of this
specification shall apply.
ENGINEERING DOCUMENTS, DESIGN
Section 6 "Design Requirements" of this specification describes the
responsibilities and contractual obligation of the Contractor.
Contractor shall submit design drawing in 30 percent and 90 percent design
stages. The 30 percent submittal shall include typical details. Contractor shall
incorporate the Owner's comment on the 30 percent submittal into the
continuing work and shall consider the 90 percent submittal as the final
design product. Make change in the 90 percent submittal only as response to
the Owner's comments.
ENGINEERING DOCUMENTS, DETAILING

Subsequent to the approval of the design drawing shop drawing and erection
diagrams shall be submitted for all materials furnished, fabricated, delivered
and erected. Shop drawings shall include details of all members and their
connections and bill of materials showing the piece mark number, the
number of members required, shape designation, detailed length, unit weight
of each member, total weight for each member and total weight for each
drawing. Erection drawings shall show the marking and position of each
member, details of member's field connections, and bolt schedules for
erection. An index of shop details and erection drawings shall be provided.
Design calculation shall be submitted for those connections that do not
confirm to AISC Manual Connection Tables and are designed by the
Contractor.
QUALITY CONTROL PROCEDURES
Contractor shall submit at least the following procedures :
- Field test and inspection procedures
- Non destructive testing procedures

BOOK III
- Cleaning and painting procedures

- Packaging and shipping procedures

The Contractor shall prepare and provide for the Owner the following quality
control documentation :
- Material certificates and material test reports
- Welding qualification reports
- Qualification report of manual welders and welding machine operators
- Erection inspection report
- Documentation that surface preparation and surface coatings have been
examined and that all such preparations and coatings conform to the
requirements.
- Welding inspection report including NDE reports, when applicable.
- Bolting Inspection Report.
TABLE 4.4.25 – 1
WITNESS POINTS
Part or Assembly Operations, Test, or Examination
Fabrication, inspection, Observe fabrication methods, inspection procedures and verify

handling, storage and adequacy of measures for controlling handling, storage and
shipping shipping on a first operation basis.
Welds and materials In-process nondestructive examinations on a first operation

basis for each examination required by the procurement
documents and applicable codes and standards.
Welds Fit-up and welding on a first operation basis for each applicable
code and procedure requiring submittal to Buyer.
Welds Post-weld heat treatments on a first operation basis for each

procedures requiring submittal to Owner.
Welds Major weld repairs
Protective coatings Surface preparation on a first operation basis for each type of
preparation

BOOK III
TABLE 4.4.25 – 2
HOLD POINTS
Part or Assembly Operation, Test, or Examination
Mill test reports Review of mill test reports at time steel is delivered to the
fabrication.
Welds Review and signoff of all completed radiographs.
Full penetration welds Inspection required radiographic or ultrasonic examination,

review and signoff of all completed radiographs or witness
ultrasonic examination.
Supplier's quality verification Review and signoff for completeness and documents.
accuracy.
Release for shipment
4.4.2.27 DRAINAGE AND DUCT WORKS

The work specified in this section covers design and supply of all labor,
materials, transportation, equipment and services, installation or construction
and testing of the following works :
Sewage and storm drainage work including but not limited to ditches, piping,
manholes, culverts etc.
Duct work for electrical cables and pipes.
The requirements for the excavation and the concrete work are covered in
Book IIIA, Technical Specifications refer to "Earth Works" and refers to
"Concrete Work" respectively.

The Contractor shall comply with the requirements of Sect 4.4.3.1 refers to
"Codes and Standards".
The Codes and Standards of the following organizations extracted form Book II
refers to "Codes and Standards" are specifically applicable to the design of the
work included in this Specification:
AASHTO American Association of State Highway and Transportation
Officials.

BOOK III
ASTM American Society for Testing and Materials.
4.4.2.27.3 CONCRETE PAVED DITCHES

Concrete paved ditches shall be constructed according to the approved
drawings and at the locations shown thereon, or as directed by the Owner.
Construction of the paved ditches and cutoff wails shall be in conformance with
lines, grades and dimensions designed by the Contractor and approved by the
Owner. The concrete shall have a minimum compressive strength of 225 kg/cm 2
conforming to the requirements of Technical Specification refers to "Concrete
Work".
The cement and sand used shall meet the requirements as specified in
Technical Specification refers to "Concrete Work".
4.4.2.27.4 STORM SEWERS AND CULVERTS

Drainage culverts, storm sewers and paved ditches shall be one of the following
type as specified, or as indicated on the approved drawings.
STORM SEWER
Storm sewer sections shall be rectangular concrete paved ditches with the
minimum width of 30 cm.
Concrete paved ditches shall be constructed according to the details on the

approved drawings and at the locations shown thereon, or as directed by the
Owner. Construction of the paved ditches and cutoff walls shall be in
conformance with lines, grades and dimensions shown on the approved
drawings.
REINFORCED CONCRETE DRAINAGE PIPING

Pipe and Fittings : Reinforced concrete, confirming to the applicable
requirements of ASTM C76, Class IV or approved
equal.
Size : As indicated on the approved drawings
Markings : Each length of pipe shall be clearly marked with
name of manufacturer, location of plant where
made, date of manufacture and pipe class.
Joints : The Contractor shall provide all materials required to
complete the work and shall install rubber gasket
and joint material between the joints of concrete
pipe sections in strict accordance with the
manufacturer's instructions.
Coating : not required.

BOOK III
Concrete pipe shall not be backfilled until inspected and approved by the
Owner.
CULVERT
Culverts shall be reinforced concrete and if located under roads they shall be
designed to withstand an HS20-44 loading. Expansion joint shall be provided for
the culverts having more than 15 m length and for expansion joints, the water
stops as specified in Technical Specification refers to "Concrete Work" shall be
used.
MANHOLES
Construct manholes of precast concrete, complete with cast iron frames and
covers, steps etc. herein specified.
Precast Concrete Manholes

Type: Precast reinforced concrete ring type with precast reinforced concrete
base and rubber "O-ring" or flat type rubber compression joints, conforming to
applicable requirements of ASTM C478, "Specifications for Precast Reinforced
Concrete Manhole Risers and Top" and to requirements herein specified or
approved equal.
Loading Design manholes for HS20-44 truck loading.
Precast Elements
a. Base closed end pipe type with bell end.
b. Ring sections for walls shall be provided in multiples of 200 mm in
height, with tongue and groove joints as required by depth of each
manhole. The wall thickness for rings shall be 100 mm for 900 mm
diameter manholes, 125 mm for 1200 mm diameter manholes and
150 mm for 1800 mm diameter manholes.
c. Top section shall be eccentric cone type with a minimum wall
thickness of 100 mm for 900 mm diameter manholes, 125 mm for
1,200 mm diameter manholes and 150 mm for 1,650 mm diameter
manholes, or shall be flat slab type not less than 200 mm thick, as
required by manhole depth.
Arrange both types for use with cast iron manhole frame and cover.
d. The rings and top cone shall have precast openings for field
installation of cast iron steps and for all required drainpipes entering
manholes.
Joints shall be rubber "O-ring" of flat rubber compression type, with
manufacturer's standard rubber ring. Mortar joints may be used only per
Owner's approval.
Frames, Covers and Steps
Cast iron as indicated on the approved drawings.
BOOK III
Coating: Coat uniformly with coal tar pitch varnish.

Type: As indicated on the approved drawings.
Installation of Manholes
Subgrade shall be levelled and free of projecting stones, rocks etc.
A layer of sand, not less than 100 mm thick, shall be placed over the subgrade
before installing the precast base. Exercise care in installing the base level with
full bearing throughout the sand cushion to ensure that the completed catch
manhole is plumb.
Install sections, using rubber rings, in strict accordance with manufacturer's
instructions, or as approved by the Owner.
4.4.2.27.5 CABLE DUCT, TUNNEL AND PIPE TRENCH

All reinforced concrete ducts; tunnels and trenches shall be constructed in
accordance with the approved drawings.
The ducts and trenches shall be poured in place reinforced concrete
construction. All ducts and trenches shall be covered with removable trench
covers. All trenches shall be drained. Pumps if required for draining, shall be
automatic permanent type.
The covers shall be precast reinforced concrete and shall have a smooth and
even upper surface, be square in shape, free from cracks and from damage to
edges.
At all changes in direction, thrust blocks having a minimum volume of 0.20 m3
per pipe or larger as required by design shall be provided and shall be cast in
situ, centered on the bisector of the bend angle.
Sectional steel for covers support shall be embedded in concrete. It shall be
thoroughly set in line and level and duly fixed to the form and/or maintained as
to avoid any displacement during pouring. Tolerance of setting (distance
between vertical flanges) shall be + 0.5 cm (5mm) and - 0.00.
Draw pit shall be provided in duct not exceeding 8 m in length.
The ends of non-continuous cable or pipe ducts shall be temporarily sealed to
prevent the ingress of backfill material.
In reinforced concrete cable ducts, the reinforcement shall not be installed as
such forming a closed loop around the ducts.
Individual reinforcement bars, which would form part of closed loop, shall be
electrically insulated from each other in order to break the loop.
Tunnels shall be cast in place reinforced concrete completed with manholes,
ladders, drain pits, automatic permanent pump and drainage ditch. Manholes
shall be provided at every 100 m distance and at change of direction. Minimum
height of tunnel shall be 1.75 m and minimum width shall be 2 m. Mechanical
ventilation shall be provided in the cable tunnel.
Expansion joint shall be provided at every 50 m distance, at every junction and
at charge of direction of ducts, tunnels and trenches.

BOOK III
Unless otherwise required, all steel embedded in concrete shall be galvanized.
4.4.2.28 ROAD WORK, PARKING WORKS

The scope of work under this section shall cover the furnishing of design , all
materials, labor, equipment, transportation, and installation services for the
following work and as shown on the approved drawings:
- Preparation of subgrade to proper grade for concrete, including compaction
- Preparation of subbase
- Rigid Pavement Construction.
- Providing curbs and gutters.
- Wheel stop installation at parking areas.
4.4.2.28.2 CODES AND STANDARD

The Contractor shall comply with the requirements of this book section
4.4.3.1.”CODES AND STANDARD”.
The Codes and standard of the following organizations extrated from this book
section 4.4.3.1 “Codes and Standard are specifically applicable to the design,
manufacture and testing of the work included in this specification
AASHTO M 155-63 : Granular Material to Control Pumping under
concrete pavement
ACI 117 : Standard Tolerances for Concrete Construction and
Material
ASTM A615 : Specification for Deformed and Plain Billet-Steel
Bars for Concrete Reinforcement
ASTM A663 : Specification for Steel Bars, Carbon, Merchant
Quality, Mechanical Properties
ASTM C39 : Test Method for Compressive Strength of
Cylindercal Concrete Specimens
ASTM C309 : Specification for Liquid Membrane Forming
Compounds for Curing
ASTM C496 : Test Method for Spliting Tensile Strength of
Cylindrical Concrete spcimens
ASTM D2628 : Specification for Preformed Polychloroprene
Elatomeric Joint Seals for Concrete Pavements

BOOK III
4.4.2.28.3 SUBGRADE PREPARATION FOR ROADS AND PARKING

Subgrade shall be excavated or filled, as required, and then shall be graded and
compacted to provide a firm foundation of uniform density throughout.
Completed subgrade shall be true to alignment, grade and cross-section,
including the required crown as shown on the approved drawings.
CBR test on the finished level of completed subgrade shall have a minimum
value of 6 in the 98% dry density compacted condition, as per ASTM D698,
Method D.
Prior to placing any fill required to bring the subgrade to its proper level,
stripped areas shall be covered against any loose or otherwise unapproved fill
materials, organic materials, or any foreign or deleterious matter.
Any holes, ruts and similar defects shall be filled in with approved fill materials
as approved by the Owner. Unstable areas, projecting stone or rock, and similar
defects shall be cut out and such areas shall be filled. Round shaped gravel shall
categorically not be used.
All fill required shall be compacted as specified in Specification refers to "Earth
Work" sect 4.4.2.3
Following the completion of subgrade preparation, the Contractor shall
proceed with the next phase of works.
Drainage culverts under the subgrade shall have been constructed before the
subgrade work is carried out.
The Contractor shall provide temporary drainage as required to facilitate his
work activities during the wet season.
4.4.2.28.4 ROAD WORKS
GENERAL
The Contractor shall perform all-phases of road construction work as required
in this specification and in accordance with the approved drawings.
MATERIALS
Materials used for the base concrete shall be as specified below:
Sub Base Material
To minimize pumping of the pavement slab granular material shall be used as
Sub base under concrete pavement.
Such material shall consist of sand, sand-gravel, crushed stone, crushed or
granulated slag, or combination of these material.
The material shall meet the following requirement
Maximum size Not more than 1/3 the thicknes

of subbase

BOOK III
Passing 0.075 min size 15 percent maximum

Plasticity index 6 max
Liquid Limit 25 maximium
The material shall be graded suitably to permit compaction of such a density

that a minimum increase in densification will occur after the pavement is in
service.
Pavement slab
The Pavenent material shall consist of concrete which shall have compressive
strength ( f’c) = 290 kg/cm2 at twenty eight (28) days.
Forms
Forms shall be wood or metal and shall extend for the full depth of the
concrete. All formwork shall conform to the requirements of Specification
refers to "Concrete Work".
Reinforcement, Tie Bars and Dowels
Reinforcing steel for concrete pavements shall comply with the requirements of
ASTM A615,
Tie bars and dowelss shall be Grade 40
All steel shall be clean and free from mill scale, loose rust or oil.
Joint Sealers
Joint filler and sealing compounds shall be applied as indicated below :
Type of joint sealer shall be of one of the following types as detailed :
 Preformed elastomeric strips ( comply to ASTM D2628, ASTM D553 )
 Silicone sealants ( comply to ASTM D792, ASTM D2240, ASTM C794, ASTM
C793-7 )
Joints in concrete slab
Joints shall be designed as logitudinal and transverse construction joint,
transverse expansion joint, and logitudinal and transverse weakened-plane
joints. Unless otherwise detailed on the drawings transverse expansion joint
and contraction joint shall be normal to the logitudinal joints, and continuous
from edge to edge of the pavement throughout all paving slabs which are
connected in a single paved area. Expansion and contraction joint be provided
at maximum 30 m interval.
Placing Concrete
The Engineer shall be notified at least 24 hours in advance of placing concrete.
Mechanical spreader of approved type and design shall be used to move the
volume of freshly deposited concrete transversely.
Concrete shall be consolidated by means of suitable vibrating screed, internal
vibrator, or other approved vibratory equipment such that the concrete would
BOOK III
be effectively consolidated without segregation. Amplitude of the vibration

shall be maintained such that the vibrations are perceptible on the surface of
the concrete at least one foot from the vibrating equipment.
Measuring and indicating devices shall be provided to monitor the actual
frequency of vibrations.
Screeding and tamping shall be performed by making one complete pass over
the entire area of the pavement. The tamper shall be adjusted to produce the
proper tamping action and the screed shall also be adjusted to an elevation
slightly above finished grade, in order to have completed surface with required
grade, true to cross section indicated, and free from laitance and porous areas.
Following the placement of concrete, and after it has been screeded with a
transvese finishing machine, it shall be screeded logitudinally with a power-
operated logitudinal finishing machine of an approved type. The longitudinal
screed shall be worked cross-wise in order to level any irregularities in the
surface.
Following longitudinal screed, an approved scraping tool shall be used for
removing any accumulation of excess mortar, laitance, or inert material from
surface.
For the final finish, surface shall be dragged with a single full width strip of
burlap to produce a uniform gritty texture on the surface. Keep burlap wet and
shall be priodically washed out with water to remove accumulations of mortar.
Curing and protection

Concrete shall be cured by protecting against loss of moisture and rapid
temperature changes for a period of not less than 7 days from the completion
of the finished operations.
Necessary protection shall be provided to prevent cracking of the pavement
due to temperature changes during the curing period.
Blankets used in the curing process shall be removed as necessary to comply
with requirements for saving of contraction joints. If this method is used the
concrete surface shall be maintained wet with water sprays until the covering
materials are replaced.
Traffic shall be prohibited on new concrete pavement until the concrete has
attained its 28-day compressive strength as determined by strength test in
accordance with ASTM C39.
Field Quality Control

Strength test. The contractor shall perform strength test of concrete as
specified in section 4.4.2.5.21, tabel 4.4.2.5-5

BOOK III
4.4.2.28.5 CONCRETE WALKS, DRIVES AND INCIDENTAL PAVING
GENERAL
The work shall consist of the construction of concrete walks, drives and
incidental paving slabs, in accordance with this specification and in reasonable
close conformity with the lines and grades as indicated on the approved
drawings or as directed by the Owner.
MATERIALS
Materials shall conform to Specification refers to "Concrete Work" unless
otherwise specified. All concrete shall be GRADE 22.
CONSTRUCTION REQUIREMENTS
Excavation
Excavation shall be made to the required depth and width required for the
installation and bracing of the forms. The subgrade shall be shaped and
compacted to a firm, even surface conforming to the section shown on the
plans. All soft and yielding material shall be removed and replaced with
approved material at the Contractor's expense. Excavation and fill work shall
conform to the requirements of Specification refers to "Earth Work".
Forms
Forms shall be wood or metal and shall extend for the full depth of the
concrete. All formwork shall conform to the requirements of Specification
refers to "Concrete Work".
Subgrade
The subgrade shall be thoroughly moistened immediately prior to the placing of
the concrete.
Depositing and Finishing

The concrete shall be deposited on the moist subgrade and struck off to the
required thickness. It shall be tamped sufficiently to bring the mortar to the
surface. The surface shall be finished with a wood float or steel trowel,
provided that the surface is finally brushed in order to leave a slightly rough
finish. All joints and edges shall be rounded with an edging tool having a 6 mm
radius.
Joints
Expansion joints shall be of the dimensions specified, and shall be filled with
premolded expansion joint filler. Dummy joints shall be formed by a jointing
tool or other acceptable means as directed. The dummy joints shall extend into
the concrete for at least 1/4 of the depth and shall be approximately 3 mm
wide.

BOOK III
Construction joints shall be formed around all appurtenances such as manholes,

utility poles, etc., extending into and through the paving. Unless otherwise
specified, 6 mm remolded expansion joint filler shall be installed in these joints.
Expansion joint filler of the thickness indicated shall be installed between
concrete paving and any fixed structure such as a building or bridge. This
expansion joint material shall extend for the full depth of the paving.
Unless otherwise specified, expansion joint filler shall be 12 mm thick and shall
be installed every 30 m or fraction thereof, between intersecting paving and
any fixed structure such as a building, bridge or curbing. This expansion joint
material shall extend for the full depth of the paving.
1. Walks: Unless otherwise directed, the spacing of dummy joints for
walks shall be equal to the width of the walk.
2. Drives: A longitudinal dummy- joint shall be formed along the
centerline of drives more than 4.5 m wide, and transverse dummy
joints shall be formed in drives at not more than 4.5 m intervals.
3. Incidental Paving: Unless otherwise directed, dummy joints for
incidental paving shall be formed at intervals not exceeding 6.0 m in
length or width, and incidental paving poured adjacent to existing
jointed concrete shall be jointed to match the joints in the existing
concrete, with intermediate joints formed as necessary not to exceed
the 6.0 m maximum joint spacing.
Curing
Concrete shall be cured for at least 72 hours. Curing work shall conform to the
requirement of Specification refers to "Concrete Work".
4.4.2.28.6 CURBS AND GUTTERS
GENERAL
The work shall consist of the construction of curbs and gutters as shown on the
approved drawings in accordance with this specification and in reasonably close
conformity with the lines, grades, dimensions and typical sections as indicated
on the approved drawings or as directed by the Owner.
MATERIALS
Concrete for concrete curbs and gutters shall be GRADE 22 conforming to the
requirements of Specification refers to "Concrete Work".

BOOK III
Subgrade
The subgrade shall be shaped to the required depth below the finished surface
in accordance with the dimensions shown on the plans and shall be compacted
to a firm, even surface. When possible, the subgrade shall be shaped and
compacted at the same time and in the same manner as the subgrade for the
pavement slab. All soft and yielding spots or any unstable material encountered
shall be removed and replaced with suitable material, at the Contractor's
expense, and be thoroughly compacted. When foundation underdrains are to
be placed under curbing and gutters, the excavation and backfilling for the
same shall be completed and compacted before the subgrade for curbing and
gutters is prepared.
Concrete Forms
The forms for the curbing or gutter shall be of wood or metal, straight, free
from warp and of sufficient strength when staked to resist the pressure of the
concrete without springing. All forms shall be cleaned thoroughly and greased
or soaped before concrete is placed against them. Forms which have become
worn, bent or broken shall not be used until satisfactorily repaired and
straightened.
Repaired forms shall not be used until it has been inspected and approved by
the Owner. An approved mechanical curb forming machine may be used
without forms.
Concrete Joints
Joints shall be formed in continuous curbing to correspond with transverse
joints in the pavement slab. All joints shall extend entirely under the curb
section and through the curb and shall be finished and filled with prescribed
filler.
All other types of curbing shall be provided with 6 mm joints at intervals of 6 m,
unless otherwise indicated on the plans, except where shorter sections are
necessary for closures, the separation shall be effected by using steel plates
6 mm in thickness, cut to the true section, and set vertically in the forms until
the concrete has set sufficiently to permit withdrawal of the plates.
Backfilling
After the curb or gutter has sufficiently set, the Contractor shall backfill
adjacent to the curb or gutter with approved material. This material shall be
thoroughly tamped in layers of not over 150 mm compacted thicknesses.

BOOK III
4.4.2.28.7 WHEEL STOPS
GENERAL
The work shall consist of the construction of wheel stops as shown on the
approved drawings in accordance with this specification and in reasonably close
conformity with the dimensions and typical sections as indicated on the
approved drawings or as directed by the Owner.
MATERIALS
Concrete for wheel stops shall be Precast Concrete, GRADE 22 conforming to
the requirements of Specification refers to "Concrete Work".
The forms for the wheel stop shall be of wood or metal, straight, free from
warp and of sufficient strength when staked to resist the pressure of the
concrete without springing.
All forms shall be cleaned thoroughly and greased or soaped before concrete is
placed against them. Forms which have become worn, bent or broken shall not
be used until satisfactorily repaired and straightened. Repaired forms shall not
be used until it has been inspected and approved by the Owner. An approved
mechanical wheel stop forming machine may be used without forms.
4.4.2.29 FENCE WORKS, GATES, GUARD RAIL

The work specified in this section covers the furnishing of all materials, labor,
transportation, equipment and services necessary for the installation of fences,
gates, space, guard rails and hand railing as shown on the approved drawings or
as directed by the Owner.
The work performed shall be in accordance with the specifications. The
materials and workmanship for fences and gates shall conform to the following
or approved equal standards:
- United States Department of Commerce (USDC): USDC - "CS246-Steel
Galvanized Fence Fabric".
- "Industrial Steel Specifications for Fence Posts, Gates and Accessories".
4.4.2.29.2 FENCE TYPE

Fencing shall consist of concrete slab with minimum high overall height of 250
cm. The fence shall have a top rail, and five strands of barbed wire mounted on
45 degree extension arms. The upper strand shall be approximately 30 cm out
from the fence and 30 cm above the top of the panel. Posts shall be set in
concrete.

BOOK III
Steel wire mesh ( BRC ), Fy minimum = 4,950 Kg/cm2
BRC FENCE shall be Hot-dip galvanized with thickness of 80 microns.
POSTS, RAILS, BRACES, GATES AND APPURTENANCES

General
Pipes shall be hot dip galvanized conforming to ASTM A120-79.
Fittings and Accessories shall consist of Bolt & nut, U clip and post and shall be
hot dip galvanized.
Galvanizing: Hot dip galvanized pipe (inside and outside) and frame steel profile
sections (all surfaces) and other ferrous parts, with a weight of zinc coating not
less than 80 microns of thickness.
Sizes of Material for Posts, Rails, Braces and Gate Frames shall conform to the
following dimensions or as shown on the approved drawings:
End Corner and Pull Posts: round 62 mm nominal diameter, 73 mm OD.
Intermediate Posts: round 50 mm nominal diameter, 60 mm OD.
Gate Posts: round 89 mm nominal diameter, 101 mm OD. for 2 to 4 meter
nominal width of gate, single or double swing, or sliding gates.
Exterior Frames for Gates: Hot dip galvanized, round 38 mm nominal diameter,
48.26 mm OD.100 mm x 50 mm and 3.5 mm of thickness.
Interior bracing for gates: round 32 mm nominal diameter, 42 mm OD.
Clip
Hot-dip galvanized with thickness of 40 microns. U clip steel plate thickness 1.2
mm.
Bolt & Nut

Hot-dip galvanized with thickness of 40 microns, length 3½”, diameter 5/16”.
BARBED WIRE AND ATTACHMENTS

Three lines of two strand 2.5 mm diameter steel wire with 2.11 mm diameter
four point barbs spaced approximately 125 mm on center.
All wire shall be hot dip galvanized, with the weight of zinc coating per square
meter of surface area not less than 0.24 k g/m2 for 2.5 mm diameter wire and
not less than 0.20 k g/m2 for 2.11 mm diameter wire.
Barbed wire shall be fastened to extension arms with heavy galvanized steel
pins, and to post extensions with galvanized steel bands.

BOOK III
4.4.2.29.4 FENCING DETAILS

Post Setting: Contractor shall provide posts of sufficient length for depths
Post Tops and Extension Arms: Malleable iron or pressed steel, with post tops
for square posts designated to exclude moisture from inside the posts, and with
integral extension arms for barbed wire
4.4.2.29.5 GATES
Gate shall be swing and sliding type. The swing type shall be hinged to swing
180 degrees from closed to open and sliding type shall be rolled on rail,
complete with frames, latches, stops, keepers, hinges, fabric and braces rail.
Gate leaves shall have intermediate members and diagonal truss rods as
required for rigid construction and shall be free from sag or twist. Joints
between frame members shall be made by welding or by means of heavy
fittings, and shall be rigid and watertight.
Hinges shall be of a heavy pattern with large bearing surfaces and shall not
twist or turn under the action of the gate. Latches shall be the plunger bar type,
full gate height, and arranged to the gate stop, except that single gates less
than 3 m wide may be provided with a forked latch. Latches shall be arranged
for padlocking with a padlock accessible from both sides of the gate. Stops shall
consist of a roadway plate with an anchor set in concrete and arranged to
engage the plunger.
Keepers shall consist of mechanical devices for securing and supporting the free
end of the gates when in the full open position. Keepers shall be mounted on
70 mm outside diameter pipe posts filled with concrete and set in concrete
foundations.
Gates shall be installed such that they cannot be removed without disassembly
of the hardware. Hardware attachment bolts shall be pinned to prevent
removal.
4.4.2.29.6 FENCE CONSTRUCTION

The installed fence shall conform to the alignment and finish grade indicated on
the approved drawings. Unless otherwise indicated or specified, all posts shall
be plumb. Clearance below the bottom of the fence shall not exceed 50 mm.
It is the intent of this specification that the plan and profile of each reach of
fence between corner posts, or between corner posts and gate posts, shall be
straight. The Contractor shall grade ground surfaces as required to achieve the
straight profiles before each reach of fence is installed.
Where posts are set in ground, concrete foundations of 90 cm deep shall be
provided. Concrete foundations shall be not less than 30 x 30 cm for line posts
and with a diameter not less than the post size plus 20 cm for terminal and gate

BOOK III
posts. Foundations shall extend above the ground surface and shall be crowned
approximately 50 mm. Concrete for foundations shall conform to the cast in
place concrete section. Each foundation shall be cured for at least 72 hours
before further work is done on the post.
4.4.2.29.7 GUARD RAIL
MATERIALS
The rail elements shall be corrugated sheet steel beams conforming to plan
details and the thickness of the metal shall be as specified on the plans. All
guard rail elements, terminal sections and fittings shall be interchangeable with
similar parts, regardless of source or manufacturer. The guard rail, terminal
section and appurtenance shall be in accordance with AASHTO Designation: M
185, the plans and the following requirements:
- Unless otherwise specified, the beam shall be Class B, with buffer end
sections being either Class A or B.
- The beams shall be galvanized after fabrication with Type 1 or 2 coating in
accordance With AASHTO Designation: M-180. The fabrication shall file a
Brand Registration and Guarantee in accordance with AASHTO
designation M-180. Certificates of analysis shall be furnished for each per
shipment covering all tests and measurements required by AASHTO
Designation: M-180.
Guard Rail Posts and Spacer Blocks

Railing posts shall be of treated timber. Spacer blocks shall be of the same
material and with the same treatment as the post. Timber posts shall be
treated timber of Damar Laut and shall be of the section and length as specified
or as shown on the approved drawings.
The timber is treated by Creosote, Creosote Coal-Tar Solution or
Pentachlorophenol Petroleum Solution. Treatment shall be 251 kg per cubic
meter of timber and the type of preservatives to be used are as follows:
- Creosote Oil - AWPA P1 for regular treatment; AWPA P13 for marine
treatment.
- Creosote Coal - Tar Solution - AWPA P2, Grade A, for regular treatment;
AWPA P12 for marine treatment. The ratio shall be 80% Creosote Oil and
20% coal-tar.
- Pentachlorophenol - Petroleum Solution - AWPA P8 and P9.
CONSTRUCTION
The installed guard rail shall conform to the alignment and finish grade as
indicated on the approved drawings. Unless otherwise indicated or specified, all

BOOK III
guard rail posts shall be plumb and spaced 4 meters apart. Where posts are set
in ground, concrete foundations shall be provided. Concrete for foundations
shall conform to the requirements specified in Specification refers to "Concrete
Works".
The length, depth and other sizes of the guard rail, guard rail post and spacer
blocks shall be as indicated on the approved drawing or as directed by the
Owner.
4.4.2.30 FINISHED GRADING AND ENVIRONMENTAL PROTECTION

The work specified in this section covers supply of all labors, materials,
transportation, equipment and services necessary for the soil and crushed
stone fill work for the final grading and environmental protection work as
shown on the approved drawings or as directed by the Owner.
4.4.2.30.2 FINISHED GRADING
GENERAL
Finished grading work will therefore involve filling of the low areas of roads,
and other areas with soil and top soil to provide elevation, slopes and drainage
as shown on the approved drawings or as directed by the Owner.
ROUGH GRADING
The Contractor shall fill, spread and level the roads and general site area to
elevation grades and slope to elevations as required. The fill material shall
consist of graded crushed stone or sand and gravel for the roads is indicated on
the approved drawings. The fill material in the areas where seeding or sodding
is indicated on the approved drawings shall be soil from a borrow source
approved by the Owner. If the elevation in the areas where topsoil over soil
cover is indicated on the approved drawings is higher than what is required, the
area shall be scraped to the required elevations. The crushed stone fill
materials shall be of gradation of "Base Course" as specified in Specification
refers to ‘Trees and Shrubs’ paragraphs, soil cover shall consist of a 200 mm
thick compacted layer of soil free from lumps, stones, roots and all other
organic materials and shall be from an approved off-site borrow source.
FINAL GRADING
Contractor shall perform final grading near the completion of the work or as
directed by the Owner. Contractor shall grade and level the areas to produce a
smooth grade free from debris, organic materials, objectionable stones, clods,
lumps, pockets or high points, properly drained true to the indicated elevations
with smooth transition between different elevations.

BOOK III
4.4.2.30.3 ENVIRONMENTAL PROTECTION
SEEDING AND SODDING

General
Contractor shall furnish materials and perform seeding operations to produce a
uniform stand of healthy grass where indicated on the approved drawings as
"seeded surfaces" or "seeded topsoil" or as directed by the Owner.
Topsoil
A 100 mm thick layer of topsoil shall be uniformly spread over the areas where
seeding or sodding has been specified. Topsoil shall be obtained from an offsite
borrow source approved by the Owner and shall be fertile, friable, natural
surface soil obtained from a well drained area. Top soil shall be free of all stone,
brush, weeds, stumps, roots or other organic litter. Topsoil shall have 5-20
percent organic matter and an acidity range between pH 5.0 to 8.0 inclusive.
Prior to the delivery to the site, the Contractor shall provide a statement
regarding the source of the topsoil and shall provide test certificates for
chemical and mechanical analyses.
Liming and Fertilizing

General
Contractor shall test the soils to determine the proper amount of pH and
nutrient adjustment required. Test results and subsequent application rates of
lime and fertilizer are subject to the approval of the Owner.
Liming
Use agricultural ground lime, at the rate of 0.5 kg per square meter, with
surface soil before completion of ground preparations. The lime must be
applied prior to seeding and may be applied in conjunction with the fertilizer.
Immediately after application, the area should be disked, harrowed to
incorporate the lime or lime-fertilizer into the soil.
Fertilizer
Fertilizer shall consist of nitrogen, phosphate and potassium nutrients.
Fertilizer shall be applied at such a rate that each hectare will receive the
following amounts of available units:
- Nitrogen 70 kg
- Phosphate (P2O5) 115 kg
- Potassium (K2O) 115 kg
Fertilizer may be placed during ground preparation or mixed and placed with
seed and mulch during final seeding.
Condition of fertilizer prior to placing shall be approved by Owner.

BOOK III
Seeding and Mulching

Seed used shall conform to the requirements of "BINA MARGA" standards and
shall consist of a mixture of the following seeds in the amounts indicated:
Type of seed in mixture kg-per-hectare
Fescue (Kentucky 31 or Alta) 60
Red top, solid 24
Clover, alsike (inoculated) 16
Seeding shall be performed in accordance with the BINA MARGA specifications
with a maximum depth of planting of 12 mm.
Mulching: Immediately after seeding, seeded areas shall be covered with
sprayed asphalt straw mulch.
Except as otherwise specified above, the methods of preparation of seed-beds,
fertilizing, mulching, seeding, sprinkling, maintaining, repair and reseeding as
required will be at the option of the Contractor. The work shall be considered
completed after a uniform and dense stand of healthy perennial grass, free
from bare spots and gullies formed by erosion, has been produced.
Sodding
a. Contractor shall spread topsoil and fertilizer over the area to be sodded as
previously specified and shall furnish and install sod to produce a healthy
grass cover here indicated on the approved drawings or as directed by the
Owner.
b. The sod to be used shall be approved by the Owner.
c. The Contractor shall furnish water, and shall maintain sod including
watering and mowing for a period of not less then 90 days after laying, but
not earlier than the time the Owner agrees that a healthy growth of grass
has been achieved at the area.
TREES AND SHRUBS

General
Contractor shall furnish plants and shrubs, and perform planting operations to
produce healthy plants and shrubs as indicated on the approved drawings or as
directed by the Owner.
All works shall be done in the manner normally required in good trade and
practice of landscaping and the Contractor must use proper means to provide
all plant materials approved by the Owner for planting, shall be dug, loaded,
moved, unloaded, planted, fertilized, pruned, watered, and maintained in such
a manner as to insure their lives for healthy growth in their new locations.

BOOK III
The Contractor shall perform cleanup work in the working areas daily, and
periodically throughout the limits of the project, in order to present a neat
appearance of the project area at all times.
All plants shall be inspected and approved at the jobsite by the Owner before
they are eligible for planting. Such approval shall not be misconstrued to mean
final acceptance. Plant materials damaged enroute to the planting site will be
subjected to rejection at no cost to the Owner.
Quality and Source of Plant Materials

All plant materials shall be nursery grown, unless written permission is obtained
from the Owner to use selected native stock. Such permission will be granted
only if the Contractor demonstrates that it is impracticable to obtain nursery
grown plant material or if, in the opinion of the Owner, selected native stock
will be better-suited or superior in quality to that obtained from a nursery.
If permission is given to use selected native stock, the Owner will inspect the
materials before digging and the Contractor shall tag each plant selected (as
described herein before) and dig the plants as directed. In the event any
selected plant does not show a sufficient root system after being dug, it will be
rejected. The handling care and other requirements of collecting native plants
shall be the same as such described for nursery grown stock.
All plants shall be root pruned, heavily canned and typical of the species. They
must possess a healthy, normal and fibrous root system of sufficient size to
insure plant growth. The branch system shall be of normal development and
free from disfiguring knots, sun scald injuries, abrasions of the bark, dead or
dried wood, broken terminal growth or other objectionable disfigurations. All
trees shall have reasonably straight trunks and shall be well branched and
symmetrical in accordance with their natural habits or growth.
Handling and Storage

During handling and storage, the Contractor shall protect the plants from drying
out by covering the root system with suitable materials or wetting the foliage, if
necessary. Balled and burlapped materials shall have the earth balls covered
with sawdust, woodchips or other suitable materials and shall be kept in a
moist condition. Bare root materials in bundles shall have the bundles opened,
plants separated, and then heeled-in in the trenches. Container grown plants
shall be kept sufficiently moist to insure their livability.
Delivery and Receipt of Plant Materials

The Contractor shall notify the Owner at least 24 hours before making any
delivery of plant material to the project. Each shipment shall be accompanied
by an invoice showing the sizes and varieties included in that particular
shipment.

BOOK III
Inspection
All plant materials are subject to inspection at any time during the life of the
contract by an authorized representative of the Owner. Approval of plant
material during any of such inspections before or during operations, however,
shall not be construed as final acceptance of the plants involved.
Rejection of Plant Material

Any plants having any of the following unnatural, or objectionable features will
be rejected: excessive abrasions of the bark; dried out root system; excessive
dead wood; dried up wood; excessive sun scald injuries; undeveloped and weak
top or roots or both; crooked or one sided development of tops; no straight
leaders on trees naturally and normally having them; broken or removed
leaders; untrue types or sizes; excessively damaged balls of soil; balls of soil dug
from loose soil which could not be expected to properly hold the ball in
handling; plants actually dead; and plants not otherwise complying with plant
specifications herein.
The rejected material shall be removed from the site and replaced as quickly as
possible with new plant material of the same kind, meeting the original
requirements, at no additional cost to the Owner.
Construction Methods
Care and Handling of Plants Before and During Planting
The contractor shall, in loading, unloading or handling plants, exercise the
utmost care to prevent injuries to trunks, limbs, branches and roots.
Immediately following delivery and inspection at the site of the work, all plants
must be cared for in an approved horticultural manner satisfactory to the
Owner. Plants must not be allowed to dry out.
If not immediately planted, balled plants must be adequately protected by
covering the balls of soil with soil, sawdust, hay or straw and shall be watered
frequently. The solidity of the balled plants shall be carefully preserved. They
must not be handled by their tops in lifting, moving or setting, but must be
handled at all times by their balls of soil.
Pruning
If necessary, plant material shall be pruned at the site in accordance with
standard modern practice. Cuts over 25 mm in diameter shall be painted with
approved tree paint.
Location of Plants
BOOK III
Planting stakes will be set by the Owner at the designated locations of all
plants. Each stake shall bear an item number or color code as designated by the
Owner to coincide with a particular item number.
Planting Pits
Planting pits may be machine or hand dug. Square or circular pits with vertical
or slanted sides shall be dug to the dimensions as required for proper setting of
plants.
Setting Plants
All plants shall be planted in pits. Deep planting shall be avoided and, unless
otherwise specified or directed, all plants shall be set at such a level that, after
settlement, a normal or natural relationship of the crown of the plant with the
ground surface will be established. Each plant to be planted in an individual pit
shall be planted in the center of the pit, unless otherwise directed. When balled
and burlapped plants are set, topsoil shall be carefully tamped under and
around the base of each ball to fill all voids
All plants shall be planted in topsoil which shall be thoroughly settled by
watering and tamping as to eliminate settling and leaning of the plant material.
When plants are to be grouped together in a plant bed or in a line
approximately 1.6 m, or less from each other, the entire area shall be loosened
and lumps broken to a minimum depth of 150 mm prior to excavating plant
pits.
Topsoil
Shall be as specified in Subsection refer to Topsoil of this Specification.
Fertilizer
The contractor shall furnish and place commercial fertilizer. The fertilizer shall
be spreaded uniformly on the excavated material in a circle at the outer edge of
the planting pit. The fertilizer shall be mixed with the excavated soil before
backfilling operations are begun.
Backfilling
All plants shall be plumb and set at the proper depth. Suitable material
removed from the excavation shall be mixed with fertilizer and the pit shall be
backfilled as directed. Care shall be exercised in placing backfill under the sides
and over the bail so as not to disturb same. Backfill to 3/4 of the depth of the
ball on all sides, then water uniformly on all sides of the ball in order to
eliminate voids and air spaces and allow settlement of the plant. Plants which
settle or lean, before or after watering, shall be straightened, raised, replaced
BOOK III
or the condition otherwise remedied. Excavated material considered by the

Owner to be of unsuitable planting quality shall not be used in the backfill, but
shall be replaced with topsoil by the Contractor as directed by the Owner, at no
additional cost to the Owner.
All excavated material which are not used as backfill, except soils which contain
stones, broken concrete or other foreign matter, shall be disposed of in project
areas as directed by the Owner. Soils containing stone, broken concrete or
other foreign matter shall be disposed of offsite by the Contractor to the
satisfaction of the Owner.
Water
The Contractor shall furnish and apply water in sufficient quantities for proper
irrigation of the plants. The plants shall be watered during planting operations
as required hereinbefore, immediately after planting and at intervals as
directed by the Owner until final acceptance.
Bed Preparation
Should the drawing requires plants to be located in beds, the planting bed areas
shall be scraped to remove all grass, weeds, sticks, stones, bricks, mortar,
concrete and other debris. Beds shall then be tilled with a rototiller to the
required depth. Peat moss, or anorganic matter satisfactory to the Owner, and
commercial fertilizer shall then be added to the soil at the following minimum
rates: peat moss or anorganic matter, 1.5 kg pounds per square meter, and
fertilizer 0.25 kg per square meter. After the peat moss and fertilizer have been
added, beds shall be tilled again to thoroughly mix all components. Beds shall
then be raked smooth and all foreign matter such as dirt lumps, concrete,
sticks, grass, mortar, brick, etc., removed from the soil. Finish grade of beds
shall be the same as finish grades for adjoining concrete walks. Herbicides used
in bed areas shall be approved types.
Mulching
Unless otherwise specified, any approved material suitable for mulch may be
used. Mulching shall be accomplished as soon as possible after the plants are
set. The mulch shall be placed uniformly on all sides of the plant and watered as
soon as possible. When plants are planted in a row approximately 1.5 m apart
or less, the entire row shall be mulched solid. Bed areas shall also be mulched
solid.
Weeding
Weeds shall be kept out from within the planting basin of each plant including
basin walls. The Contractor shall mow around all plant materials not planted in
beds for a distance of 1.5 meters. Should the Contractor decided to use
BOOK III
selective herbicides, he shall be allowed to do so only after the grass in this 3 m

circle has been cut to a height of not more than 50 mm. Such areas must be
weeded by hand. Weeding shall be performed as required to maintain a neat
appearance as directed.
Period of Establishment and Replacements

Upon completion of the planting of all plants, and providing all plants in place,
living and conform to this specifications, the Owner will give provisional
acceptance. The Contractor shall be required to take care for all planted areas
for a period of establishment, which shall be one full growing season after the
provisional acceptance is made. A growing season shall be for a period of six
months (during this period of establishment the Contractor shall be required to
employ all possible means to preserve the plants in a healthy growing
condition). Such plant establishment work shall include cultivation, watering,
pruning, controlling insect pests and disease, and any other work necessary to
insure healthy plant growth. Dead or unsatisfactory plants shall be promptly
removed from the site at no additional cost to the Owner.
All dead and unsatisfactory plants shall be replaced in kind, quantity and size
with live, healthy plans installed as originally specified. Alternate or substitute
varieties of plants shall be used only upon approval by the Owner. Such
replacement plantings shall be made at the Contractor's expense.
Replacements made at that time will not require a period of establishment.
Upon completion of the said replacement by the Contractor and prior to final
acceptance of the contract, the Contractor shall weed around all plants and
remove all discarded materials, rubbish and equipment from within the areas
affected by operations under this contract. The said areas shall present a neat
and acceptable appearance at the time of final inspection.
A final inspection of all plant material will be held for approximately two weeks
after the replacement planting has been completed. A final acceptance will be
made only if all plants are in place, living and are in conformance with the plans
and the specifications.
4.4.2.31 CHIMNEYS
Concrete chimneys shall be designed to comply with :
 CICIND Model Code for Concrete Chimneys
 ACI 307 Cast-in-place concrete chimneys.
The design shall take into account any special dynamic loading or movement
effects, such as vortex shedding and wake buffeting, arising from the proximity
of the hillside local to site. The efflux velocity of emitted gases shall be not less
than 15 m/s at maximum countinuos rating.

BOOK III
The design wind pressure shall be equal to the wind velocity of 120 km/h and
other requirements in accordance with American National Standards to work (
ANSI A 58-1-1982 )
The chimney shall include thermal and corrosion protection to ensure that
minimum maintenance is required over the operational life of the power
station.
The Chimney’s windshield shall be of reinforcement concrete of approx 150
meter height. To ensure the minimum maintenance over the operational life of
the station, the chimney shall include low viscosity corrosion inhibitor
protection conform to chloride testing in accordance to ASTM 1152 lower than
0.007.
The foundation system for the Chimney shall be circular shape, supported by
bored pile. The foundation shall be proportioned in such a way that the bearing
and allowable settlement criteria shall not exceed, with no uplift permitted and
no increase in allowable in bearing for wind load. The reinforcing shall be
designed using a radial concept.
The chimney shall be designed for two (2) liner. The chimney shall be designed
to give good access for inspection and maintenance, with provision of small
power and lighting service.
Lightning protection shall be provided appropriate to the configuration and
location of the plant.
Chimney Height
The height of the chimney shall ultimately be determined from studies within
the Detailed Environmental Impact Assessment ( plume dispersal calculations )
and operational factor.
4.4.2.32 POND LINING
4.4.2.32.1 SCOPE
The work specified in this section covers all design, labour, materials,
transportation, equipment and service necessary for the ash run off ponds as
shown on the Drawings or as directed by the Owner. There are two alternatives
of pond lining:
a) Clay lining
b) HDPE lining

BOOK III
Materials shall be selected with an approved off-site borrow source. The

material shall have a plasticity index (PI) greater than or equal to 15. More than
50% of the materials shall pas a # 200 sieve as determined by ASTM D1140.
The material shall be free from roots, sticks, sod tufts and other organic matter.
The material shall be free from cobbles and boulders with less than 5% of the
dry weight of soil retained on a # 4 sieve with a maximum size of 25 mm.
Contractor shall procure all material required for the work from off-site
sources. All sources shall be approved by the Owner.
Protective Bedding Layer: As specified in Specification Slope Stabilization -
Riprap.
Protective Riprap Layer: As specified in Specification Slope Stabilization - Riprap.
Excavation for the basin can be started after the soil stabilization work for the
area has been completed and the Owner has informed the Contractor that the
work for the pond can be started.
The surface of the pond slopes and bottom, upon which the clay liner is to be
placed, shall be free from vegetative and foreign matter.
The pond slopes and bottom where the clay lining is to be placed shall firstly
receive a layer of sand with a maximum size of 6 mm placed in 1 lift with a
minimum compacted thickness of 150 mm. The sand shall be compacted to a
relative density not less than 80 percent as determined by ASTM D2049.
The sand and clay lining shall be placed under dry conditions. The Contractor
shall provide to the Owner for his approval, the details of any dewatering
schemes he deems necessary to perform this work.
4.4.2.31.4 PLACEMENT OF THE CLAY LINING
The clay shall be placed on the pond slopes or previously compacted clay, in
stair-step horizontal layers, in such a manner that each succeeding layer will be
stapped back. Lining in the pond shall be placed in succeeding 150 mm thick
lifts until the grade elevation is reached.
The equipment for spreading the clay shall be suitable for the purpose and as
approved by the Owner.
Each successive layer in a section shall be placed as soon as practicable after
the preceding layer is completed. Contractor shall avoid the deposition of
uncontrolled fill or foreign materials between layers of clay.

BOOK III
Clay shall not be placed, in the opinion of the Owner, when weather conditions
are such that the material cannot be completely compacted and protected
before the advent rain.
4.4.2.31.5 DELIVERY AND STORAGE
The clay shall be compacted using kneading action by sheep foot rollers as
approved by the Owner.
The clay shall be uniformly compacted to 95% of the Modified Maximum Dry
Density (ASTM D1557) obtained in the laboratory on representative samples
from the approved borrow area.
Compaction shall be in stair-step horizontal lifts in such a manner that each
succeeding layer will be stepped back on the slopes. The bottom lining will be
compacted in 150-mm thick layers to a total thickness of 750 mm.
Placement of the protective bedding and riprap shall be in accordance with

Specifications “Slope Stabilization”.
The protective bedding and riprap layers shall be in thickness as indicated on
the Contractor’s drawings. The material shall be noncalcaroius and stable under
chemical attack as specified in Specifications “Slope Stabilization”.
The riprap shall be placed in such a manner to minimize segregation and assure
a uniform gradation of the rock on the slopes and bottom of the excavation.
4.4.2.31.6 TESTING AND QUALITY ASSURANCE/QUALITY CONTROL
Laboratory: A testing laboratory furnished by the Contractor shall perform

quality control test as indicated.
FREQUENCY
The Contractor shall perform the following test. The indicated frequencies are
provided as guidelines to the Contractor. The Contractor shall be responsible
for all costs associated due to any change in actual testing frequency as
determined by the Owner in the field.
Minimum Frequency
1. Density Test on Subgrade (ASTM D1556 or D2922) One/100 Sq.m
2. Moisture Content on Granular Stockpile

(ASTM D1556 or D2922) One/100 Sq.m

BOOK III
3. Gradation on Granular Stockpile (ASTM D422) One/100 Sq.m
4. Density Test on Clay Line (ASTM D1556 or D2922) One/100 Sq.m
5. Density of Protective Sand (ASTM D1556 or D2922) One/100 Sq.m
For submitting Quality Assurance/Quality Control Procedures and

Documentation the provision of clause 4 “Submittals” of this specification shall
apply.
4.4.3 DESIGN PHILOSOPHY AND BASIC REQUIREMENTS
4.4.3.1 CODES AND STANDARD

1) General
The latest Indonesian Standards and Codes of Practice or International
Standards such as American Concrete Institute (ACI), American Society for
Testing and Materials (ASTM), Japanese Standards (JIS) and British
Standards (BS) shall be applied. Alternative internationally accepted codes
and standards such as DIN may be used.
2) List of References
The full name of the referenced codes and standards are as follows:
Reference Abbreviation Name
ACI 301 Structural Concrete
ACI 318/318R Building Code Requirement for
Structural Concrete and Commentary
ACI 347R Formwork for Concrete
AISC American Institute of Steel
Construction
AISC S303 Steel Building and Bridges
ASCE American Society of Civil Engineering
UBC Uniform Building Code
ASTM American Society for Testing and
Materials
ASTM 36/A 36M Carbon Structural Steel
ASTM A 82(1997a) Steel Wire, Plain for Concrete
Reinforcement
ASTM A 184/A 184M Fabricated Deformed Steel bar Mats
for Concrete Reinforcement

BOOK III
ASTM A 325M High-Strength Bolts for Structural Steel

Joints
ASTM A 615/A 615M Deformed and Plain Billet-Steel Bars
for Concrete Reinforcement
ASTM C33 Concrete Aggregates
ASTM C150 Portland Cement
AASHTO American Association of StateHighway
& Transportation Officials
AWS American Welding Society
AWS D1.1 Structural Welding Code-Steel
AWS D1.4 Structural Welding Code-Reinforcing
Steel
JIS Japanese Industrial Standards
JWR Japanese Welding Regulation
AIJ Architectural Institute of Japan
BS British Standard
INDONESIAN STANDARDS
SII Standar Industri Indonesia ( Indonesian Industrial Standard )
SKI Standar Konstruksi Indonesia (Indonesian Construction
Standard)
SNI Standar Nasional Indonesia ( Indonesian National
Standard )
Indonesia Resistant Seismic Design for Building (SNI-1726-2012)
Indonesia Steel Building Design Regulation. ( SNI-03-1729-2002 )
Indonesia Reinforced Concrete code (SNI-03 – 2847-2002 )
4.4.3.2 STRUCTURE DESIGN REQUIREMENTS
The proposed Project site is located at Jalan Amerika I in Krakatau Industrial Estate
Cilegon, Banten province (Coordinate : 608839.45 m E and 9337647.16 m S),
where is a tropical area near the sea and will be subjected to a hot, salty and
humid climate.
The Project site falls into zone 4 of seismic zone of the Tata cara perencanaan
ketahanan gempa untuk bangunan gedung ( SNI – 1726 -2012 )
The site conditions data are obtained from the meteorology station at Serang,
Banten and are summarized herein-below:
Sea water data

BOOK III
Highest High Water Sea Level (HHWL) = EL +1.73 m

Mean Sea Level (MSL) = EL ±0.865 m
Low Water Sea Level (LWL) = EL +0.00 m
Design condition = 30.0 ºC
Site Leveling
Ground Level (GL) = EL +4.15 m
Main building 1st floor = GL +0.20 m
Auxiliary building 1st floor = GL +0.20 m
Top of outdoor equipment foundation = GL +0.20 m
Temperature
Average 30.0 ºC
Rainfall
Average annual rainfall 1,513 mm
Average monthly rainfall 114 mm
Relative Humidity
Relative Humidity 78.2% to 85.4%
Annual average humidity 81.8 %
Wind Direction and Velocity

Dominant wind direction From West (50.0 %)
Wind direction at the maximum speed West
Maximum wind velocity (based on ANSI A58.1) 3.2 knot
*ANSI : American National Standards Institute

The design of piles and foundations shall be based on the soil investigation carried
out by the Contractor and on the preliminary loading tests performed at site as
specified in the Technical Specification.
Unless otherwise required by manufacturer’s equipment specifications, the total
settlement of structures shall not exceed 3 cm.
The supporting structural steel for all buildings and structures furnished by the
Contractor shall have adequate strength, stiffness and rigid and shall be adequately
braced for the loads to which the steel will be subjected, and shall be completely
suitable for the service.

BOOK III
All steel structures shall be designed by the working stress method, and all
reinforced concrete structures shall be designed by the ultimate strength method,
based on the latest edition of the AISC and ACI-318 Codes respectively.
The design shall conform to applicable requirements of the codes and standards
referenced in clause above.
All Contractor’s designs, detailing and shop drawings shall be approved by the
Owner before fabrication and construction.
4.4.3.3 DESIGN LOADINGS
The design of the civil works shall take account of all loads applied including Dead,
Imposed, Wind, Thermal, Dynamic, Settlement, Movement, Seismic and other
loading condition where appropriate. Temporary load during testing, maintenance
and erection shall also be considered.
The standards used and loading assumptions made shall be stated in the design
basis and calculations.
LOADING CRITERIA
All structural components shall be designed for the following minimum loads:
Dead Loads
The dead loads consist of structure and equipment of a permanent and semi
permanent nature.
The load includes the weight of framing, roofs, floors, walls, partitions, platforms,
and all permanent equipment and materials.
The vertical and lateral pressures of liquids shall also be treated as dead loads.
Live Loads
Live loads consist of assumed unit loadings deemed sufficient to provide for
movable or transitory loads such as people, portable equipment, fixture and parts
lay down.
Live loads used for design shall not be less than those listed below. Certain other
design loads are described separately in succeeding sections.
The following minimum live load shall be used into the design:
General:
Roofs 100 kg/m2
Offices 400 kg/m2

BOOK III
Assembly and locker rooms 500 kg/m2

Laboratories 500 kg/m²
Stairs and walkways 500 kg/m2
Platform & gratings 500 kg/m2
Ground floors 1,250 kg/m2
Surcharge adjacent to plant structures 1,250 kg/m2
Load at top of any handrail on
any direction 100 kg/m2
Power Building:
Turbine Bay operating floor 1,250 kg/m2
Auxiliary Bay operating floor 1,000 kg/m2
Turbine Lay-down area 2,500 kg/m2
Mezzanine 750 kg/m²
Control room 1,000 kg/m2
Switchgear floor 1,000 kg/m²
Cable room 750 kg/m2
Battery room 1,250 kg/m2
Coal conveyor Gallery, Tripper area or
Surcharge adjacent to plant structures -
Transfer House 1,250 kg/m2
Steel grating 750 kg/m2
Notes:
a.1 Equipment loads shall be considered when designing floors. Live
loads given shall not be superimposed over the areas occupied by
the equipment unless there is space for possible storage or traffic
under the equipment.
a.2 The floors shall be designed for the removal of equipment as
required per the equipment removal arrangement.
a.3 Interior partition wall loads shall be considered when designing
floors.
Pipe Hanger Loads

Piping loads for main steam, boiler feed, condensate, and extraction lines shall be
specifically determined and located.
Piping expansion loads and dynamic load shall be considered on an individual
design basis. Loads imposed on perimeter beams around pipe chase areas will also
be specifically determined.

BOOK III
Pipe dead loads for other areas shall be determined as uniform loads per square
meter of floor area and shall be carried to columns and foundations as pipe dead
loads.
Impact Loads
The following minimum impact factors shall be used in addition to other loads for
components supporting reciprocating or rotating machines, hoist, cranes, or other
equipment creating dynamic forces, unless the Contractor uses larger values:
 For supports of elevators 100 %
 For cab-operated traveling crane support girders
and their connections 25 %
 For pendant-operated traveling crane support
girders and their connections 10 %
 For supports of light machinery, shaft or motor driven 20 %
 For supports of reciprocating machinery or power
driven units 50 %
 For hangers supporting floors and balconies 33 %
Construction Loads
All structural components shall be designed to anticipate loadings imposed during
construction.
Appropriate areas of the ground floor slabs of the power plant buildings and
adjacent underground utilities shall be designed to support the operating loads of
large construction cranes. The steel framing system shall be designed for stability at
all stages of erection.
Wind Load
Minimum loads shall be based on wind velocity of 120 km/h or wind stagnation
pressure of 60 kg/m², adjusted for height above ground, shape factor and other
requirements in accordance with American National Standards Institute (ANSI) A
58.1.
The chimney shall be designed by taking into account oscillation caused by wind
pressure.
Seismic Load
The seismic load shall be accordance the latest Indonesian earthquake standard
published by Ministry of pemukiman & prasarana wilayah.
Crane Load
Crane lateral forces shall be determined in accordance with the requirement of
AISC.

BOOK III
Lane Load
The minimum truck and lane loading shall be the AASHTO HS-20-44 loading.
Abnormal Load
The load shall include loads by postulated accident condition such as emergency
torque of generator, and other loads as given by equipment manufactures.
Combination Loads
The load combination for reinforced concrete structure with ultimate strength
design refer to ACI 318/318M-2002
The load combination for steel structure with elastic design refer to ASCE 2002 or
SNI 1726-2002.
4.4.3.3.1 DETAIL DESIGN REQUIREMENT

Foundation Design
The pile length shall be based on the soil investigation result and loaded tests of
piles.
A minimum safety factor shall be provided as shown below:
- Overturning 1.50
- Slidding 1.5
- Uplift 1.5
Friction coefficient : 0.3 between concrete and soil
In general the foundation design shall ensure that:

The machine can be operated efficiently and reliably without undue or excessive
wear. Foundation dynamic analysis shall be submitted for approval.
The foundation itself suffers no damage or settlement sufficient to cause the
machine to function inefficiently or to require realignment.
The waves propagated through the soil by vibration of the foundation would not be
harmful to persons or to adjacent structures, sensitive machinery or processes.
The foundation adapted is the most economical which will meet all the necessary
requirements.
The seasonal variations in the ground water table level and the effect of such
variations shall be taken into account on the foundation characteristic.
Concrete Design
Individual foundation of a building shall be interconnected in two directions
generally at right angles by members designed for an axial tension and
compression of equal to 10 % of the maximum vertical load on either-foundation
under seismic conditions.

BOOK III
Steel Structure Design

All structure shall be designed to support the above imported loads.
Design, detail, construction and erection of structural steel shall conform to the
requirements of AISC or other International code but should be similar or better
than AISC code.
The depth of fully stressed beams and girders shall not be less than Fy/56000 (Fy in
kg/cm2) times span unless allowable stresses are reduced. The corresponding
maximum L/D ratio for A36 shall be 22 for simply supported members. The L/D
ratio not exceeds 30 under any circumstances.
For cantilevered beams, the maximum L/D ratio shall not exceed 5.
For strut members, i.e. members subjected to axial load and bending due to self-
weight only, the L/D ratio shall not exceed 22.
For flexural members supporting reciprocating or rotating machinery, the
maximum L/D ratio shall be 12.
The deflection of beams, girders under normal load shall not exceed 40 mm or
L/300 whichever is less.
The deflection of plate girders or vertical trusses supporting columns or heavily
loaded posts shall be limited to L/1000 but not to exceed 20 mm.
All connections shall be shop welded and field bolted and shall conform as a
minimum to AISC Manual Table II (bolt) and Table III (weld) unless noted otherwise.
Special connections shall be designed by Contractor for connections having large
shears, axial forces, moments and copes.
The maximum slenderness ratio (KL/r) of the steel columns shall be limited to 200.
The steel lateral load-resisting system shall be analyzed and designed to function
independently from shear-resisting concrete or concrete masonry exterior and
interior walls, and concrete floor slabs acting as shear-resisting diaphragms.
The lateral deflection or drift of a story relative to its adjacent stories due to
seismic event shall not exceed 0.005 Hsx Hsx is the story height of the vertical
bracing panel.
The maximum drift due to wind load shall be limited to 0.002H, where H is the
building height below the level under consideration.
The bracing system should be laid out with regard to permanent and temporary
access requirements for equipment removal purposes.
The horizontal deflection of girt due to wind load shall be limited to 1/180 of the
span. For girt supporting windows, the allowable horizontal and vertical deflections
shall be consistent with the manufacturers’ requirement (typically 6 mm for glass
windows). The vertical deflection of the carrier beam shall be limited to the lesser
of 25 mm or 1/300 of the span.

BOOK III
The minimum access gallery width shall be 75 cm unless noted otherwise. A

minimum headroom clearance of 2.1 m shall be maintained over all galleries. All
gratings shall be galvanized and suitable for the outdoor environment.
Grating, checkered plate or metal deck shall not be considered as lateral support
for the floor beam.
The column base plates and shear bars shall be designed so that the bearing
stresses on concrete foundations do not exceed the allowable value compressive
strength in 28 days of concrete
All column base plates shall be founded on concrete foundations at grade level
unless otherwise noted.
4.4.3.4 ARCHITECTURAL DESIGN REQUIREMENT
Floor
An additional topping slab over the structural concrete slab shall be used where
switchgear is to be installed or where specifically required for setting of
Contractor’s equipment.
Ceramic tile floor finish shall be used in the building areas such as, the offices, the
meeting rooms, the kitchens, the hall ways, the stairs, and other areas indicated on
the Bid drawings.
Raised floor/elevated floor shall be used in the computer and control rooms for
encase equipment drains and conduits.
Glazed tiles shall be used for the toilets, locker and shower rooms.
The battery room floor and wall shall be coated with epoxy coating. The epoxy shall
have chemical resistance to alkalis acids solvents, and beverages with the material
density and bonding strength of not less than 1.3 kg/cm3 and 25 kg/cm2
respectively.
Metal Siding & Metal Deck Roofing

The metal siding and metal roof decks for the building shall be in accordance with
technical specification.
Insulated metal siding and insulated metal roof shall be provided at least for the
steam turbine buildings, control building, and others building as required, and shall
be designed to obtain thermal and noise reduction in accordance with the above
referenced specification.
The color of metal siding and roof deck shall be as specified in the Bid drawings or
as selected by the Owner after award of this contract with no additional cost to the
Owner.
All gutters shall be galvanized steel, similarly coated and colored to match the
siding.
BOOK III
All metal siding and roof shall be designed weather, water and dust tight.
The metal deck roof pitches shall be minimum of 50 with respect to horizontal
plane. All roof water shall be collected at edge gutters and down spouts and
discharged on the concrete splash blocks at grade.
Where insulated siding and roof ( external wall & electrical room ) is indicated, the
insulated shall conform to the following requirements :
Material : shall be fibrous glas, rock or slag with minimum density of of 25.3 kg/m3
The roof insulation shall be reinforced on down face with vinyl or aluminium foil.
The thickness of vinyl shall not be less than 0.01 mm and the thickness aluminium
shall not be less than 0.0025 mm
The wall insulation shall be completely enclosed with 150 micron thick
polyethylene protective cover. Thickness of insulation shall be minimum of 3.37 cm
Exterior and Interior Masonry Walls

Exterior Walls
Walls for the building, will be made of Hollow concrete block masonry wall. The
wall shall be plastered finished on both side surfaces.
All complete exterior walls shall weather, and dust tight.
Interior Walls
Hollow concrete block masonry which is plaster finished on both side surface shall
be provided for the interior walls.
Doors
Wooden doors with anodized aluminum frame shall be used for the office, the
toilet rooms and the light duty interior door applications.
Steel doors and anodized aluminum frame shall be used in other buildings based on
Owner’s approval.
Single doors shall be minimum 0.80 m wide and 2.10 m high. Where double doors
are required they shall be sized with consideration for equipment removal. Doors
more than 2 m wide shall be electric operated steel rolling doors.
Vision panels of the doors shall be clear polished wire glass.
The doors located in the control shall be sound proof and shall have a minimum
sound transmission class rating of 40 decibels.
All normally opening door leaves shall be fitted with heavy duty type door closers.
The Contractor shall submit shop drawings to the Owner for approval before
fabrication.
Windows
Windows shall be anodized aluminum with clear polished glass except in the
turbine building where wire reinforced glass shall be used.

BOOK III
Windows provided in the control room shall be insulated glass or double glass in
order to obtain noise and thermal insulation.
Louvers
Louvers shall be used in the equipment rooms and other areas for ventilation
purposes.
Louvers shall be anodized aluminum louvers and at exterior locations shall be
provided with the insect screen.
Ceilings
The layout of suspended ceilings shall be made with close coordination with the
ventilation, the air conditioning and the lighting requirements.
Suspended acoustic tile ceiling shall be provided in the office areas, the computer
room, the laboratory, etc.
Suspended moisture resistant acoustic tile ceiling shall be provided in the toilets,
the locker and the shower rooms and kitchen.
Stairs
Steel stairs shall be used in general plant area where it is use for service of
equipment or to travel from one gallery level to another.
Ladders
Ladders shall be provided in all pits, manholes, to all roof over 6 m above the
ground where there is no access by a stair on to the floor and the equipment
galleries where no stair system is provided.
Hand Rails
Hand rails shall be provided for the following areas :
 Around every stairway floor opening
 Around every floor opening into which a person can walk
 Every open-sided floor, walkways and platforms
 Adjacent to dangerous equipment

BOOK III
4.4.3.5 OTHER CIVIL DESIGN REQUIREMENT
Roads
CBR test on the finished level of sub grade shall be held to a maximum value of 8
with 6 is preferable.
Minimum radius of curvature shall be 15 m.
Unless otherwise noted on the Bid drawing the main road width shall be 8 m with 1
m shoulder, other roads shall be 6.00 m with 1.0 m shoulder.
Loading over culverts and pipes shall be in accordance will AAHSTO HS20-44 except
for areas subject to loading by the special heavy haul vehicles.
The Contractor shall provide additional traffic signs along the new road in the
Power Plant as directed by the Owner.
Storm Drainage
The Contractor shall design and provide the drainage system but not limited to as
specified in the Technical Specification and as shown on the Bid drawing.
For the storm drainage system, the ditches and the culvert shall be adequate to
discharge surface run off due to a 10 years recurrence interval storm.
The minimum size of culverts shall be 300 mm wide and the culverts shall be made
of reinforced concrete, construction and design for a maximum velocity of 2.5
m/sec.
The storm sewer shall be provided with adequate number of manholes with heavy-
duty frame and covers.
Minimum diameter of manholes shall be 1000 mm and manholes shall be installed
at the changes in grade, size or alignment, at all intersections and interval, not
greater than 100 m.
The ditches shall be of reinforced concrete and minimum slope as directed by the
Owner.
Transformer Area Drainage & Oil Separator

To contain accidental oil spills shall be routed through WWTP, all drainage from the
transformer area and Diesel fuel-unloading facility shall be routed through an oil
separator.
The design of transformer pit and piping from the transformer pit to oil separator
shall be based on the largest flow expected from the following condition unless
Contractor requires larger.
Surface run-off shall consider 10 years recurrence interval from the transformer
area.
Deluge system flow for the largest transformer fire protection system-estimated
flow rate 30 liters/s.
Accidental oil spills from the largest transformer-estimated spilled oil volume of
3000 liters unless the Contractor requires larger.

BOOK III
The size of the main line connected to the oil separator shall be sized to handle
additional flow from other area as required.
Sanitary Waste Water

The Contractor shall design and provide the septic tank which shall be reinforced
concrete with manholes and baffle.
The septic tank with drainage system shall have a sufficient capacity to
accommodate the minimum of 50 person for the facilities of the control building,
the water treatment plant, and the substation building.
Drainage from the mess room and toilet area of above-mentioned buildings shall
be routed to the septic tank before discharged to the wastewater storage pond.
The elevated piping from the building to the ground level and piping to the waste
water storage pond shall be cast iron; and under ground piping to septic tank shall
be PVC pipe with the minimum size of 150 mm diameter.
Clean out shall be provided at every 30 m and each change in direction of the
sewer system.
Prior to the design of the tile drainage absorption field, Contractor shall perform
percolation tests to determine the absorption rate. Based on the field percolation
test results the size of the absorption field shall be determined.
Plant Water
Drainage system from the plant water shall be discharge to the wastewater storage
pond.
Piping material shall be cast iron, PVC or GRP according to the requirement.
Shelter
The shelter shall be provided for, but not limited to the following equipment/plant:
a. Demin Pump
b. Service Water Pump
c. Other structures as directed by the owner
The shelter shall be designed with steel structure and provided with metal roofing.
Floor shall be designed to be reinforced concrete slab.
Oil Pipe and Cable Bridge

Oil pipe and Cable Bridge shall be steel structure pipe sleepers and bridge
abutments shall be reinforced concrete founded on prestressed concrete pile.
Chemical Resistant Lining

All water and wastewater concrete tanks and ponds shall be lined with epoxy
coating with fiberglass fabric reinforcements suitable for the chemistry of the
effluent.

BOOK III
4.4.4 SUPPORT DATA

During the tender document preparation, the owner has carried out several
preliminary site investigations to provide the support data for bidder.
However, such data shall be treated as for the information only and will not relieve
the bidder’s responsibility to carry out further investigation during EPC contract.
4.4.4.1 SOIL INVESTIGATION
The soil investigation were carried out by PT. Petrosol from October 16 up to
November 19, 2011 at ± 50 m from KDL CFSPP 1 x 150 MW . The results of
geotechnical analysis are presented here in :
Soil Profile
Soil profile is determined based on soil investigation result.In general, soil profile
consist of loose silty sand in the surface, and dense to very dense silty sand in the
bottom. Soil profile condition in the location comprise of :
1. First later from surface to 13 up to 15 m depth is silty sand with

consistency very loose to loose. N-SPT value in this layer between 1 and
5.
2. Second layer is silty sand with consistency dense to very dense in 13 m
to 14 m depth until the end of boring with N-SPT value more than 20.
Groundwater
It is reported that the groundwater data appears to be detected at all boreholes.

The elevation of groundwater is -0.60 m in all area.
Single Pile Calculation Results
Single pile capacities calculation provide pile capacities to be used in foundation

design under condition where deep foundation is selected as the foundation
system. Calculation of single pile capacities are performed based on the following
conditions :
1. Since the soil is dominated by loose and saturated sand layer, it possible
that liquefaction condition will be occurs during earthquake. Therefore
pile capacities for two types of soil conditions, normal soil condition and
liquefaction condition, are calculated frome existing ground surface to
end of boring at each borehole locations.
2. Soils displacement (vertical and horizontal) due to embankment film
does not involve in the pile capacities calculations. Vertical displacement
of soil may generate negative skin friction, whereas lateral displacement
of soil will produce additional lateral force.

BOOK III
3. Pile types that used in the calculation were driven pile (concrete) with
diameter of 450 mm.
4. In this study, the calculation of negative skin friction is excluded from
the analysis of pile bearing capacity since the soft soil layer is not found
at the proposed area.
5. The analysis of lateral capacity of pile was performed based on the
following assumptions:
 Fixed head pile
 No vertical load applies to the pile
6. It is noted that factor of safety should be applied to the ultimate
capacity due to the uncertainties during analysis process.
Liquefaction
It is known that the soil at the proposed project location is dominated by loose and
saturated sand layer above hard layer. Hence, it is possible that liquefaction
condition will be occurs during earthquake. The soil will loose their shear strength
when the liquefaction occurs. Therefore the pile will also lose their skin friction
capacity along loose sand layer and become freestanding pile. Refer to the lateral
capacity of pile diameter 45 cm as presented, it is known that the lateral capacity in
normal condition vary from 40 kN to 60 kN, however at liquefaction the capacity
far drop to 0.3 kN to 0.9 kN, is mean, piles will far from enough strength against
lateral load, especially during earthquake/liquefaction condition. In detail design
process, the engineers should consider about this liquefaction condition to increase
the resistance of the top loose sand layer until 15 m depth against liquefaction, it is
suggested or proposed to carry out sand compaction piles over the project area.
Therefore, at each proposed heavy structure location site exploration drilling shall
be carried out. In addition locating cavities at depth could be carried out by using
geophysical survey methods such as cross-hole ground penetrating radar and,
earth – resistivity ( Geo-Electric sounding ).
Large openings near the surface may be detected by gravity methods.
It should be noted that the foundation shall be designed in such a manner that
neither land subsidence nor cavity collapse will impair the structure.
4.4.4.2 TOPOGRAPHY
Detailed information regarding topographic of project site can be seen in the
related Topographic Maps at Book V Part 6.

BOOK III
4.4.4.3 BATHYMETRI
The area measured is about ± 30 Ha. Detailed information regarding Bathymetri of
project site can be seen in the related Bathymetri Maps at Book V Part 6 at Book V
Part 6.
Figure 4.4. Bathymetri Maps

Part 4.4 - Civil

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BOOK III

PART 4.4 Civil Works

PART 4.4 CIVIL WORKS ................................................................................................... 7

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.i

4.4.2.5 CONCRETE WORKS .................................................................................... 73

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.ii

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.iii

4.4.2.17.7 SETTING ................................................................................................... 167

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.iv

4.4.2.23.7 PAINTING WORK SYSTEM ....................................................................... 225

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.v

4.4.2.29 FENCE WORKS, GATES, GUARD RAIL....................................................... 304

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.vi

PART 4.4 CIVIL WORKS

4.4.1 GENERAL CIVIL AND ARCHITECTURAL DESIGN REQUIREMENT

4.4.1.1 BUILDING AND STRUCTURAL DESCRIPTIONS

4.4.1.1.1 STEAM TURBINE BUILDING

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.7

The Steam Turbine Building shall be mounted on a monolithic slab/mat

4.4.1.1.2 BOILER HOUSE AND AUXILIARY

The Boiler House shall be mounted on a monolithic slab/mat reinforced

4.4.1.1.3 CENTRAL CONTROL BUILDING

The Central Control Building shall be designed as a concrete framing structure

Windows shall be anodized aluminum frames and insulated glazing. Air

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.8

4.4.1.1.4 ADMINISTRATION BUILDING (Not Applicable)

The Chimney arrangement drawings shall be included in the Bidder’s proposal

4.4.1.1.6 ACCESS ROAD AND BRIDGES

4.4.1.1.7 COOLING WATER INTAKE AND DISCHARGE

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.9

The Bidder shall undertake survey works to provide sufficient hydrographic

4.4.1.1.8 COOLING WATER INTAKE PUMP HOUSE

The Cooling Water Pump House is placed on offshore which shall be of

4.4.1.1.9 DEFLECTOR WALL (If Needed)

The Bidder shall design it accordingly and approved by owner.

4.4.1.1.10 ELECTRO CHEMICAL BUILDING

Electro Chemical Building shall be erected on shallow Foundation or bored

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.10

4.4.1.1.11 WASTE WATER TREATMENT FACILITIES

4.4.1.1.12 WATER TREATMENT PLANT

Water Treatment Plant structure shall be reinforced concrete founded on

4.4.1.1.13 HSD OIL TANK FARM FOUNDATION

4.4.1.1.14 PIPE WORK SUPPORT STRUCTURE

Pipe work support structures shall sit on reinforced concrete sleeper

4.4.1.1.15 COAL STORAGE AND COAL HANDLING FACILITIES STRUCTURE

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.11

4.4.1.1.17 CABLE DUCTS AND UNDERGROUND CABLE DUCT

4.4.1.1.18 CABLE TRENCH

Cable trench shall be founded on shallow foundation or bored pile (if

4.4.1.1.19 150 kV SUBSTATION BUILDING

The 150 kV substation building shall be designed as reinforced concrete

The foundations for the substation building shall be shallow foundation. If

PT KDL's Coal Fired Steam Power Plant 1x150 MW Project 4.4.12

4.4.1.1.21 AUXILIARY/MISCELLANEOUS BUILDINGS AND STRUCTURE

The foundation of auxiliary/miscellaneous building and structures shall be

4.4.1.1.22 SITE DRAINAGE

The Power Station complex shall be provided with an integrated and

The drainage shall be either pre-cast or cast in-situ reinforced concrete.

Following is the proposed design concept for each drainage system;

a). Storm Water Drainage

The minimum requirement of drainage ditch shall be of reinforced concrete

The underground storm water drainage shall be provided with adequate

RELATIONSHIP OF MANHOLE INTERVALS AND PIPE DIAMETER

DIAMETER OF PIPE Under Under Under Under Under