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AINUL HAYAT SEJAHTERA

SWRO and Salt Plant
Civil/Structural Project Technical Specification

111 Somerset Road #12-05

Singapore 238164

302000-00058-

www.advisian.com
Synopsis

This Technical Specification describes the minimum design requirements of Civil and Structural
Engineering for Ainul Hayat Sejahtera SWRO & Salt Plant Project.

Disclaimer

This document has been prepared on behalf of and for the exclusive use of Ainul Hayat Sejahtera ,
and is subject to and issued in accordance with the agreement between Ainul Hayat Sejahtera and
Advisian.

Advisian accepts no liability or responsibility whatsoever for it in respect of any use of or reliance
upon this report by any third party.

Copying this MFS without the permission of Ainul Hayat Sejahtera and Advisian is not permitted.

Project No: 302000-00058 – AINUL HAYAT SEJAHTERA SWRO & Salt Plant:
Civil/Structural Project Technical Specification

Advisian
Rev Description Author Review Approval Date

A Issued for Internal 09/21/2018

Review N Walavalkar F. Leon D Mishra
Table of Contents
1. Introduction ............................................................................................................. 4

2. Definitions ................................................................................................................. 4

3. Codes and Standards ............................................................................................ 5

4. General ....................................................................................................................... 7

5. Earthworks .............................................................................................................. 12

6. Foundations ........................................................................................................... 14

7. Reinforce Concrete .............................................................................................. 16

8. Steel Structures ..................................................................................................... 18

9. Site Work and Site Preparation ....................................................................... 20

10. Storm Water and Drainage System ............................................................... 21

11. General Levelling and Grading of Site .......................................................... 25

12. Roads and Parking areas ................................................................................... 25

13. Fence and Gates ................................................................................................... 30

14. Seawater Intake/Outfall Facility and Pumping Station ........................... 31

15. Pipe Racks ............................................................................................................... 31

16. Buildings .................................................................................................................. 37

Table List
Table 1: Concrete Grades ................................................................................................................................................. 17

Table 2: Recommended Road Width .......................................................................................................................... 26

Table 3: Vertical Clearances ............................................................................................................................................ 27

Table 4: Road Gradients ................................................................................................................................................... 28

1. Introduction
This section contains the minimum design requirements of the COMPANY for civil/structural
engineering and design activities, for the various civil /structural works associated with the Ainul
Hayat Sejahtera SWRO & Salt Plant Project, as specified in scope of work (section 2 of this
document).

It shall be the CONTRACTOR’S responsibility to develop the workable, safe design from his own
conceptual studies and various requirements of this documents. CONTRACTOR shall also consider
any design requirement/s envisaged during detail engineering (but not listed here) due to specific
functional requirements of Structure/Equipment/Process for smooth and safe functioning of the
plant to the satisfaction of the COMPANY.

Requirements of this specification shall be enforced at all levels of the CONTRACTOR’s

procurement process. The COMPANY shall have access to all SUB-CONTRACTOR(s) and
SUPPLIER(s) to the same extent as required.

The CONTRACTOR shall notify the COMPANY of any apparent conflict between the requirements
listed here this document, the Codes and Standards noted herein. Resolution and/or interpretation
precedence shall be obtained from the COMPANY in writing before proceeding with the
design/construction.

2. Definitions

COMPANY/OWNER Ainul Hayat Sejahtera and its successors in interest and

assignees.

PROJECT Work associated with Ainul Hayat Sejahtera SWRO and

Salt Plant.
The party which carries out all or part of the design,
CONTRACTOR
engineering, procurement, construction, commissioning
or management of the PROJECT. CONTRACTOR includes
its approved MANUFACTURER(s), VENDOR(s),
SUPPLIER(s) and SUBCONTRACTOR(s).
The party(s) which manufactures and/or supplies
MANUFACTURER/VENDOR/SUPPLIER
material/product and services to perform the duties
specified by the CONTRACTOR.
SUBCONTRACTOR The party(s) which carries out all or part of the design,
procurement, installation and testing of the System(s) as
specified by the CONTRACTOR.

SHALL Indicates a mandatory requirement

SHOULD Indicates that the requirement is strongly recommended

to be adhered to.
3. Codes and Standards
The following Codes, Standards and Specifications form a part of this specification. When an
edition date is not indicated, the latest edition in force at the time of contract award shall apply.
Where there are conflicts between the requirements of different Specifications, Codes and
Standards the most stringent criteria shall apply.

AMERICAN SOCIETY OF SAFETY ENGINEERS (ASSE)

ANSI/ASSE A1264.1 Safety Requirements for Workplace Walking / Working Surfaces and their
access; Workplace, Floor, Wall and Roof Openings; Stairs and Guardrails
Systems.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI A14.3 Fixed Ladders – Safety Requirements.

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE 7 Minimum Design Loads for Buildings and Other Structures – Including
Supplement 1

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC).

AISC 360 Specification for Structural Steel Buildings

AISC 325 Steel Construction Manual
AISC 303 Code of Standard Practice for Steel Buildings and Bridges
AISC 341 Seismic Provisions for Steel Buildings

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 216.1 Code Requirements for Determining Fire Resistance of Concrete and
Masonry Construction Assemblies
ACI 224.3R Joints in Concrete Construction
ACI 301 Specifications for Structural Concrete
ACI 302.1R Guide for Concrete Floor and Slab Construction
ACI 318M/318R Building Code Requirements for Structural Concrete and Commentary
ACI 336.2R Suggested Analysis and Design Procedures for Combined Footings and
Mats
ACI 350M/350R Code requirements for Environmental Engineering Concrete Structures
and Commentary
ACI 530 Building Code Requirements for Masonry Structures and Commentary

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M Structural Welding Code-Steel

AWS D1.4/D1.4M Structural Welding Code-Reinforcing Steel

AMERICAN PETROLEUM INSTITUTE (API)

API 650 Welded Steel Tanks for Oil Storage, Appendix E

PORTLAND CEMENT ASSOCIATION (PCA)

PCA IS 003 Rectangular Concrete Tanks

PCA IS 072 Circular Concrete Tanks without Pre-stressing

NATIONAL CONCRETE MASONRY ASSOCIATION (NCMA)

NCMA TEK Manual for Concrete Masonry Design and Construction.

US DEPARTMENT OF LABOR, OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION(OSHA)

OSHA 29 CFR Part 1910

AMERICAN ASSOCIATION OF STATE HIGHWAYS AND TRANSPORTATION OFFICIAL (AASHTO)

AASHTO LRFD Bridge Design Specifications

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A6/A6M Specification for General Requirements for Rolled Structural Steel Bars,
Plates, Shapes, and Sheet Piling
ASTM A36/A36M Specification for Carbon Structural Steel
ASTM A53/A53M Specification for Pipe, Steel, Blank and Hot-Dipped, Zinc-Coated, Welded
and Seamless.
ASTM A123/A123M Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products
ASTM A143/A143M Standard Practice for Safeguarding Against Embrittlement of Hot-Dip
Galvanized Structural Steel Products and Procedure for Detecting
Embrittlement
ASTM A185/A185M Specification for Steel Welded Wire Reinforcement, Plain, for Concrete
Reinforcement
ASTM A193/A193M Specification for Alloy-Steel Bolting Material for High-Temperature Service
ASTM A307 Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength
ASTM A320/A320M Standard Specification for Alloy-Steel and Stainless Steel Bolting materials
for Low-temperature service
ASTM A325 Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi,
Minimum Tensile Strength
ASTM A392 Standard Specification for Zinc-Coated Steel Chain-Link Fence Fabric
ASTM A490 Specification for Structural Bolts, Alloy Steel, Heat treated, 150 ksi,
Minimum Tensile Strength
ASTM A500 Specification for Cold-Formed Welded and Seamless Carbon Steel
Structural Tubing in Rounds and Shapes
ASTM A615/A615M Standard Specification for Deformed and Plain Carbon-Steel Bars for
Concrete Reinforcement
ASTM A786/A786M Standard Specification for Hot-rolled Carbon, Low-alloy, High strength
Low-alloy and Alloy Steel floor plates
ASTM A824 Standard Specification for Metallic-Coated Steel Marcelled Tension Wire
for Use With Chain Link Fence
ASTM A830/A830M Specification for Plates, Carbon Steel Structural Quality, Furnished to
Chemical Composition Requirements
ASTM A1011/A1011M Standard Specification for Steel, Sheet and Strip, Hot-rolled, Carbon,
Structural, High-strength Low-alloy, High-strength Low alloy with
Improved Formability, and Ultra-High Strength
ASTM C90 Specification for Load-Bearing Concrete Masonry Units
ASTM C270 Specification for Mortar for Unit Masonry
ASTM C476 Standard Specification for Grout for Masonry
ASTM F436 Specification for Hardened Steel Washers
ASTM F567 Standard Practice for Installation of Chain-Link Fence
ASTM F626 Standard Specification for Fence Fittings
ASTM F959 Specification for Compressible-Washer-Type Direct Tension Indicator for
use with Structural Fasteners
ASTM F1043 Standard Specification for Strength and Protective Coatings on Steel
Industrial Fence Framework
ASTM F1083 Standard Specification for Pipe, Steel, Hot-Dipped Zinc-Coated
(Galvanized) Welded, for Fence Structures
ASTM F1184 Standard Specification for Industrial and Commercial Horizontal Slide
Gates
ASTM F1910 Standard Specification for Long Barbed Tape Obstacles
ASTM F1554 Standard Specification for Anchor Bolts, Steel, 36, 55 and 105 ksi yield
strength
ASTM F2200 Standard Specification for Automated Vehicular Gate Construction

INTERNATIONAL CODE COUNCIL (ICC)

IBC International Building Code

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 9001 Quality Management Systems – Requirements

ISO 9004 Quality Management Systems – Guidelines for Performance Improvement

Indonesian Codes

SNI 03-1726 Design Methods of Earthquake Resistant Buildings

4. General
4.1 Design Requirements
CONTRACTOR shall prepare various engineering documents like basis of design,
specifications, reports, calculation notes, drawings, material takeoffs etc. to execute the work
defined in the scope of work. All these deliverables shall comply design requirements listed
in this document.
CONCESSION CONTROL: Any technical deviations to requirement listed here including, but
not limited to, the Technical specifications or Material Specification shall be sought by the
CONTRACTOR only through formal CONCESSION REQUEST. CONCESSION REQUESTS
 require COMPANY’S review/approval, prior to proposed technical changes being
implemented. Technical changes implemented prior to COMPANY approval are subject to
rejection.

a) Reference Codes and Standards: All structural engineering design shall be within the
parameters of the documents listed in section 3, and these documents shall be considered as
a part of this design basis.
b) Measurement: All dimensions, quantities, and units of measurement shown on drawings, or
used in specifications and calculations, shall be given in metric units, except pipe size which
shall be given in inches. Levels shall be indicated in meters, all other dimensions in
millimeters.
c) Topography Survey and Geotechnical Investigation Report: COMPANY shall provide
geotechnical investigation report and topography survey report to the CONTRACTOR.
However COMPANY accepts no liability for the information contained in these reports (if
any).
i. Topography Survey: All design shall be in accordance with the horizontal and vertical
controls contained in the topography survey report provided by the COMPANY.
ii. Geotechnical Investigation Report: All design shall be in accordance with the
recommendations contained in the soil report provided by the COMPANY.

4.2 Basic Engineering, Design And Drawing Concepts:

CONTRACTOR shall prepare following deliverables during basic engineering phase.

a) Basis of Design:
CONTRACTOR shall prepare Basis of Design for Civil, Structural and Architectural work based
on the requirements listed in this document and submit it to the COMPANY for approval.
Approved Basis of Design shall be used for further detail engineering.
b) Specifications:
CONTRACTOR shall prepare specifications for Civil and Structural work based on the
requirements listed in this document. These specifications shall cover material, construction,
quality and acceptance criteria as a minimum. CONTRACTOR shall submit these
specifications to the COMPANY for approval. Approved specifications shall be used during
execution of the work.
In addition to the specifications, CONTRACTOR shall prepare additional documents like work
procedures, method statements which are required to execute the work and submit it to the
COMPANY for approval.
c) Standard Drawings
CONTRACTOR shall prepare standard drawings for Civil, Structural typical work (like general
notes, fire-proofing, stairs, guardrail etc) based on the requirements listed in this document.
These standard drawings shall comply with provisions of project specifications, national and
international codes and standards applicable for this project and industry practices as a
minimum. CONTRACTOR shall submit these standard drawings to the COMPANY for
approval. Approved standard drawings shall be used during execution of the work.
d) Basic Design and Preliminary Calculations
Prior to starting detailed design, a basic design shall be made consisting of:
Basic sketch
Loading Derivation
Calculation
Stability check
Main Structural members
 Basic Sketches: The sketch shall show the proposed structure (in perspective and/or a series
of cross sections). Structural members may be shown as single lines. The sketch shall include
the foundations, and also differentiation of structural levels based on material of
construction (steel and concrete).
Calculations: The calculation shall give the design philosophy and shall follow all loads as
listed in section 15, including the estimated dead loads (self-weights) of the relevant
structural components. The calculation shall state the loads in the main structural members
(axial loads, bending moments, shear and possibly torsion), and shall include the loads on
the foundation (load per unit of area).
The calculation shall take into account the soil investigation report.
CONTRACTOR shall use COMPANY approved commercial software commonly used in the
industry for
i. Structural analysis and design
ii. Foundation design
iii. Finite element design
CONTRACTOR shall identify these software to be used for the detailed design, these shall be
identified during the basic design stage and supply all documentation to demonstrate their
accuracy and applicability to the COMPANY for approval.
The submission of calculations by the CONTRACTOR to the COMPANY shall include the
editable native electronic format of the program input/output, for the ease of review by the
COMPANY.
Stability Check: The stability of the structure shall be checked for serviceability or allowable
load combinations as per ASCE 7.
Main Structural Members: In the assessment of the sizes and dimensions of the main
structural members the most critical load combination shall be considered. Structural details,
such as connections of steel beams and columns or details of reinforcing steel over the full
length of a reinforced concrete beam, shall be designed and detailed by the Engineer.
Standard steel connection details may be designed by the subcontractor but shall be
checked by the CONTRACTOR.

4.3 Detailed Engineering and Design:

The detailed design shall be based on the basic design and supported by design calculations.
Detail engineering be based on reliable load data, mechanical data sheets and vendor
drawings.
Contractor shall prepare design calculations for all plant buildings, process structures, pipe-
racks, pipe supports, equipment foundations, pavements, culverts and other component
associated with the plant based on firm data, design input from other disciplines like piping,
electrical, instrumentation etc., vendor drawings with equipment loads.
The calculation note shall clearly indicate:
i. The table of contents
ii. Design philosophy to includ engineering assumptions
iii. Applicable codes, formulas, graphs/tables
iv. References to literature etc., for subjects not covered by applicable codes
v. Loading tables with loading location diagrams
vi. If computer programs/spreadsheets are used, the following information shall be
supplied:
 Logic and theory used
 Analytical model of the structure used for computer analysis
 A hand calculation to prove the validity of the computer analysis except if
validated by QA/QC system.
 Loads and load combinations
 Pictorial presentation of Inputs/outputs.
  Inputs shall contain the Node numbering, loading presentation, material
assignment etc. Output shall contain the deflection presentation and other
related items.
 Support reactions
 Member end forces
vii. Editable native electronic files shall be included for each submission.
Based on calculations performed during detail engineering, CONTRACTOR shall develop
detail drawings with all construction details. Drawings shall have adequate numbers of plan,
elevations, sections, rebar details and connection details as required to execute the work.
CONTRACTOR shall develop Bill of Quantities and update it periodically based on ‘Issued for
Construction’ quantities. CONTRACTOR shall share this document with OWNER on bi-weekly
basis.

4.4 Drawings and Related Documents:

Detail engineering drawings prepared by CONTRACTOR shall comply with with following
requirements.
a) General :
Drawings shall be of the standard metric sizes, i.e. A0, A1, A2, A3, A4. CONTRACTOR shall
use COMPANY approved commercial software for the preparation of drawings. Drawings
shall be suitably prepared to facilitate archiving.
CONTRACTOR shall follow COMPANY Document Numbering System. Revisions and Holds
shall be suitably clouded for easy identification.
Layout drawings shall show the highest point of grade as specified in the piping plot
plan/equipment layout and the reference of this level to the local datum level for Process
Units, in off-sites the actual level shall be indicated.
All headings and notes shall be in English.
Each drawing shall bear the following information, in the title block:
 Order number of the COMPANY
 Name of plant
 Name of unit
 Name of part of the unit
 Drawing and revision number
Before release of any Construction drawings, all drawings shall be approved by COMPANY
prior to start of construction at site.
Drawings shall be submitted together with the relevant calculations, including those required
for submission to local authorities. CONTRACTOR shall include the editable native electronic
format of the drawings as agreed with COMPANY.
Revisions to drawings shall be identified with symbols adjacent to the alterations, a brief
description in tabular form of each revision shall be given and, if applicable, the authority
and date of the revision shall be listed. The term “Latest Revision” shall not be used. Claim to
all drawings prepared by the CONTRACTOR under any order placed by the COMPANY shall
be vested in the COMPANY, and the latter shall have the right to use these drawings for any
purpose without any obligation to the CONTRACTOR.
The CONTRACTOR shall not disclose or issue to third parties without written consent of the
COMPANY any documents, drawings, etc., placed at his disposal by the COMPANY or any
documents prepared by himself in connection with inquiries and orders for purposes other
than the preparation of a quotation or carrying out these orders.
b) Structural Concrete Drawings:
These drawings shall give overall plan/layout of building/structure and foundations along
with appropriate grid numbering system, plant north direction, appropriate level/s. Sufficient
number of cross-sectional details shall be provided along with member sizes or thicknesses
and rebar details. Drawings shall contain grade wise material take-off for concrete and rebar.
 The general information/data shall be shown as General Notes on the right-hand side of the
drawing.
The general notes shall state that:
 Levels are expressed in meters, with reference to the highest point of grade
 Dimensions are expressed in millimeters
 Bar diameters are expressed in millimeters
 The quality (or qualities) of concrete*
 The quality (or qualities) of steel reinforcing bars*
Scale of drawings: Plan drawings shall be made to a scale of 1:50 and detail drawings to a
scale of 1:20 in the standard metric size A1.
c) Structural Steel Drawings:
Following types of drawings shall be prepared
i. General arrangement drawings:
This drawing shall show the complete structure to be constructed. It shall contain
following details as a minimum-
 Key plan
 All dimensions
 Levels
 Member locations
 Location and details of expansion joints
 Section property
 Plate thicknesses
 Grating thicknesses
 Section orientation
 Work points for connections
 Type of connections
 Extent of floor plates or grating along with their spanning direction
 Extent of handrails
 Louvers and cladding arrangements
 Extent of fireproofing
 Lifting capacities of cranes and monorail beams
ii. Baseplate drawing
This drawing shall show all dimensions and details of the base plate including
anchor bolts, which shall be taken into account in the design of the (concrete)
foundation. Baseplate details shall also include sizes for anchor bolt holes,
grouting holes, shear key and connection to the column. When the need for a
slight adjustment of the anchor bolts during erection is expected, this shall be
indicated on the drawing. The scale for details shall be at least 1:10.
iii. Construction drawings (Fabrication drawings)
These drawings shall clearly show all constructional details of the structure to be
constructed to the scale. In addition to the requirements listed under general
arrangement drawings (part i of this section) following details shall be provided as
a minimum
 Beam making
 Cut length of members
 Notches/ coping
 Gusset plate details
 Connection details
 Erection details
 Lifting arrangement
 Details of consumables
 BOQ from fabrication perspective.
 iv. Bills of material
Bills of material shall show weights of each member used, weights of plates, area
of floor plates or gratings, length of guardrails/handrails, area of structural steel
painting as a minimum.
d) Overall Civil Layout Drawings
These drawing/s shall show following details as a minimum.
i. Site Grading – This shall include details like type of grading, its levels, slopes etc.
ii. Road Layout- This shall include details like road coordinates, road width, shoulder
width, road levels, gradients, turning radius, culverts etc.
iii. Drainage layout- This shall include details like drainage layout, cross-sectional
details, manhole locations and details,
iv. Underground piping layout- This shall include pipe routing, pipe crossing details,
v. Cable trench layout- This shall include layout of trenches, type of trenches, cross-
sectional details, duct bank locations/details, details at trench crossings.

5. Earthworks
Earthwork and related activities shall comply with following requirements.
5.1 CONTRACTOR shall review geotechnical investigation report provided as a part of contract
document. Based on recommendations of this report, CONTRACTOR shall develop standard
specification to provide the minimum requirements for materials and workmanship
associated with Site Preparation and Earthworks at the new and existing facility.
CONTRACTOR shall submit this specification for COMPANY approval. This specification shall
be used to execute the work.
5.2 This specification shall cover the extent of work as described herein but is not limited only to
the demolition, site clearance, excavation, filling, hauling, compaction, and disposal, borrow
pit, dewatering, inspection, testing and quality control etc. involved in the Works.
5.3 The contractor shall consider the geotechnical nature of ground to be excavated, the
presence of groundwater table, any chemical or oil contamination, the proximity of adjacent
structures and any other relevant information in this regard for the safe design.
5.4 Earthworks shall not commence until the contractor has provided the COMPANY with, and
obtained their approval to the following:-
i. Work / Excavation permits
ii. Methods of excavation
iii. Means of support to the sides of excavation
iv. System of dewatering
v. Demolition of existing surface, underground structures and obstacles
(wherever applicable )
vi. Moving of any existing services, pipes, culverts and the like on the Facility or
affecting the Work
vii. Safety arrangements
viii. Contractor shall make necessary trial pits in advance to obtain excavation
permits
5.5 The Datum for the site will be given by the COMPANY and all levels will be referenced to this
point. The accuracy of levels, other than that of the Datum, will be the contractor's
responsibility. Contractor shall construct survey monument within the plan area and establish
coordinates/levels to that point.
5.6 The works shall be properly set out by the contractor to the dimensions shown on the
drawings. The setting out shall be approved by the COMPANY prior to commencement of
excavations.
5.7 Excavation shall include for excavating in and handling whatever material may be met with,
including loose or compacted hardcore and for grubbing up any disused drains, pipes,
cables and roots and any other obstructions met with whatsoever.
5.8 The contractor shall ensure that no pollution, silting up or damage shall occur to any gully,
ditch, culvert or pipe as a result of these works. The contractor shall make good any such
damage entirely at his own expense. Any such damage shall be entirely borne by contractor
at his own expense.
5.9 Excavated material surplus to requirements shall be loaded and transported off-site to the
COMPANY approved dumping site at the CONTRACTOR’S expense.
5.10 Freshwater shall be used for all earthwork operations unless directed by the COMPANY to
the contrary. Seawater will not be permitted to be used for any work.
5.11 COMPANY shall permit the contractor to obtain fill materials from the approved borrow pits
after ascertaining the suitability and quality of materials selected.
5.12 Minimum four (4) permanent reference monuments shall be constructed preferably at the
four corners of the Site or as directed by the COMPANY onsite and shall be protected at all
times.
5.13 The contractor shall be responsible to provide, if necessary, a complete dewatering system
with sufficient numbers of equipment to keep the area(s) of excavation dry and free from
subsurface water and to maintain the water table below the required formation/foundation
levels indicated on Contract / approved drawings.
5.14 Prior to commencement of excavations, the contractor shall prepare and present to the
COMPANY the detailed proposals for dewatering the site as necessary.
5.15 Explosives shall not be used for any purpose on the Works.
5.16 The contractor shall provide sufficient safety signs on and along the excavated areas. Lamps
with fluid fuel shall never be used.
5.17 Where excavation reveals a combination of suitable and unsuitable materials, wherever it is
practicable, excavations shall be performed in such a manner that the suitable materials are
excavated separately for use in the Works without contamination by the unsuitable materials.
5.18 Backfill material free from boulders, concrete lumps and any other foreign matter shall
normally be the materials obtained from the excavated areas. However, only material
designated as " suitable " in compliance with the COMPANY requirements shall be placed in
layers not exceeding 150mm and compacted evenly around the foundations, walls, columns
and grade beams etc. by hand or mechanical rammers up to original ground level to achieve
95% of maximum dry density at OMC as determined by ASTM D1557 or AASHTO T180.
Where soil conditions dictate and as approved by the COMPANY, ASTM D 4253 shall be
used as an alternative test method.
5.19 Wherever possible, mechanical compaction shall be used in for structural fill.
5.20 Proper care shall be taken during backfill operations to prevent any damage to the
Permanent Works. In particular, damage to protective membranes/ coatings shall be
repaired before backfill is continued.
5.21 Compaction methods to be used for the selected materials shall be proven onsite by field
trials and laboratory tests to the complete satisfaction of the COMPANY. The contractor shall
obtain acceptance of the method from the COMPANY prior to commencing any compaction
work.
5.22 Confined areas shall be mechanically compacted using a vibrating plate or suitable sized
pedestrian controlled roller.
5.23 Where other services are encountered, they shall be properly supported and protected
including reinstating disturbed work, covers or similar protection, upon completion of the
new work.
5.24 Where cables are required to be laid in trenches, excavation shall be carried out in trenches
as per piping, electrical or instrumentation requirement.
6. Foundations
The design of foundations shall include all specified functional and testing requirements for
the structures supported thereon. The responses of structures vary widely in their capacity to
accommodate movement of their foundations, and the design of both the structure and the
foundation shall be considered interrelated.
Foundation design, in addition to the above applicable criteria, shall include the following
requirements:
6.1 Foundations shall be designed in accordance with the project geotechnical (soils) report.
6.2 Foundations for structures shall be sized and stability determinations shall be made using
service loads only. Load factors shall not be included in these design operations. Foundation
design shall include two cases namely (i) with soil overburden and (ii) without soil
overburden; and the most adverse case shall be considered, along with the effect of
buoyancy if applicable.
6.3 Unless there is a conflict with the project geotechnical investigation report, individual
foundations are normally used for major equipment. If combined foundations are
appropriate, the centroid of the bearing area should coincide with the resultant of the
applied operating load (excluding live load).
6.4 All foundations shall be placed on seal (blinding) slabs. The seal slabs shall be placed on firm,
undisturbed soil. Some seal slabs, however, may be placed on well-compacted earth fill, if
approved by the COMPANY. In such cases, the engineering drawings shall specify the kind of
fill material and the degree of compaction required for the fill material.
6.5 Spread footings, combined footings, and mats should be designed assuming linear soil
pressure distribution. Where the rigidity of the foundation is questionable, an analysis
considering the interaction between flexibility of the foundation and the subgrade soil
reaction should be considered. ACI 336.2 R contains suggested design procedures.
6.6 Foundations shall be proportioned so as to minimize general and differential settlements.
6.7 Where seasonal changes in soil moisture content are extreme at a site, special details may be
required to minimize foundation movements. Control of foundation movements is especially
critical for masonry structures. The CONTRACTOR shall determine design parameters to
control movement.
6.8 The stability ratio (SR) based on service (un-factored) loads, for isolated spread footings shall
not be less than 1.5 when soil overburden is considered and not less than 1.2 when soil
overburden is not considered, and is determined as follows:
SR = D(P) / 2M = D / 2e
Where:
D = Diameter or width of footing
P = Minimum gravity load at bottom of footing (exclude product and live loads,
include buoyancy)
M = Maximum overturning moment at bottom of footing
e = Eccentricity = M / P
6.9 The uplift factor of safety, based on service loads, shall not be less than 1.25. This factor of
safety must be maintained when 70 percent of dead load is combined with no reduction of
wind load for uplift.
6.10 “The stability ratio (SR) based on service loads, for buildings, process structures and other
framed structures shall not be less than 1.5 when soil overburden is considered and not less
than 1.2 when soil overburden is not considered, and is determined as follows:
SR = Resisting Moment / Overturning Moment
Where
Resisting Moment = Moment due to dead load of foundation and structure
(include buoyancy).
Overturning Moment = Moment due to lateral loads.
6.11 The overturning and resisting moments shall be computed about the most critical axis of
rotation of the foundation block at the soil-concrete interface. There may be more than one
axis of rotation. The stability ratio (SR) of retaining walls based on service loads shall not be
less than the following:
a. For sustained loading:
SR = Resisting Moment / Overturning Moment
= 3.5 for cohesive soils
= 2.0 for cohesionless material
b. For sustained loading combined with temporary loading:
SR = Resisting Moment / Overturning Moment
= 2.0 for cohesive soils
= 1.5 for cohesionless material
Where:
Resisting Moment = Moment due to dead load of wall and soil overburden (include
buoyancy)
Overturning Moment= Moment due to lateral loads
Resisting moment and overturning moment shall be taken about the toe of the retaining
wall and bottom of footing.
6.12 For all service load conditions, the sliding resistance of foundations and retaining walls
developed by friction between the footing and membrane shall at least be equal to 1.5 times
the applied lateral loads when soil overburden is considered and 1.2 times the applied lateral
loads when soil overburden is not considered in the stability calculations of foundations. The
effects of buoyancy on the concrete and soil weights shall be considered.
The sliding resistance of foundations shall be developed by either friction between the
footing and membrane or by a combination of friction and passive resistance on
foundations. In cases where sliding resistance is developed by a combination of friction and
passive resistance then, a minimum factor of safety of 2.0 shall be provided when soil
overburden is considered and 1.50 when soil overburden is not considered. The friction at
bottom surface (not on sides) and passive resistance upto the bottom level of reinforced
concrete only shall be considered for resistance.
6.13 Foundation bottom level shall be defined taking into consideration geotechnical (soil) report
and other factors and shall be clearly identified on the drawings. Keep bottom of footing at
uniform elevation where possible. Consideration shall be given to interferences with
underground systems.
Minimum depth of foundation (up to the bottom of RC footing) shall be 0.60m below FGL
for minor foundations such as pipe sleepers, instrument and electrical supports, signposts,
crossover platforms and equipment foundations weighing less than 1MT. For other
foundations, depth of foundation shall be as per applicable Geotechnical recommendations
and underground services routing subject to a minimum depth of 1m from FGL.
6.14 Contractor shall consider the relative merits of precast structural concrete elements such as
small foundations, sleepers, manholes, culverts and small structures. Precast foundation
design shall include calculations for lifting and handling stresses.
6.15 No piping/cables shall pass through a foundation, unless for the equipment to be fixed on
the same foundation itself. If some existing piping/cables are found in the way of new
foundations, the foundation shall be relocated. If relocation of the foundation is found to be
not feasible then rerouting of pipe/cables shall be proposed to the satisfaction of
COMPANY.
6.16 Foundations for vertical vessel or stacks shall meet the following stability criteria against
overturning.
a. At least 80% of the foundation shall be in compression for the design overturning
moment during empty or, erection condition.
b. At least 90% of the foundation shall be in compression for the design overturning
moment during normal operating condition with the exception of (c) below.
 c. Foundations for tall vertical vessels (h/d>10), shall be in full compression (100%) for
the design overturning moment during normal operating condition.
6.17 Pile Foundations shall be considered where soil structural behavior can be affected by
liquefaction from excessive vibrations such as those generating from high-frequency
vibrating equipment in high water table zones or soil condition is very poor.
Recommendations provided in Project Geotechnical Report shall also be followed.
6.18 Anchor bolts shall be cast along with the foundation concrete without provision for
pockets/anchor boxes. Pockets/anchor boxes shall be permitted by the COMPANY for
certain specific cases only, on valid justification.
6.19 Overlapping of foundations (one over another at different levels) is not allowed unless
alternative arrangement is not feasible. In such cases suitable additional loading shall be
considered in the design of lower level foundations and additional protection measures to
be agreed with the COMPANY.
6.20 As required by the design and Machine manufacturers’ recommendation, vibration isolation
pad around dynamic foundations shall be provided.
6.21 Foundations subjected to dynamic loads shall be designed as per recommendations of ACI
351.3R (Foundations for Dynamic Equipment) and Design of Structures and Foundations for
Vibrating Machines (by Suresh C. Arya, Michael M. O’Neil and George Pincus)
6.22 All concrete faces for miscellaneous concrete elements (non-structural) – e.g. duct banks,
guardrail foundations, etc. shall be provided with minimum reinforcement against shrinkage
and thermal cracking.
6.23 CONTRACTOR shall study geotechnical investigation report carefully. If any sensitive
structure, building or equipment foundation need to be supported on piling, CONTRACTOR
shall provide pile foundation for the same. In this scenario, CONTRACTOR shall decide type
of pile, calculate vertical as well as lateral capacities of piles and design pile. CONTRACTOR
shall submit all relevant reports, calculations and drawings to the COMPANY for approval.
CONTRACTOR shall validate pile capacities by testing piles at COMPANY approved location.
6.24 Concrete surfaces below ground level that will be in contact with soil except blinding
concrete for foundations shall be protected by three (3) coats of cold applied modified
bituminous paint of total thickness of 1000 microns (1.0 mm). Each coat of paint shall be left
to dry before the next coat is applied and backfilling shall commence only after the paint is
completely dry.
6.25 Foundations shall be placed over a layer of polyethylene sheet, 1000 gauge thick, laid over
blinding concrete. All sides of foundations and column necks shall be permanently covered
with impervious polyethylene sheet of 1000 gauge with minimum 150 mm overlap of the
sheeting.
6.26 Exposed external surfaces of concrete columns up to 150 mm below ground level and
concrete pedestals / piers up to 300 mm above ground level shall be protected with one (1)
coat of low viscosity primer and then coated with two (2) coats of light grey-colour epoxy
paint of approved quality with a minimum 125 microns dry film thickness (DFT) per coat.
6.27 Requirement listed under section 7 Reinforce Concrete are applicable for foundations.

7. Reinforce Concrete
The design and construction of reinforced concrete structures shall comply with following
requirements.
7.1 Cast-in-place concrete structures shall be designed in accordance with ACI 318 except as
specified otherwise in this specification
7.2 For Concrete Construction and On-Site Testing Laboratory and ACI 301 shall be used during
design, installation and inspection of concrete.
7.3 Cast-in-place concrete structures shall be designed for the loads and load combinations
specified ASCE 7.
 7.4 The strength design method shall be used for the structural design of concrete members
unless otherwise indicated. Load combinations and load factors for all concrete design shall
be in accordance with ACI 318 and IBC / ASCE 7.
7.5 The design and details of cast-in-place concrete structures shall consider the monolithic
nature of concrete construction.
7.6 Construction joints in a concrete structure shall be located so as to least impair the integrity
and strength of the structure. Construction joints in beams at column or pedestal faces
should be avoided. The CONTRACTOR Site Management shall approve the location of all
construction joints.
7.7 Moving concentrated loads on elevated concrete beams and slabs shall be treated in
accordance with applicable recommendations of the referenced AASHTO specifications.
7.8 Slabs at grade for buildings and process areas shall be designed in accordance with the
publications as per Section 12.23. Section 12.23 is also applicable for concrete pavements
for heavy storage areas.
7.9 Underground structures such as basements, rectangular tanks, sumps and pits shall be
designed in accordance with the latest referenced PCA bulletins. The design of such
structures shall include the effects of groundwater pressures and buoyancy. A minimum
factor of safety of 1.1 for buoyancy shall be used, ignoring soil cohesion. Concrete process
treatment structures shall be designed in accordance with ACI 350 R.
7.10 For all liquid retaining structures, special precautions should be taken for water tightness. All
joints shall be fully detailed by CONTRACTOR.
7.11 A corrosion allowance of 3 mm shall be required for all anchor bolts. Bolts shall be hot-dip
galvanized in accordance with ASTM A123 and A143.
7.12 Concrete shall be as shown in the Table 1 given in this section. The criteria given in the table
are designed to produce concrete of the required durability and strength. Concrete shall
comply with ACI 301 except where CONTRACTOR has taken written permission from the
COMPANY for such deviation.
7.13 Before concrete placement the CONTRACTOR shall obtain approval from the COMPANY of
the mixes proposed for each class of concrete. The mixes shall be designed to achieve the
minimum workability for the placement and compacting the concrete with the equipment
proposed for use.
7.14 Grade of Concrete:

Table 1: Concrete Grades

CONCRETE GRADES STRENGTH APPLICATION MAXIMUM CEMENT

AND 28 DAY CUBE MPa FREE CONTENT
STRENGTHS NOMINAL (Cylindrical WATER/ Minimum
Strength in
GRADE (2) (3) (4) (5) (7) CEMENT (kg/m3)
N/mm2)
(Cylindrical Strength in RATIO
N/mm2)

20 20 Blinding, Electrical Duct 0.50 250

banks, Screed
25FP(6) 25 Fireproofing 0.40 380
30 30 Equipment Foundations, 0.40 380
Structures, Footings, Pipe
Sleepers, Pits, Basins, walls
25F(1) 25 Paving Slabs, Trenches, 0.40 380
Ditches, slope protection
panels
 45 45 Pre-stressed Concrete, 0.40 380
Piles, Marine Facilities over
water, Structures in
continuous contact with
sea water, water retaining
structures.
Notes:
(1) Grade 25F concrete containing fibers shall be used for large areas of concrete, which are externally exposed
(such as paving slabs, trenches, ditches and slope protection panels).
(2) All concrete mixes to be designed for pumping.
(3) Grade is included only to provide a strength basis for design. It is not intended to identify durability levels.
(4) All concrete mixes to contain HRWRA (High Range Water Reducing Admixture).
(5) Concrete shall have a maximum aggregate size of 20mm except the concrete for screed and fireproofing
which shall have a maximum aggregate size of 10mm.
(6) Grade 25FP designates fireproofing concrete using lightweight aggregate.
(7) Strength level acceptance shall meet the requirements of ACI 301

7.15 All large flat areas of concrete which are externally exposed (such as paving including
trenches, ditches, floor slabs and slope protection panels) shall contain polypropylene fibers
at a dosage of 0.6 to 0.9 Kg/m3 of concrete volume, depending on the cement content and
the fiber manufacturer's recommendations. Fibrillated fibers shall be used where a broom
finish is required and monofilament fibers shall be used where a troweled finish is required.
Fibers shall be accordance with ASTM C1116/C1116M.
7.16 The CONTRACTOR shall submit for COMPANY approval his anticipated slump for each mix
design. Unless otherwise permitted or specified, the concrete shall be designed and
produced to have a slump not greater than 120 mm.
7.17 Prior to commencement of the work the CONTRACTOR shall furnish the following details to
the COMPANY.
Name and qualification of SUPPLIER(s).
Certificate of quality assurance.
Quality control facilities/procedures.
Certificate and test reports on concrete production and products.
Source(s) of aggregates, cement, etc.
Quality of water, aggregates and cement.
Production capacities.
Description of Plant Equipment and Facilities.

8. Steel Structures
8.1 Structural Steel Design shall be in accordance with the referenced AISC 360 and AISC341
specifications and codes. The plastic design method shall not be used in steel design.
8.2 Steel structures shall be designed for the loads and load combinations specified in ASCE 7.
Normally, only pinned column bases shall be used in the design of steel structures. Use of
fixed base plates for certain type of pipe racks and buildings may be necessary because of
deflection considerations.
8.3 Loads listed in section 15 are also applicable for steel structure/buildings as required.
8.4 Where headroom, access, or equipment arrangement will permit, wind and other lateral
loads on a steel structure shall preferably be carried to the foundations through vertical X-
bracing or K-bracing placed in the transverse and longitudinal column lines of the structure.
As a second choice, wind and other lateral loads on a structure should be transmitted to the
foundations through moment resistant frames in one direction and vertical X-braced or K-
braced frames in the other direction. Structures that resist lateral load with rigid frame
systems in two directions should be avoided. The method of bracing selected for a structure
should generally be used throughout the structure.
8.5 Compression bracing for steel structures shall normally be designed with wide flange and
structural tee shapes. For tension bracing, single angle or structural tees may be used.
Double angle bracing, because of maintenance difficulties, is not permitted for either
compression or tension bracing. When using structural tees in compression, the design shall
include bending induced by eccentrically loaded connections. Rods/cables as bracing
members shall not be permitted.
8.6 Braces for structures subject to vibration from equipment shall be designed as compression
braces.
8.7 Horizontal bracing shall be provided in the plane of a floor, platform, or walkway, when
necessary to resist lateral loads or to increase the lateral stiffness of the floor, platform, or
walkway. Floor grating shall not be assumed to resist lateral loads in diaphragm action. Floor
plate should be investigated before it is considered to resist loads in diaphragm action.
8.8 In a floor system, beam compression flanges shall be considered to be fully braced when a
concrete slab is cast to match the bottom face of the compression flanges on both sides, or
when checkered plate is welded to the compression flanges. Grating is normally clipped or
bolted and therefore shall not be considered as adequate compression flange bracing. In
such cases, additional vertical and/or horizontal bracing in the floor system shall be
provided.
8.9 Steel Structures shall be designed so that the surfaces of all parts will be readily accessible
for inspection, cleaning and painting. Pockets for depressions which would hold water shall
have drain holes or be otherwise protected.
8.10 Connections for steel structures shall conform to the following requirements:
a) Shop connections may be bolted or welded. Field connections shall normally be
bolted; however, when approved by COMPANY, welded field connections may be
used.
b) Bolted connections for primary members shall utilize high-strength bolts conforming
to ASTM A325 or A49. A minimum of two M20 bolts shall be used for all connections.
These connections shall be designed as bearing type connections. Those connections
subject to vibration or stress reversal shall be friction type. Loads for bearing type
connections shall be based on threads included in shear plane. Turn of the nut method
or load-indicator washers shall be used for tightening all connections. All bolts shall be
designed, installed and inspected in accordance with ASTM A325 or A490.
c) Bolted connections for secondary members (e.g. purlins, girts. stair framing. etc.) shall
be made with A307 bolts with the appropriate finish.
d) Connections shall normally be designed and checked by the CONTRACTOR in
accordance with the project construction specifications and loads shown on the
drawings. Moment connections and special connections, however, shall be designed
by the CONTRACTOR and shall be shown on the engineering drawings.
e) Moment connections can be bolted or welded type depending on the type of
structure and situation. The CONTRACTOR will determine the type of connection to be
used for each structure.
f) All shear connections shall be designed, detailed and checked by the CONTRACTOR.
Reactions shall be shown on the engineering drawings or as per the calculation note
provided by CONTRACTOR.
g) Plant area shall have the primary structural connections continuously seal welded
except high strength bolted field connections. Primary structural connections include
horizontal and vertical vessel supports, beams and columns on major pipe racks,
inaccessible maintenance areas, etc.
h) The forces in truss members and all main bracing shall be shown on the engineering
drawings with plus signs indicating tension and minus signs indicating compression or
as per the calculation note provided by CONTRACTOR.
 i) The minimum thickness of any structural steel plate or bar shall be 12mm, except for
the base plate which shall be 20mm. Gusset plate shall not be thinner than the
member to be connected, and shall have a thickness of at least 10mm.
j) CONTRACTOR shall note that the minimum thickness of any part of a rolled section for
use as a structural element shall not be less than 6 mm except for cold-formed
sections used for purlins/side girts/side runners shall be minimum 2mm.
k) Welded steel grating for platform covering shall be 30 mm x 6 mm bearing bars at 30
mm on center. Crossbars shall be twisted square 6 mm on each side and spaced not
over 100 mm center to center and shall be hot-dip galvanized in accordance with
ASTM A123 and A143 or BS EN 1SO 1461 for a corrosive environment.
l) E70xx welding electrodes shall be specified for all shop and field welding of structural
steel. All welds shall be continuous.
m) All bracing shall be arranged to minimize torsion and where practicable, be arranged
concentrically about the resultant line of force. The connections wherever possible,
shall be arranged so that their centroid lies on the resultant of the forces they are
intended to resist. When the condition cannot be achieved, the members and
connections shall be designed to resist any local bending due to the eccentricity of the
force.
8.11 Steel structures supporting equipment shall be fireproofed where required by project fire
safety analysis.
8.12 Bracings located within the fireproofing zone shall also be fireproofed similar to other
members as bracings are part of structural stability (except for slotted connection).
Fireproofing loads shall be considered under dead loads in the structural design.
8.13 Lifting/transportation calculations, drawings and Method statement shall be provided if the
structural components/modules are planned to be installed by lifting.
8.14 Guardrail configuration shall conform to the IBC and OSHA requirements as a minimum.
8.15 Workplace walking and working surfaces shall conform to the safety requirements of
ANSI/ASSE A1264.1.
8.16 All fixed ladders shall conform to ANSI A14.3.

9. Site Work and Site Preparation

9.1 All work areas shall be cleared of vegetation, contaminated soil, debris, refuse or deleterious
materials and also debris from demolition work prior to commencing excavation or filling.
9.2 Work areas shall at all times be kept free from surplus materials and rubbish.
9.3 Spoil from site clearance shall be loaded, carted away as directed by the COMPANY to an
approved dumping area. Only the selected soil (topsoil and surface soil) free from roots,
debris and oil contamination shall be stockpiled elsewhere on site for further use in site
landscaping and reinstatement.
9.4 The contractor shall provide and erect slope stakes, profiles, templates, sight rails and the
like and properly set out the proposed work from the baselines, levels, co-ordinates or a
datum given by the COMPANY.
9.5 The contractor shall verify all information and references (benchmarks, levels, coordinates,
North direction) shown on drawings prior to commencement of site works. The contractor
shall be responsible to carry out any survey work of the Site, whenever directed by the
COMPANY and shall get approvals from the COMPANY for all the drawings prepared by him.
9.6 The contractor shall take all necessary precautions and preventive steps as directed by the
COMPANY to protect any existing services, drains, water and gas mains, power and
telephone cables and any other installations, from being endangered from excavations
and/or slips and falls. In case of any damage to such existing services and or any other
installation, it shall be made good by the contractor at no cost to the COMPANY whatsoever.
9.7 The contractor shall demolish all the redundant installations, buildings, structures and below
ground obstructions within relevant work areas in accordance with the drawings and as
directed by the COMPANY.
9.8 The contractor shall load, haul and dispose of all the debris resulting from the site
preparation/demolition work as directed by COMPANY to an approved dump yard. None of
the debris shall be used as filling within the Site.
9.9 Where excavations are taken below the general formation level shown on the drawing, the
over-excavated areas shall be backfilled with suitable fill material in layers not exceeding
200-mm loose depth and mechanically compacted to the required elevation.
9.10 All operations on open cut areas shall be regulated to minimize the overrunning of the areas
with construction plant. Haul roads shall be constructed in these areas as required.

10. Storm Water and Drainage System

10.1 Dependent upon source, type and level of contamination, effluents shall be classified into
various categories. Each category shall be used to define the required drainage network and
treatment facility. The segregation of all effluent streams shall start at the source.
10.2 The following are sources of effluents:
 Rainwater
 Firefighting water
 Wash/flush water
 Desalination Unit blow-down
 Brine drainage
 Neutralized effluents from all neutralization sumps through the plant
 Cooling water blowdown/filter backwash
 Equipment drains
 Sampling points
 Accidental process spillages
 Maintenance operations
 Domestic sewers
 Substation transformer pens/enclosures
 Floor/roof drains
The system shall consist of drains, funnel, underground piping, clean-outs, catch basins,
manholes, sealed manholes and vent pipes. The non-oily water sewer system can be directed
to the following disposals where required: Waste Water Treatment Plant Effluent, if it is
intended to reuse.
10.3 Effluent Classification: Atmospheric non-hazardous drainage effluents are classified as
belonging to one of the following categories:
a) Entirely clean rainwater draining to the Clean Water Sewer (CWS) drain – This is applicable
exclusively to areas where surface rainwater cannot be contaminated by chemicals.
b) Accidentally Contaminated water draining to AC drain – This system collects storm water
or fire water run-off from roads and paved equipment areas divided into catchment areas.
These streams are normally envisaged to meet the water effluent specifications, but could
on occasion be contaminated.
c) Continuously Contaminated drain (CC) – This system collects effluent water with possible
chemical content that exceeds the required effluent water specifications.
d) Domestic sewage draining to the sanitary sewer (SS).
10.4 The Process Closed drains are dedicated buried closed drainage systems, carrying discharge
collected via flanged closed drain hubs to buried collection vessel/s. These are designed as
per respective piping specifications. The collected discharges are pumped via above ground
drain headers to the designated units for processing. Closed drain hubs are flanged (and
generally pressurized) systems which are distinct from atmospheric open drain hubs. These
 are listed here to ensure appropriate space allocation and integration with other
underground services.
10.5 Effluent Routing: Effluents shall be routed by means of separate drainage networks to
selected treatment facilities and/or discharge points. The segregation of the drainage
networks shall be done based on the contamination criteria. The selection of the routing of
drainage networks shall be determined in conjunction with the plant layout requirements.
10.6 Network Components:
The design aim is to achieve improved surface water run-off and provide better segregation
of effluents at source. Following design parameters shall apply:
a) Manholes, Sumps And Catch Basin Details
 Manholes shall be located at suitable spacing intervals to facilitate maintenance,
inspection, and cleaning.
 Manholes or cleanouts shall be provided at changes in horizontal direction.
 Maximum spacing of manholes shall be 200 ft (60 m) for sewers less than or equal to 12
inches (300 mm) in diameter and shall be 500 ft (150 m) for sewers larger than 12 inches
(300 mm) in diameter.
 The bottom of each manhole, sump and catch basin shall be at least 200 mm below the
bottom of the lowest connected pipe.
b) Underground Piping
 Underground piping in drainage service should have a minimum diameter of 100 mm.
 The minimum soil cover above the underground piping shall be 0.60 meter.
 Underground piping shall not be installed underneath spread footings or foundations.
 No pipework shall pass through a foundation. In the event that any existing/new
foundation interferes with new/existing underground pipework, the pipework shall be
re-routed to clear the foundation.
 Where it is unavoidable to re-route pipes to avoid foundations, said pipes shall be
installed within a pipe sleeves.
c) Open Channels
 The size of open drain channels shall be determined by hydraulic calculation for the
actual design condition applicable.
 The cross-sectional profile of open drain channels may be rectangular or hydraulically
shaped.
 Open channels may be constructed in-situ or by utilizing precast sections.
 The minimum width of rectangular channel shall be 300 mm, and the minimum depth
for all channels shall be 150 mm.
 No piping and/or pipe supports shall be installed directly over or across open channels.
 Open channels shall be covered with grating only at those places where
operator/maintenance access is required.
 Open channels located at the toe of an embankment shall be provided with a 'walking
strip'(minimum 350 mm wide) for maintenance access.
d) Culverts
 A minimum culvert diameter of 18 inches (450mm) shall be used.
 Culvert minimum gradients shall be determined using the design flow rate. Culverts shall
be sized so as to prevent headwater depths that will cause flooding within the plant
facilities. In general, a minimum gradient of 0.30 percent shall be provided where
possible. Otherwise, the slope of the upstream or downstream channel should be
matched.
 The culvert at a road intersection should be aligned with the ditch and located as nearly
perpendicular to the road as possible.
 Culvert headwalls shall be used where required for flow and erosion control. Plain or
flared-end culverts may be used with consideration given to traffic and hydraulic design.
10.7 Materials:
 Drainage networks and components should be of leak-proof design. System tightness shall
be controllable and measurable, even after a long period of operation. CONTRACTOR shall
use any of the following material based on design requirement :
a) Concrete Pipes:
 Concrete sewer pipe 10 inches (250 mm) and smaller shall be in accordance with ASTM
C14 (class as specified in the contract documents) non-reinforced, bell and spigot, or
tongue and groove sewer pipe.
 Concrete sewer pipe 12 inches (300 mm) and larger shall be in accordance with ASTM
C76, reinforced sewer pipe (class and wall as specified in the contract documents).
 Joints shall be sealed using elastomeric “O” rings in accordance with ASTM C443 unless
otherwise specified in the contract documents.
 Joints may be sealed with cement grout if the service is for storm sewer lines that are 24
inches (600 mm) in diameter and larger.
b) PVC Pipes:
 PVC pipe 12 inches (300 mm) or less in diameter shall be minimum schedule 40 pipe in
accordance with ASTM D1785.
 Joints shall be solvent cemented in accordance with ASTM D2855, using cement in
accordance with ASTM D2564 or shall have elastomeric ring gaskets in accordance with
ASTM D3212
c) HDPE Pipe:
 HDPE pipe and fittings shall be manufactured from virgin high-density polyethylene
resin, in accordance with ASTM D3350, Cell Class PE345434C minimum, with a standard
dimension ratio (SDR) as specified in the contract documents.
 Joints shall be butt fusion welded, socket fusion welded, or flanged.
 Alternate joining method shall consist of arch-band split sleeve couplings made of
carbon steel conforming to ASTM A36 or stainless steel grade 304L or 316L. The
coupling shall be designed with closure plates and sealing pads for installation and a
leak-proof seal. O-Ring gaskets shall be used and shall consist of ethylene propylene
diene monomer (EPDM), nitrile, silicon, or polyisoprene as required for the service
intended. Couplings shall allow for angular deflection, expansion, and vibration if
required. If a restrained joint is required, it shall be accomplished with restraining rings
welded to the exterior of the pipe and a restraining-type coupling.
 HDPE mechanical coupling joints are also acceptable if approved by the purchaser.
 Piping material for all other drainage network shall be as per Process and Piping
drawings and specifications.
10.8 The following general design parameters shall apply to the design of underground drainage
piping:
a) Pipe connections and materials shall be selected such that the underground pipes and
sewers in plant areas can easily be installed and will not give rise to leakage or collapse
due to e.g. settlement of subsoil, shock loads of aggressive oils/chemicals released
accidentally or during plant shutdown (polluted effluent), cleaning of pipes by rodding.
b) Pipes passing through walls of manholes, sumps, etc., shall be provided with a puddle
flange or hydrophilic sealant as indicated on the standard drawings.
c) In instances where differential settlement or differential expansion between pipe and
sump can be expected, a flexible connection shall be applied.
10.9 Design Parameters for Drainage Network
a) General:
The following minimum requirements shall be applicable to designs in order to achieve
functional drainage networks.
Drainage networks shall be designed to convey without flooding the maximum
flow resulting from the greater of the following load combinations:
i. Rainfall (Qrain) + any other known contributing continuous flow.
 ii. Firewater (Qfire) + any other known contributing continuous flow.
a) Rainfall Peak Flow / Accumulated Flow
Peak flow calculations will determine the design of drainage collection systems.
Rainfall intensity 128mm/hr for 5 years return period. However CONTRACTOR shall
collect more accurate data from local authorities and confirm this value during
basic engineering phase.
Calculations for establishing the run-off values shall be carried out using
established and proven methods. One method most frequently used is the
Rational Method. The information below is from this method. Another acceptable
method would be the Colebrook-White equation.
Qrain = C i A
Where:
Qrain = quantity of rainwater run-off in m3/hr
C = run-off coefficient
i = design rainfall intensity (mm/hr) based on the time of concentration (Tc)
A = catchment area under consideration in m2.

The Rational Method assumptions and design parameters are as follows:

 The maximum run-off resulting from particular rainfall intensity occurs if the
duration of rainfall is equal to or greater than the time of concentration (Tc). The
time of concentration is defined as the time required for water to flow from the
most distant point of the catchment area under consideration to the point of flow
measurement.
 The maximum run-off resulting from a particular rainfall intensity, whose duration
is equal to or greater than the time of concentration, is directly proportional to the
rainfall intensity.
 The frequency of occurrence of the peak discharge is the same as that of the
rainfall intensity from which it was calculated.
 The peak discharge per unit area decreases as the drainage area increases, and the
intensity of rainfall decreases as its duration increases.
 The coefficient of run-off remains constant for all storms on a given watershed.
10.10 Hydraulic Calculations:
a) Hydraulic calculations shall be prepared to achieve an economical and effective
drainage network design. All drainage piping, sewers and open drain channels
shall be designed in accordance with FHWA (Hydraulic Design Series No. 3, 4 & 5
and Hydraulic Engineering Circular No. 22) or in accordance with accepted
standard formulae and calculation methods, including sump influences (losses),
weir overflow losses, and friction coefficients which take into account the
anticipated future condition of the drainage network.
Although there are many 'empirical' formulae which can be used, the formulae
given below should be used in order to simplify and standardize the design
method and presentation.
The design of drainage networks should be based on gravity flow where the
installed depth of the underground pipes relates directly to the weir level at the
main outlet point, e.g. treatment facility. At locations where the available positive
head is insufficient to achieve a gravity flow condition, pumping facilities shall be
provided.
b) Hydraulic Gradients
The hydraulic gradient (I) can be determined by using Chezy's formula:

I = V2 /C2R
Where:
 V = velocity (m/s)
C = Chezy coefficient (m 0.5/s)
R = hydraulic radius, or hydraulic mean depth (m)
I = hydraulic gradient or incline (m/m)
R is the relationship between the amount of liquid being conveyed and the
contact area between this liquid and the inside of the channel.
R = cross-sectional area of flow divided by the wetted perimeter

The Chezy coefficient can be calculated using the simplified Colebrook formula:

C = 18 log10(12R/k)

Where
C = Chezy coefficient (m0.5/s)
R = hydraulic radius (m)
k = Nikuradse wall roughness factor (m)
The value k is independent of the diameter of the drainage pipeline.
10.11 Domestic Sewage, direct to a sewage treatment facility
Sewers and drainage systems shall be designed to protect the atmosphere, soil, surface
water, and groundwater from contamination and to provide safe, economical collection and
flow of all sewage to treatment and/or holding facilities and subsequently to approved
disposal.

11. General Levelling and Grading of Site

11.1 CONTRACTOR shall prepare site grading layout drawings based on the topography survey
drawings, equipment layout and plot plan and submit it to the COMPANY for approval. All
site grading work shall be done as per approved drawings.
11.2 General area grading shall be completed to within a tolerance of +60 mm of the elevations
shown in the drawings.
11.3 Roads, parking areas, and building areas shall be excavated or filled to subgrade elevations
shown in the Contract Documents. Rock encountered through cut sections shall be
excavated to 1 foot (0.3 m) below subgrade elevation and shall be backfilled to the proper
elevation.
11.4 The Contractor shall suspend earthwork operations after consultation with the COMPANY if
unsatisfactory field conditions (caused by rain, inclement weather, or other circumstances)
prevent satisfactory progress toward completion of the project.

12. Roads and Parking areas

12.1 All major plant areas should be accessible by primary roadways from minimum two
opposite sides and preferably all around to provide adequate access for firefighting and
other emergency equipment.
12.2 Plant areas containing process equipment should be accessible for plant maintenance
activities. Roadways to these areas should be designed to permit access for the largest
required maintenance equipment.
12.3 Road Width:
 Table 2: Recommended Road Width

SI Road Classification Recommended Width of the

No. Width Shoulder
(Minimum)

1 Main Facility Access and Primary 7.0 m to 8.0 m 2.5 m

Roads with hard shoulders

2 Secondary Roads with hard shoulders 6.0 m 2.0 m

3 Service Roads with soft shoulders – 2 5.0 m 1.5 m

Lanes

4 Service Roads without shoulders – 1 3.5 m -

Lane

5 Temporary Roads (Earthen Roads) 6.0 m to 7.0 m -

12.4 Concrete curbs, road markings and guardrails shall be utilized in roadway and parking area
design. Curbs shall be placed where shown on drawings along roads, around perimeters of
vehicle parking areas, office buildings, gardens and planted areas. Curbs shall be painted in
colour as per the direction of COMPANY. Raised portions of curbs at road edges and paved
areas shall be interrupted every 10m to allow stormwater to run off.
12.5 Crash barriers shall be installed where considered essential to protect personnel, equipment
or piping. For example, road crossings over and under piperacks or pipetracks, roads close to
piperacks or pipetracks, roads adjacent to steep slopes, T-junctions and sharp bends.
12.6 The preferred crash barrier system consists of galvanized steel supports embedded in
concrete poured in pre-bored holes at 3m spacing to carry a guard-rail. The system shall be
able to absorb impact energy by deformation without collapse.
12.7 Materials for concrete curbs, road markings and guardrail construction shall be in
Accordance AASHTO guidelines
12.8 Roads are generally composed of a sub-base course, a base course and bituminous type
flexible pavement. A sub-base is required if the settlement behavior and/or the bearing
capacity of the subgrade is insufficient to support the paving and traffic without excessive
deformations or maintenance during the lifetime of the plant. Shoulders where provided
shall be able to support, without damage, slow-moving and parked vehicles for which the
road is designed.
12.9 Paving for heavy and light-duty roads shall be designed to the “AASHTO Guide for Design of
Pavement Structures”. CONTRACTOR shall consider the following design factors included in
the AASHTO publication while designing the pavement:
1. High groundwater level
2. Non uniform soil support (settlement/differential settlements sub-grade)
3. Soil support value S (flexible paving)
4. Equivalent single-axle loads
5. Regional factor
12.10 The terminal serviceability index for heavy and light-duty roads shall be 2.5 and 2.0
respectively as defined in the AASHTO publication.
12.11 The sub-base, base and paving shall be adequately supported horizontally either by a
sufficiently paved berm or by concrete curbs.
12.12 The roads listed below shall be of the heavy-duty type:
 a) Main roads on site and all roads in and around processing units.
b) Roads to and around main buildings and loading facilities.
c) Main access roads to the site.
Light-duty roads comprise all other roads on site.
12.13 The boundary between the road and road shoulder shall be clearly marked with lines or
curbs.
12.14 All heavy-duty and light-duty roads shall have either a crown at the centerline of the road or
be properly sloped to provide for positive drainage runoff. The paved areas adjacent to the
roads shall have a smooth transition to the edge of the roads.
12.15 Road Crossings
a) Roads should cross at an angle of 90 degrees.
b) For crossings of roads of unequal width, the narrower road shall determine the radius
of the curvature.
c) All circular edges of a heavy-duty road crossing shall be in one horizontal plane.
12.16 Interface Site Preparation: The design of the sub-grade shall be based on the results of the
geotechnical survey, including calculations and determination of the grain-size
distribution/silt content, plasticity index, friction properties and permeability. Average, high
and the highest possible groundwater level as well as the in-situ permeability shall also be
considered.
Acceptance of the sub-grade, sub-base and base before surfacing, shall be based on the
design requirements and resulting criteria. Examples of suitable tests, as far as compaction is
concerned, are CBR*, plate beating test, static cone penetration test (SCPT**) or in-situ
density tests in accordance with ASTM, BS or equivalent standards.
(* California Bearing Ratio, ** Static Cone Penetration Test)
Interpretation of test results shall take into consideration the maximum moisture content of
the sub-grade, sub-base and base material that is considered representative for the
operating situation.
12.17 Bridges, culverts and pipe crossings under the road shall be designed for AASHTO HS.20
loading as a minimum.
12.18 Horizontal and Vertical Clearances
At roads without raised curbs, a horizontal clearance of 1.0m shall be maintained between
the edge of the shoulder and any structure projecting above grade adjacent to the shoulder.
The minimum horizontal clearance for guard rails and traffic signs shall be 0.5m.
At roads with raised curbs, the minimum horizontal clearance shall be 0.6m from the face of
the curb.
Vertical clearances shall be from the crown or high point of the roads. Minimum clear vertical
distance for all overhead structures, platforms, piping supports and equipment should be
maintained over the plant paving surface as recommended below.

Table 3: Vertical Clearances

S.I. Description Minimum

No. Clearance

1 Over Plant roads for heavy cranes 6.5 m

2 Over Plant access-ways for major mobile equipment 5.0 m

3 Over Plant general paved areas accessible to mobile 4.0 m

equipment
 4 Over pumps and turbines from high point of paving 2.5 m

5 Over walkways, passageways and platforms 2.1 m

12.19 Road Gradients: The following grade limitations shall apply:

Table 4: Road Gradients

Sl.No. Designated Areas Gradients (Maximum) Gradients

(Minimum)

1 Main Facility Access and 1 in 30 (3%) 1 in 100 (1%)

Primary Roads

2 Secondary Roads 1 in 20 (5%) 1 in 100 (1%)

3 Service Roads 1 in 20 (5%) 1 in 50 (2%)

4 Ramps 1 in 15 (6.5%) 1 in 25 (4%)

5 Parking Areas 1 in 20 (5%) 1 in 100 (1%)

6 Cross-fall on each way for all - 1 in 50 (2%)

roads

7 Cross-fall on shoulders 1 in 30 (3%) 1 in 50 (2%)

12.20 Roadway Crown:

Where applicable, the crown or high point elevation of the roads adjacent to, or encircling a
building, shall be at least 150mm lower than ground floor slab of the building. Drainage shall
flow away from buildings.
12.21 Road Drainage:
The drainage of roads comprises surface runoff and sub-surface drainage systems.
a) Surface Drainage: Road surfaces shall have a minimum cross slope of 1:50 to provide
proper drainage under all weather conditions. Ditches and collectors along the roads
shall form an integral part of the surface drainage system of the site. Open ditches and
channels, where required along roads in plant areas, shall be concrete-lined. The need
for lining of ditches and channels along other roads depends on the probability of
spillages and erosion sensitivity of the soil.
b) Road Crossings At Drainage Systems: If roads block natural drainage, the natural
drainage shall be restored by means of culverts, ditches or rerouting watercourses.
12.22 Traffic Signs, Traffic Markings And Striping: Traffic signs, traffic markings and striping, where
required, shall be in accordance with local laws and COMPANY instruction.
12.23 Paved Area Scope
a) This section describes the minimum requirements for paved areas, e.g.:
 Process areas
 Material laydown yards
 Cleaning yards
 Parking areas
 Parts of on-plot pipe racks or pipe tracks which contain flanged connections,
valves or sampling points (i.e., possible leakage points).
b) Paving is generally limited to those parts of a site where spillage of chemicals or
hydrocarbons from operations and maintenance cannot be excluded, or where loads
other than personnel on foot shall be accommodated.
c) Paving consists of a reinforced concrete layer on a sub-grade. A sub-base between the
sub-grade and paving may be required depending on the acceptance of the sub-
grade. CONTRACTOR shall develop typical cross sections of standard light and heavy-
duty and submit it to the COMPANY for approval. The paved areas shall be divided
into slabs separated by expansion joints. Prevention of chemical spillage or
hydrocarbons into the subsoil through the joints is required in process areas.
d) In areas where light-duty paving is sufficient without the probability of a spill, tiles or
bricks may be acceptable.
e) Paving shall be classified as follows:
 Light-duty paving
 Heavy-duty paving
f) Site Preparation Interface
The subgrade shall be prepared prior to the construction of the sub-base and the
paving. If required, the prepared sub-grade shall be tested to verify whether the
compaction satisfies the requirements. Suitable tests are plate-bearing test, in-situ
density tests, shallow DCPT’s, CBR, etc., in accordance with ASTM, or equivalent
standards.
g) Measures shall be taken to prevent intrusion of sub-grade material into the sub-base
or base layers of the pavement structure.
h) Calculation Method
Paving slabs shall be designed in accordance with the AASHTO Guide for Design of
Pavement Structures and with accepted rational methods, e.g. modified Westergaard’s
formulae. The minimum axle loads are as follows:
1. Light-duty paving shall be designed for smaller trucks with wheel loads of 50kN.
2. Heavy-duty paving shall be designed for minimum AASHTO HS.20 loading.
In specific areas identified for heavy lifts, such as cranes, paving shall be designed for
the expected loading.
i) A modulus of sub-grade reaction is used to represent soil supporting concrete paving
slabs. To determine or to verify the modulus, the standard plate bearing test, with a
762mm diameter plate, shall be used. For other diameters or methods, the results shall
be corrected to obtain a value comparable to the standard method.
j) In addition to the sub-grade reaction, the consequences of short and long-term
settlements and differential settlements shall also be considered.
k) Locations of contraction/expansion joints shall be selected similarly to, and together
with, slab reinforcement to prevent uncontrolled cracking as a result of shrinkage,
thermal expansion /contraction, natural changes in moisture content and other
conditions (acceptable tensile strain = .015). Following standards shall be used for
further details-
i. ACI 325.12R - Guide for Design of Jointed Concrete Pavements for Streets and
Local Roads
ii. ACI 350-06 - Code Requirements for Environmental Engineering Concrete
Structures and ACI 504R - Guide to Sealing Joints in Concrete Structures
l) Special paving may be required to support higher loads or to satisfy additional
requirements. The design principles shall be the same as described above.
m) Expansion and Contraction Joints Expansion joints shall be provided between two
adjacent slabs where required by design. Generally, dowels are required and the joint
shall have sufficient width to accommodate local temperature differentials.
n) The joint shall be filled with an elastic joint filler and sealed with a chemical-resistant
sealant.
 o) Contraction joints shall be spaced not more than 7m apart. Maximum slab size shall be
20m x 20m.
p) Paving shall have a minimum slope of 1:100.

12.24 Erosion Protection Of Slopes, Embankments, Ditches, Open Drains, Etc.

The CONTRACTOR shall investigate the availability erosion protection methods and
products. Examples of erosion protection layers are:
i. Concrete slabs
ii. Flexible asphaltic, bituminous products, e.g. sand bitumen mix
iii. Impermeable polyethylene (or equivalent), anchored with tiles, brickwork, rock,
etc.
iv. Layer of crushed rock, gravel, tiles or brickwork in combination with filter cloth
if required.
v. Concrete Tiles
a) Slopes for bund walls, cuts, embankments, open drains and ditches shall be protected
against erosion and subsequent damage and failure as a consequence of wind, water,
and spillages.
b) In case of the accidental contamination of drainage systems, the cover layer of open
drains and ditches shall protect the subsoil against pollution from chemical products.
12.25 Machinery to be Used
The machinery and tools to carry out earthworks for excavation, loading, transportation,
backfilling and compaction of sub-grade shall be in good working condition for the whole
duration of the works. The technical information and catalogs of the machinery and tools
shall be submitted to the COMPANY for approval prior to start of works. If necessary, the
COMPANY will test the machine's performance on sample basis prior to actual use in works.

13. Fence and Gates

13.1 CONTRACTOR shall furnish all equipment, tools, materials, labor, and supervision and shall
perform all operations necessary for installation of fences and gates, where indicated by
contract documents.
13.2 Submittals
a) Before start of field installation, shop drawings of gates, bracing, and typical fence
details shall be submitted to COMPANY for approval.
b) Before start of installation, material data for fabrics, posts, rails, tension wire, and rods
showing compliance with this Practice shall be submitted to COMPANY.
13.3 Galvanized Chain Link Steel Fence -If galvanized fence is specified in contract documents,
materials shall be uniform and consistent and shall be in accordance with the following
requirements:
a) Fabric- Fabric shall consist of galvanized chain link material, in accordance with ASTM
A392, Class 2, 2-inch (50-mm) mesh 9-gage (0.148 inches [3.76 mm] in diameter) steel
wire, with top and bottom selvedges twisted and barbed.
b) Line Posts- Line post size for chain link fence framework shall be in accordance with
ASTM F1043 for Heavy Industrial Fence.
1. For fabric less than or equal to 8 feet (2.4 m) high, line posts shall be NPS 2 (DN
50) Standard Weight (Schedule 40) galvanized steel pipe (OD = 2.375 inches [60.3
mm]) in accordance with ASTM F1083 unless otherwise specified in contract
documents.
2. For fabric greater than 8 feet (2.4 m) and up to 12 feet (3.6 m) high, line posts shall
be NPS 2.5 (DN 65) Standard Weight (Schedule 40) galvanized steel pipe (OD =
2.875 inches [73.0 mm]), in accordance with ASTM F1083 unless otherwise
specified in contract documents.
13.4 Corner, Pull, and Terminal Posts: Corner, pull, and terminal posts shall be NPS (DN) Standard
Weight (Schedule 40) galvanized steel pipe in accordance with ASTM F1083 at least one size
larger than line posts.
13.5 Rails –Rails shall satisfy following requirements
a) Top, brace, bottom, and intermediate rails shall be NPS 1.25 (DN 32) Standard Weight
(Schedule 40) galvanized steel pipe (OD = 1.66 inches [42.2 mm]) in accordance with
ASTM F1083.
b) Brace rails shall be provided with galvanized steel truss rods and truss tighteners.
c) Rail sleeves or couplings shall be in accordance with ASTM F626.
13.6 Tension Wire: Tension wire shall be 7-gage (0.177 inch [4.50 mm] in diameter) steel wire,
Type II (galvanized), Class 5 coating, in accordance with ASTM A824.
13.7 Fittings: All chain link fence fittings shall be in accordance with ASTM F626.
13.8 Barbed Wire: Barbed wire shall consist of double 12.5-gauge (0.099 inches [2.51mm] in
diameter) twisted steel wire with 14-gauge (0.080 inches [2.03 mm] in diameter), 4-point
round steel barbs spaced on 5-inch (127- mm) centers, Coating Type Z, Coating Class 3, in
accordance with ASTM A121. Top 1 foot (300 mm) of the fence shall consist of three strands
of barbed wire attached to Type I, pressed steel, galvanized barbed wire arms in accordance
with ASTM F626.
13.9 Barbed Tape: When specified in contract documents, barbed tape materials shall be in
accordance with ASTM F1910.
13.10 Gates Material
a) Gate materials such as fabric, bolts, nuts, tension bars, barbed wire, brace rail, truss
rods, and tighteners shall be the same as fence materials and coating.
b) Gates shall be manually or electrically operated as specified in contract documents.
c) Swing gates and posts shall be in accordance with ASTM F900. Frames shall be NPS 1.5
(DN 40) Standard Weight (Schedule 40) pipe (OD = 1.9 inches [48.3 mm]) welded
construction.
d) Slide gates shall be in accordance with ASTM F1184.
e) Automated vehicular gates shall be in accordance with ASTM F2200.
13.11 Gate Installation
a) Fencing and gate installation shall be in accordance with ASTM F567 unless exception
is approved by the COMPANY.
b) Gates shall be braced and trussed to prevent sagging, buckling, and warping.
13.12 Grounding: Unless otherwise noted in contract documents, grounding of the fence, fence
posts, and gates shall be in accordance with project electrical specifications and shall be
performed by a qualified electrical sub-contractor.

14. Seawater Intake/Outfall Facility and Pumping Station

INPUT BY HO

15. Pipe Racks

15.1 Pipe racks are structures that support pipes and auxiliary equipment within and between
process areas of industrial plants. Piping loads can vary greatly from project to project as can
the loads from wind and earthquake. This guideline, however, sets forth minimum
requirements, which the CONTRACTOR should incorporate into pipe rack designs if possible.
15.2 This guideline applies to the following three basic types of steel pipe racks:
a) Strutted main pipe racks
 b) Unstrutted secondary or miscellaneous pipe racks
c) "T" supports

*Loads listed in section 15.8 and load combinations in section 15.9 are applicable to
buildings and plant structure also.
15.3 Structural steel design shall be in accordance with the referenced AISC specifications and
codes. The plastic design method in the AISC manual shall not be used in steel design. Steel
for pipe rack design shall conform to ASTM A992/A992M.
15.4 Pipe racks and their foundations shall be designed to support loads associated with full
utilization of the available rack space, and any specified future expansion.
15.5 Foundation concrete shall be designed in accordance with ACI 318.
15.6 The deflection requirements for pipe rack beams and transverse bents shall be as follows:
a) The maximum allowable beam deflection Dmax due to total load shall be as follows:
Dmax = L/240 where L = the Span Length
b) The maximum allowable drift limits for pipe rack shall not exceed H/100 (where H =
pipe rack height )
c) The maximum allowable seismic drift limits for pipe rack shall be in accordance with
ASCE- 7. Pipe racks shall be considered as building. The maximum allowable drift limits
for pipe rack shall not exceed H/100 (where H = pipe rack height).
15.7 Connections for steel pipe racks shall conform to the following requirements:
a) Shop connections may be either bolted or welded. Field connections shall be bolted
where possible. Connections may be field welded when conditions are such that a
bolted connection is not suitable.
b) Bolted connections for primary members shall utilize high-strength bolts conforming
to ASTM A-325-N, bearing-type connections with threads included in the shear plane.
However, slip-critical-type connections shall be used in connection subject to vibration
or repeated stress reversal.
c) Standard connections shall be designed by the fabricator in accordance with the
project construction specifications and loads shown on the drawings. Moment
connections and special connections, however, shall be designed by the CONTRACTOR
and shall be shown on the engineering drawings.
d) Moment connections shall preferably be of the bolted end plate type.

15.8 Loading on Building, Plant Structures and Piperacks

Primary Loads: The following primary loads shall be considered in the design of
superstructures and foundations:
 Dead Load (D)
 Live loads
 Dead Load due to piping (De, Do and Dt)
 Cable Tray Loads
 Thermal Loads (T, Tp, Af and Ff)
 Wind Load (W, Wp)
 Earthquake Loads (Eo, and Ee)
 Equipment loads
 Other Loads (O)
The above primary loads are defined as follows:
a) Dead Load (D) : Dead load shall include the self-weight of the structure, weight of all
process equipment, pipes, valves and accessories, electrical and lighting conduits,
trays, switchgear, instrumentation, fireproofing, insulation, structural steel plates and
shapes, etc. Foundation concrete weight along with any soil overburden shall also be
considered as dead load. Piping loads shall be considered as dead loads for load
combination purpose. Pipe Racks shall be designed for present and future dead loads.
 Unless stipulated otherwise by the COMPANY, piping and electrical loads shall be
estimated as follows, unless actual load information is available and warrant otherwise:
b) Live loads: Live loads shall be estimated as per ASCE 7 considering functional use of
the building/ structures. For pipe-racks with operating/access platform shall be
designed for adequate live loads.
c) Dead Load Due to Piping
i. Operating dead load (Do): A uniformly distributed load of 1.9 kPa (40 psf.) for
piping, product, and insulation.
ii. Empty dead load (De): For checking uplift and components controlled by
minimum loading, 60% of the estimated piping operating loads shall be used if
combined with wind or earthquake unless the actual conditions require a different
percentage.
iii. For any pipe larger than 12-inch (304-mm) nominal diameter, a concentrated load,
including the weight of piping, product, valves, fittings, and insulation shall be
used in lieu of the 1.9 kPa (40 psf). This load shall be uniformly distributed over the
pipe's associated area.
iv. Test Load Dt: The test load shall be defined as the gravity load imposed by the
liquid (normally water) used to pressure test the piping. Large vapor lines may
require hydro testing. If so, it may be possible to test them one at a time while the
other lines on the support are empty and thus avoid the heavy pipe support
loading. When such procedures are used, special notes should be placed on the
structural and piping drawings to specify test procedures. Small vapor lines are
normally considered filled with water.
v. Structural steel self-weight Ds shall be included in the deal load condition and
added to the appropriate load combinations.
vi. For checking uplift and components controlled by minimum loading, a reduced
level of cable tray load (i.e., the actual configuration) should be considered as the
empty dead load. Engineering judgment shall be exercised in defining the dead
load for uplift conditions.
vii. Structure and their foundations shall be designed to support loads associated with
full utilization of the available rack space and any specified future expansion.
d) Cable Tray Loads
Dead loads for cable trays shall be estimated as follows, unless actual load information
is available and requires otherwise:
i. Operating dead load (Do): A uniformly distributed dead load of 1.0 kPa (20 psf )for
a single level of cable trays and 1.9 kPa (40 psf ) for a double level of cable trays.
(These values estimate the full (maximum) level of cables in the trays.)
e) Thermal Loads: Thermal loads shall be defined as forces caused by changes in the
temperature of piping. For pipe rack design, both friction forces (Ff) and anchor forces
(Af) shall be considered. Pipe supports must be designed to resist longitudinal loads
arising from pipe thermal expansion and contraction. On the average pipeway, the
lines expand and contract varying amounts at random times. These loads are applied
to the transverse beams either through friction or through pipe anchors. Thermal loads
shall be considered as dead load and included in the appropriate load combinations.
Thermal loads are designated by the following nomenclature:
Ff = Friction Forces
Af = Anchor Forces
T = Temperature Force
i. Friction Forces (Ff) : Friction forces caused by hotlines sliding across a pipe support
during start-up and shut-down are assumed to be partially resisted by adjacent
cold lines. Friction loads (Ff) caused by thermal expansion shall be determined
using the appropriate static coefficient of friction.
 All support structures and elements thereof shall be designed to accommodate
the loads or effects produced by thermal expansion and contraction of piping.
For pipe racks supporting multiple pipes, 10% of the total piping weight shall be
taken as an estimated horizontal friction load (Ff) applied only to local supporting
beams. However, an estimated friction load equal to 5% of the total piping weight
shall be accumulated and carried into pipe rack struts, columns, braced anchor
frames, and foundations. Estimated pipe friction loads shall be considered
temporary and shall not be combined with wind or seismic loads for the design of
pipe rack struts, columns, braced anchor frames, and foundations, when there are
multiple frames. During high wind or earthquake, the vibration and deflection of
the supports under load will likely relieve the friction forces.
ii. Anchor Forces (Af): Anchor forces may dictate the use of horizontal channels or
horizontal bracing as well vertical bracing at anchor bents. This should not occur
too frequently since Piping Engineering like to anchor large lines on only a few
bents in a pipeway. Anchor and guide forces and locations shall be obtained from
the piping stress analysis and piping isometric drawings.
Pipe anchor and guide forces (Af) produced from thermal expansion, internal
pressure, and surge shall be considered as dead loads. Pipe racks beams, struts,
columns, braced anchor frames, and foundations shall be designed to resist actual
pipe anchor and guide loads. For local beam design consider only the top flange
as acting in horizontal bending unless the pipe anchor engages both flanges of
the beam. Anchor and pipe forces shall be obtained from the checked pipe stress
analysis computer run.
Anchor and guide loads (excluding their friction component) shall be combined
with wind or seismic loads.
iii. Temperature Force (T): Thermal forces caused by structure expansion and
contraction should be considered in the design with the structural steel checked
for temperature change. Range of temperature change shall be as local practice.
Thermal loads (T) and displacements shall be calculated on the basis of the design
temperature. Design temperature shall be defined as the difference between the
highest and lowest one day mean temperature plus the metal temperature on
structural steel to account for the significant increase in temperatures of steel
exposed to sunlight.
f) Wind Loads (WL): Wind loads on all pipe, equipment, structural members, cable trays,
platforms, ladders, and other attachments to the pipe rack (or process structure) shall
be considered in the design. Wind pressures, wind pressure distribution, and pressure
coefficients shall be computed and applied in accordance with ASCE 7.

Wind load calculations shall be based on basic wind speed V of 3-second gust speed
at 33 ft (10 m) above the ground and associated with an annual probability 0.02 of
being equaled or exceeded (50-year mean recurrence interval). The basic wind speed V
for this site shall be 39 m/s at 10m height. However CONTRACTOR shall refer latest
local building code and confirm this value during basic engineering phase.

Exposure Category C shall be used, except for structures close to the shoreline, as
defined in ASCE 7, where Exposure Category D shall be used.
Partial Wind Load (Wp) shall be taken as 0.75 x W for test or erection condition.
The total wind load per foot on pipes, F, can be determined using the following
equation:
F = qz G Cf Ae (ASCE 7 )
where:
qz = Velocity pressure at height z above ground
 G = Gust effect factor per ASCE 7
Cf = Net force coefficient
Ae = Projected area normal to wind
qz = 0.613 Kz Kzt KdV2 I (N/m2) ASCE 7, Eq.26.10.1.si
where:
Kz is the velocity pressure exposure coefficient per ASCE 7.
Kzt is the topographic factor per ASCE 7. Kzt is equal to 1.0 for Pipe Racks
and Open Frame Structures located in this facilities.
Kd is the wind directionality factor per ASCE 7. When used with load
combinations specified in ASCE 7, Kd is equal to 0.85 for Pipe Racks and
Open Frame Structures.
V is basic wind speed of 3-second gust speed at 10m (33 ft) above the
ground.
I is the Importance Factor set forth in ASCE 7. I equal 1.15 for Category IV
structures. All Pipe Racks and Open Frame Structures in this facilities are
considered Category IV structures.
For major pipe racks, the design lateral wind load on pipes at each pipe deck shall not
be less than the wind load computed for 12-inch (300 mm) pipes at 15-inch (381 mm)
centers.
Longitudinal wind load on pipe racks is negligible compared to other longitudinal
forces and, therefore, can normally be disregarded.
For detailed wind load calculations on pipe racks and process structures, refer ASCE
publication, ‘Wind loads for Petrochemical and other facilities’
g) Earthquake Load (E)
Earthquake loads shall be computed and applied in accordance with ASCE 7and
Indonesian codes. ASCE's Guidelines for Seismic Evaluation and Design of
Petrochemical Facilities may also be used as a general reference for seismic design.
Project location comes under Zone 4 as per SNI 03-1726-2002. Contractor shall
consider SNI 03-1726-2012 provisions.
Effective peak acceleration, effective peak velocity and site soil coefficient shall be
determined in accordance with local Indonesian Codes and Standards.
Earthquake loading shall be determined using ASCE 7, Chapter 11, 12 and 13 as
appropriate.
h) Equipment Load
If pipe rack (or structure) supports equipment, appropriate loading scenarios like
 Equipment Empty
 Equipment operating
 Equipment Hydro-test
 Equipment Maintenance
 Any special load case arises due to functional requirement
Loading data supplied by equipment vendor shall be used for the design.
i) Other Load (O) Pipe Racks may be subjected to loads not covered by the four
categories described above. CONTRACTOR shall evaluate such cases and consider it in
the design of pipe rack.

15.9 Load Combinations

a. CONTRACTOR shall develop credible load combinations that could produce the
maximum stress or govern for stability should be considered in the calculations. These
load combinations shall be considered in superstructure and foundation design of
pipe racks.
b. Wind forces and earthquake forces shall not be considered to act simultaneously.
 c. The CONTRACTOR should use his judgment in selecting potential critical
combinations. Load conditions that have primarily a localized effect generally do not
need to be included in the main analysis as these loads may be considered during
individual structural component design.
d. The use of a one-third stress increase for load combinations including wind or
earthquake loads shall not be allowed for designs using the AISC ASD.

15.10 Allowable Stresses and Strength Requirements

a. Structural Steel
The allowable stresses and stress increases specified in the AISC manual shall be used
for all pipe rack steel design.
For allowable stress design, a 20% allowable stress increase shall be permitted for any
hydro test load combination.
For ultimate strength/limit states design, no load factor reduction shall be permitted
for any hydro test load combination.

b. Anchor Bolts
Unless the anchors are to be used in a special corrosive environment or are subjected
to extreme low or high temperatures or other special conditions, the following
specifications should be used:
i. ASTM A307 grade-A bolts, ASTM A36/A36M rods or ASTM F1554 Grade
36 rods for low strength requirements (fy = 250 MPa, futa=400MPa)
ii. ASTM F1554 Grade 55 rods for moderate strength requirements. Grade 55
rods should be ordered with the weldability supplement. (fy = 380 MPa,
futa=517MPa)
iii. ASTM F1554 Grade 105 rods for high-strength requirements. (fy = 724
MPa, futa=862MPa)
iv. All materials meet ACI 318 Appendix D ductility requirements unless
otherwise noted.
v. Corrosion-resistant materials used in the production of anchors include
the following:
a. Hot-dip galvanized carbon steel
b. Austenitic (chromium-nickel) stainless steels (Type 304, 316)
c. High-molybdenum stainless steel alloys
d. Titanium
Corrosion protection may also take the form of a protective coating
system or other methods to prevent contact of the anchor with the
atmosphere.
vi. Shear force should preferably be transferred to the concrete by frictional
resistance, but if the factored shear loads exceed the frictional resistance,
another method must be provided to transfer the shear from the base
plate to the foundation.
vii. This can be accomplished by either of the following methods:
a. Use a shear lug
b. Use a mechanism to rigidly connect the base plate to the
anchors (such as by field welding bearing washers in place)
15.11 Pipe Rack Superstructure Design
a. The principal structural components of a pipe rack are the transverse bent beams, the
bent columns, longitudinal struts, and vertical bracing. Design criteria applicable to
each of these components are presented below.
 b. In general, the pipe support framing system is designed as rigid frame bents with fixed
or pinned bases in the transverse direction and as braced frames in the longitudinal
direction.
c. A determined effort should be made early on the project to establish the correct
number of transverse beam levels required for piping and electrical support, and the
number of longitudinal beams required to support pipes entering or leaving the pipe-
way. Additional longitudinal and/or intermediate transverse beam may be required to
support electrical conduit, instrumentation lines, or other small lines. Electrical conduit
and cable trays usually must be supported every 10 feet unless vendor drawings
indicate larger spans.
d. Structural components of the pipe rack must be capable of resisting the axial loads,
shears, moments, and torsion produced by the load combinations given in section15.9
of this document.
e. An elastic analysis shall be used to determine moments and forces in pipe rack
members.
f. Structural Steel Expansion
For pipe rack design, provisions shall be made for thermal expansion of steel, with the
structural steel checked for temperature change. Slotted connections (sliding
connection) shall be provided in each segment of the pipe rack between vertical
bracing to allow for structural steel thermal expansion. The maximum segment for the
pipe rack shall be limited to 48 meters in length unless calculations show otherwise.
Details and requirements for the slotted connection shall be provided on the
engineering drawings.
g. Generally, the depth of horizontal members should not be less than 1/24 of the span.
h. If top flange lateral loads are significant, the transverse beam shall be investigated for
bending about the y-y axis and for torsion. This can be estimated by using My x 2 / Sy.
i. In axial load design, the total span of the beam should be used, modified by the
appropriate effective length factor for each direction. This factor should be equal to 1.0
for the weak direction of the beam.
j. Special consideration shall be given to the design of transverse beams which support
large lines to be hydro tested or which support large anchor or guide forces.
Horizontal bracing may be required locally if the local bending stresses are too high.
k. Columns shall normally be designed with pinned or fixed bases depending on the
lateral drift requirements.
l. Column base plates for major and miscellaneous pipe racks and "T" supports that are
to be attached to concrete foundations shall be four-bolt base plates.
m. Vertical bracing may be used to transmit transverse and longitudinal forces to the
foundations. K-bracing or X-bracing is usually used for this purpose.
15.12 Foundations shall be designed in accordance with the final approved project soil report
recommendations Cast-in-Place Concrete: Strength design methods of ACI 318 shall be
used.

16. Buildings
16.1 Contractor shall design and construct all process plant buildings and non-plant buildings in
compliance with ASCE7, ACI 318, AISC 360, AISC 341. For determining seismic parameters,
local Indonesian codes shall be referred.
16.2 Buildings shall be modeled and design in commercial 3D structural analysis and design
software approved by the COMPANY.
16.3 Buildings shall comply with ductility requirements AISC 341, ASCE-7 and Local Indonesian
codes.
16.4 Buildings and other structures, and all parts thereof, shall be designed and constructed with
adequate strength and stiffness to provide structural stability, protect non-structural
components and systems from unacceptable damage, and meet the serviceability
requirements.
16.5 Analysis shall employ rational methods based on accepted principles of engineering
mechanics and shall consider all significant strength, damping, and other properties of
components and connections incorporated in the analysis shall be based on approved test
data or referenced Standards.
16.6 The procedures and results of analysis, testing, and calculation used to demonstrate
compliance with the requirements of this section shall be subject to an independent peer
review approved by the COMPANY for local authority approval having jurisdiction. The peer
review shall comprise one or more persons having the necessary expertise and knowledge to
evaluate compliance, including knowledge of the expected performance, the structural and
component behavior, the particular loads considered, structural analysis of the type
performed, the materials of construction, and laboratory testing of elements and
components to determine structural resistance and performance characteristics. The review
shall include the assumptions, criteria, procedures, calculations, analytical models, test setup,
test data, final drawings, and reports. CONTRACTOR shall prepare all documentation
required for such a review and coordinate with such independent reviewer to get statutory
approvals from the local authority.
16.7 Structural systems, and members thereof, shall be designed to have adequate stiffness to
limit deflections, lateral drift, vibration, or any other deformations that adversely affect the
intended use and performance of buildings and other structures.
16.8 Load effects on individual structural members shall be determined by methods of structural
analysis that take into account equilibrium, general stability, geometric compatibility, and
both short- and long-term material properties. Members that tend to accumulate residual
deformations under repeated service loads shall have included in their analysis the added
eccentricities expected to occur during their service life.
16.9 Building shall be designed for resisting to extraordinary loads and events that may occur due
to process / operational requirements. Where required by the COMPANY or applicable code,
strength and stability shall be checked to ensure that structures are capable of withstanding
the effects of extraordinary (i.e., low-probability) events, such as fires, explosions, and
vehicular impact without disproportionate collapse.
16.10 The building structure shall include complete lateral and vertical force-resisting systems
capable of providing adequate strength, stiffness, and energy dissipation capacity to
withstand the design ground motions within the prescribed limits of deformation and
strength demand. The adequacy of the structural systems shall be demonstrated through the
construction of a mathematical model and evaluation of this model for the effects of design
ground motions. The design seismic forces, and their distribution over the height of the
building structure, shall be established in accordance with one of the applicable procedures
indicated applicable codes. and the corresponding internal forces and deformations in the
members of the structure shall be determined. An approved alternative procedure shall not
be used to establish the seismic forces and their distribution unless the corresponding
internal forces and deformations in the members are determined using a model consistent
with the procedure adopted.
16.11 Various provisions listed in section 7, 8 and 15 shall also apply as appropriate.