Vol. III (C)

TECHNICAL SPECIFICATION COVER SHEET REVISED SHEETS
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SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. TABLE OF CONTENT
CAIRO - EGYPT 000010 - 2874 0
ECG Form No. E409 Rev. 5/03 Sheet 0 of 5

URBANIUM NEW ADMINISTRATIVE BUILDING
CONTENTS
VOLUME I
GENERAL REQUIREMENTS
VOLUME II
METHOD OF MEASUREMENT, BILL OF QUANTITIES & LIST OF MANUFACTURERS
DIVISION 0: INFORMATION
000010 Table of Contents
DIVISION 1: GENERAL REQUIREMENTS
012700 Method of Measurement

012750 Bill of Quantities
012950 List of Manufacturers
VOLUME III
TECHNICAL SPECIFICATIONS – PART A
Divisions 03 Concrete
033000 Cast In Place Concrete

033316 Lightweight concrete
034800 Precast Concrete Parking Bumpers
035440 Cement-Based Screeds
Divisions 04 Masonry
042000 Unit Masonry

044200 Exterior Stone Cladding
Divisions 05 Metals
051200 Structural Steel

055000 Metal Fabrications
055213 Pipe And Tube Railings
057300 Decorative Metal Railings
Divisions 06 Wood, Plastics, and Composites
064200 Wood Paneling
Table of Contents Section 000010

Urbanium New Administrative Building (Prj. 2874) Page 1 of 5
Division 07 Thermal and Moisture Protection
071113 Bituminous Damp-Proofing

071340 Polyethylene Sheet
071416 Cold Fluid-Applied Waterproofing
071613 Polymer Modified Cement Waterproofing
071616 Crystalline Waterproofing
071800 Traffic Coatings
074213 Metal Panels
075213 Atactic-Polypropylene (APP) Modified Bituminous Membrane Roofing
075216 Styrene-Butadiene-Styrene (SBS) Modified Bituminous Membrane
075323 Ethylene-Propylene-Diene-Monomer (EPDM) Roofing
078413 Penetration Firestopping
079200 Joint Sealants
Divisions 08 Openings
081113 Hollow Metal Doors and Frames

081416 Flush Wood Doors
083113 Access Doors and Frames
084113 Aluminum-Framed Entrances and Storefronts
084423 Structural-Sealant-Glazed Curtain Walls
085113 Aluminum Windows
087100 Door Hardware
088000 Glazing
088300 Mirrored Glass
089000 Louvers and Vents
Divisions 09 Finishes
092400 Cement Plaster

092900 Gypsum Board Assemblies
093000 Tiling
095423 Linear Metal Ceilings
095427 Suspended Wood Ceilings
096340 Stone Flooring
096516 Resilient Sheet Flooring
096536 Static Control Resilient Floor Coverings
096600 Precast Terrazzo
096723 Resinous Flooring
096900 Access Flooring
097500 Stone Facing
099100 Painting
Division 10 Specialties
101405 Signage
101453 Traffic Signage
102113 Toilet Compartments
102600 Wall And Door Protection
102800 Toilet and Bath Accessories

104413 Fire Cabinets
104416 Fire Extinguishers
107113.43 Fixed Sun Screen
Divisions 11 Equipment
111500 Parking Control Equipments
Division 13 Special Construction
131200 Fabric Shades

131500 Reinforced Concrete Water Structures
Division 14 Conveying Equipment
142100 Electric Traction Elevators

149100 Facility Chutes
VOLUME III
TECHNICAL SPECIFICATIONS – PART B
Division 21 Fire Suppression
210548 Vibration And Seismic Controls For Fire-Suppression Piping And Equipment
211000 Water-Based Fire-Suppression Systems
211339 Foam-Water Systems
212100 Carbon Dioxide Fire Extinguishing Systems
212200 Clean-Agent Fire Extinguishing Systems
213113 Electrical-Drive, Centrifugal Fire Pumps
213400 Pressure-Maintenance Pumps
Division 22 Plumbing
220513 Common Motor Requirements for Plumbing Equipment

220523 General-Duty Valves for Plumbing Piping
220529 Hangers And Supports for Plumbing Piping and Equipment
220553 Identification for Plumbing Piping and Equipment
220719 Plumbing Piping Insulation
221116 Domestic Water Piping
221119 Domestic Water Piping Specialtie
221123.13 Domestic-Water Packaged Booster Pumps
221316 Sanitary Waste And Vent Piping
221319 Sanitary Waste Piping Specialties
221429 Sump Pumps
223300 Electric Domestic Water Heaters
224000 Plumbing Fixtures
Division 23 Heating Ventilating and Air Conditioning
230500 Common Work Results for Hvac

230513 Common Motor Requirements for Hvac Equipment
230516 Expansion Fittings And Loops for Hvac Piping
230519 Meters And Gages for Hvac Piping
230523 General-Duty Valves for Hvac Piping
230529 Hangers And Supports for Hvac Piping And Equipment
230548 Vibration And Seismic Controls for Hvac Piping And Equipment
230553 Identification For Hvac Piping and Equipment
230593 Testing, Adjusting, And Balancing for Hvac
230700 Hvac Insulation
230800 Commissioning Of Hvac
230900 Instrumentation And Control For Hvac
232113 Hydronic Piping
232123 Hydronic Pumps
232300 Refrigerant Piping
232500 Hvac Water Treatment
233113 Metal Ducts
233300 Air Duct Accessories
233423 HVAC Power Ventilators
233713 Diffusers, Registers, and Grilles
236426 Rotary-Screw Water Chillers
237313 Modular Indoor Central-Station Air-Handling Units
238123 Computer-Room Air-Conditioners
238126 Split-System Air-Conditioners
238129 Variable Refrigerant Air-Conditioners Units
238219 Fan Coil Units
Division 25 Building Management System
250000 Integrated Automation Systems
VOLUME III
TECHNICAL SPECIFICATIONS – PART C
Division 26 Electrical
260500 Conmen Work Result For Electrical Work

260513 Medium-Voltage Cables
260519 Low-Voltage Electrical Power Conductors And Cables
260526 Grounding and Bonding for Electrical Systems
260533 Raceway And Boxes for Electrical Systems
260536 Cable Trays for Electrical Systems
260553 Identification for Electrical Systems
261202 Medium-Voltage Dry Type Transformer
261301 Ring Main Unit
262413 Switchboards
262416 Panelboards
262419 Motor Control Centers

262500 Enclosed Bus Assemblies
262726 Wiring Devices
263213 Engine Generators
263353 Static Uninterruptible Power Supply
263533 Power Factor Correction Equipment
263600 Transfer Switches
264113 Lightning Protection for Structures
265100 Interior Lighting
265600 Exterior Lighting
Division 27 Communications
271000 Structured Cabling System

272000 Data Network Active Equipment
274133 Master Antenna Television System MATV
275116 Public Address System
Division 28 Electronic Safety and Security
281300 Access Control System

281303 Parking Management System
282300 Video Surveillance System
283100 Fire-Alarm System
283101 Disabled Persons Emergency Alarm System
283600 Liquids Leak Detection System
Division 31 Earthwork
312000 Earth Moving
Division 32 Exterior Improvements
321123 Aggregate Base Courses

321400 Unit Paving
321613 Concrete Curbs and Gutter
321723 Pavement Markings
Division 33 Utilities
331000 Water Supply And Firefighting Networks

333000 Sewage Collection Networks
Division 41 Material Processing And Handling Equipment
412215.10 Overhead Electrical Cranes

EACH TIME THE SPECIFICATION IS CHANGED ONLY THE NEW OR ENTIRE SPECIFICATION RE-ISSUED
REVISED PAGES ARE ISSUED. ENTIRE SPECIFICATION REVISED

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SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. CONMEN WORK RESULT FOR
CAIRO – EGYPT ELECTRICAL WORK 260500 - 2874 0

CONTENTS
SECTION 260500
CONMEN WORK RESULT FOR ELECTRICAL WORK
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 4
1.4 Quality Assurance 7
1.5 Coordination 10
1.6 Delivery, Storage And Handling 10
1.7 Project Conditions 11
1.8 Warranty 12
PART 2 PRODUCTS 12
2.1 Manufacturers 12
2.2 Materials 12
2.3 Performance And Design Requirements 13
2.4 Accessories 14
2.5 Fabrication 14
2.6 Selection Of Equipment Supplier 14
PART 3 EXECUTION 14
3.1 Workmanship 14
3.2 Acceptable Installers 15
3.3 Preparation 15
3.4 Installation 15
3.5 Construction 17
3.6 Field Quality Control 17
3.7 Protection 17
Conmen Work Result For Electrical Work Section 260500

Urbanium New Administrative Building (Prj. 2874) Sheet 1 of 17
SECTION 260500 – CONMEN WORK RESULT FOR ELECTRICAL WORK
PART 1 GENERAL
1.1 RELATED DOCUMENTS
A Drawings and General Provisions of the Contract including General Conditions,

Conditions of Particular Application and other Sections of Division-1, apply to work of
this Section
1.2 SUMMARY
A This section covers the furnishing of labor, materials and equipment under other
sections of this Contract; installation of all equipment, as may be furnished by the
Owner; and furnishing and installation of all additional equipment and materials
needed for the electrical requirements of this Contract.
B The scope of work includes, but is not limited to the following:
1. Switchboard and Panelboards

2. Interior Power and Lighting Systems
3. Exterior Lighting
4. Grounding and Bonding
5. All other Electrical and Auxiliary Works
6. Transformers and Distribution Equipment
7. Emergency and Security Lighting System
8. UPS, Engine Generators, Automatic Transfer Switch and Fuel Tanks
9. All interconnecting wiring and cabling including cable glands, boxes, conduits,
cable trays, ladders, termination kits, etc., underground cable ducts and
manholes, trenches, supports, steel poles, foundations and associated
miscellaneous civil engineering works
10. All necessary instruments for testing of switchgear, control gear and auxiliaries
for equipment, foundation bolts, fixings, locks, etc., any replacement fuses or
devices required, used during the Commissioning Period
11. Spares and Special Tools for Maintenance
12. The supply of Drawings, Operating and Maintenance Manuals and other
Documentation in accordance with this Specification
13. Erection, Testing and Commissioning of all relevant equipment
C Work shall include furnishing all labor, materials, tools, equipment and services to
construct and install, test and commission the complete electrical system as
indicated on the drawings, specified herein and subject to the requirements of the
Conditions of Contract.
D For any deviations from the contract drawings pertaining to the ratings of electrical
equipment, due to the use of codes and standards of the country in which the
equipment is manufactured, it shall be the responsibility of the Contractor to verify

the precise requirements and to provide and/or adjust to their correct settings or
sizes, cables, circuit breakers, starters, overload heaters, relays, instrument
transformers, etc., this shall be at no added extra cost to the Owner.
E Contract Provision: The Contractor will be required to make provision for the
following and his prices shall be deemed to include for any cost arising there from:
1. Electrical utility and authority’s up-to-date requirements, recommendations

and supervision fees.
2. Transportation of labor and materials to and from the Site of Works
3. Suitable accommodation for the storage of plant and materials
4. All lifting tackle and gear required for the necessary execution of the works
5. Workshop facilities for the drilling of brackets, lighting, welding and light
fabrication
6. Supply and installation of any component of work whether or not shown on
the drawings and/or described in the Specifications and/or Bill of Quantities,
but which can reasonably be inferred as necessary for proper completion of
the Work or for its approval and energization from the electrical utilities and
authorities.
F The General and Special Provisions shall apply to all works under this Section.
G Training of Technical Personnel: A rate shall be included in the Schedule of Prices to

provide for the training of selected members of the Owner’s Technical Staff in the
event of this option being taken up.
H Alternatives: Redesign of section or part of electrical or mechanical work, which is

required due to the Contractor's use of an alternate item, arrangement of equipment
and/or layout other than specified herein; shall be done only by the Contractor at his
own expense, if approved by the Engineer. Redesign and detailed drawings shall be
subject to acceptance and approval of the Engineer. No additional compensation will
be provided for changes in the work, either his own or others, caused by such
redesign.
I Alternate proposal shall only be permitted if equal to or better and only if with
considerable savings to the Owner than what is specified herein and when deemed
by the Owner as of absolute necessity. Contractor may proceed only upon
concurrence by the Engineer and upon approval of all redesign details, which may
have direct or indirect impact on other disciplines. No additional cost will be
provided for changes in the work.
J Redesign or altered drawings, reviewed by the Engineer, shall not relieve the
Contractor of any or all of his contractual obligations and responsibilities with the
Owner for proper and complete installation and operation of all materials and
equipment, including related accessories as required or detailed on the Contract.
K Although substitution in general is forbidden, proposed alternatives may be

submitted for approval. The Contractor shall provide sufficient data to allow
evaluation of proposed alternative and determination of compliance with Contract

documents. The Contractor shall list any proposed deviation from these Contract
documents.
1.3 SUBMITTALS
A Tendering Submittals: Contractor to fill-in the ECG compliance data sheet (when
attached to a section) and stamp it by the proposed supplier and by the proposed
electrical sub-contractor (or himself if no Sub-contractor).
B If the Contractor is assuming two suppliers for one material item in his bid, two data
sheets should then be filled and stamped, as mentioned, for the same item.
C Shop Drawings: Unless otherwise permitted by the Engineer all shop drawings shall
be prepared on A0 at least scale 1:50 sheet and drawn to a suitable metric scale for
plans and layout. Shop drawings shall be submitted for installations and layout of but
not limited to the following:
1. Cables installation and routing

2. Conduit and trunking installation and routing
3. Receptacles (socket outlets) and light switches installation
4. Boxes and fitting installation
5. Lamps and luminaires installation and layout
6. Disconnect switches and circuit breakers installation
7. Motor starters and control equipment installation details and control diagrams
8. Grounding (earthing) materials installation
9. Panelboards installation
10. Auxiliary and fire alarm systems equipment installation including control
diagrams
11. All other detail drawings as shall be required by the Engineer
12. Schematic for main and sub-main distribution
D The working drawings shall be complete submittals including the manufacturer’s

drawings and shall show the exact site conditions with specific dimensions, locations
and arrangement of the equipment itself, dimensions of mounting bases and pads
working clearances from neighboring equipment, external connections including the
location, number and size of cables and conduits connected to the equipment and
the schematic and wiring diagrams showing interconnections of all local and remote
devices, including interfaces with related systems in the new and existing buildings.
E Submission of the manufacturer’s working drawings and data shall include:
1. Equipment wiring diagrams, schematic diagrams and certified dimension

sheets for the 380V switchboards and 22 kV switchgear/substation, motor
control centers, control panels, safety switches, circuit breakers, transfer
switches, power transformers, engine generator sets, uninterruptible power
supply, Fire Alarm System, Telephone System, and panelboards with specific
descriptions of the standard electrical equipment used.
2. Time-current characteristic curves for all circuit breakers and fuses.

3. Complete working drawings showing the exact location and number of all the
surface or recessed mounted lighting fixtures, after the Contractor has done
the coordination with the type of the suspended ceiling actually installed and
the location of equipment and devices installed under other sections of this
Specification.
F Working Drawings and Data: The Contractor shall submit for approval number of
specified in general condition copies of prints of working drawing and detail drawings
of the entire installation.
G The working drawings shall be submitted early enough to get the approval as
specified in general conditions prior to any construction and not before getting the
approval of the Engineer for the equipment shown on the working drawings. This
should be coordinated to conform to the general program and schedules of work for
all trades.
H Materials/Manufacturer’s Data: On submittal sheet, the Contractor shall indicate the

general classification of materials, e.g. Raceways and Fittings; Luminaires;
Panelboards; etc. Moreover, the Contractor shall attach a product compliance sheet
indicating the specifications provisions, the product specifications and the deviation,
if any.
I “Submittals for each manufactured item shall be current manufacturer’s descriptive

literature of catalogued products, equipment drawings, diagrams, performance and
characteristic curves, and catalogue cuts.”
J Publication Compliance: Where equipment or materials are specified to conform to

industry and technical society publications of organizations such as ANSI, or IEC
Standards, submit proof of such compliance. The label or listing by the specified
organization will be acceptable evidence of compliance. In each of the publications
referred to herein, consider the advisory provisions to be mandatory, as though the
word “shall” had been submitted for “should” wherever it appears. Interpret
references in these publications to the “authority having jurisdiction”, or words of
similar meaning, to mean the Engineer. In lieu of the label or listing, submit a
certificate from an approved independent testing organization, adequately equipped
and complete to perform such services, stating that the item has been tested in
accordance with the specified organization’s test methods and that the item
conforms to the specified organization’s publication.
K Certified Test Reports: Electrical equipment and materials shall be approved by an

adequately equipped, recognized, and independent testing laboratory of the country
where the equipment has been manufactured, indicating that the equipment is in
conformance to the code requirements of that country.
L Certificates of Compliance: Submit Manufacturer’s Certifications as required on

products, materials, finish, and equipment indicated in the technical sections.
Certifications shall be documents prepared specifically for this contract. Preprinted
certifications and copies of previously submitted documents will not be acceptable.
The manufacturer’s certifications shall name the appropriate products, equipment,
or materials and the publication specified as controlling the quality of that item.

M Samples: As specified elsewhere samples of the materials such as individual circuit
breakers, luminaires, cables, conduit, receptacles and switches, etc. shall be
submitted.
N No orders for equipment or materials shall be placed by the Contractor, before

obtaining the written approval of the Engineer. Only approved materials shall be
employed at site and any materials installed without prior approval shall be removed
and reinstated by approved ones at the expense of the Contractor.
O Samples of conduit, fittings, wires, cables, switches, lighting fixtures, track lights,
receptacles, telephone, outlets and instruments, speakers, pushbuttons, and any
other small items used in the job shall be submitted by the Contractor as specified
hereinabove, labeled and to be kept in a locked room under the control of the
Engineer. Samples shall not be used in the installation.
P Manuals: Complete operations and maintenance data for all equipment furnished
under Division 26, Electrical, shall be submitted in accordance with the requirements
set forth at the Conditions of Contract. The manuals shall be prepared specifically for
this installation and shall include all required catalog cuts, drawings, equipment lists,
descriptions, complete parts lists address of vendors of relevant equipment etc., that
are required to instruct operating and maintenance personnel unfamiliar with such
equipment.
Q Operation and Maintenance Manual: Submit at least four (4) copies of manuals as
required for systems and equipment indicated in the technical sections and shall be
in the English language. Furnish three copies, bound in hardback binders or an
approved equivalent. Furnish one complete manual prior to performance of systems
or equivalent tests, and furnish the remaining manuals prior to contract completion.
Inscribe the following identification on the cover the words: “OPERATION AND
MAINTENANCE MANUAL”, name and location of the system, equipment, building,
name of Contractor, and contract number. Include in the manual the names,
addresses, and telephone numbers of each sub-contractor installing the system or
equipment and the local representatives for the system or equipment.
R Include a table of contents and assemble the manual to conform to the table of
contents, with tab sheets placed before instructions covering the subject. The
instructions shall be legible and easily read, with large sheets of drawings folded in.
The manual shall include:
1. Internal and interconnecting wiring and control diagrams with data to explain
detailed operation and control of the system or equipment
2. A control sequence describing start-up, operation and shutdown
3. Description of the function of each principal item of equipment
4. Installation and maintenance instructions
5. Safety precautions.
6. Diagrams and illustrations.
7. Testing methods.
8. Performance data.

S Parts list: The list shall indicate sources of supply, recommended spare parts and
name of servicing organizations.
T Appendix: List of qualified permanent servicing organizations for support of the

equipment, including addresses and certified qualifications.
U Closeout Submittals and Record Drawings: As required under the Condition of

Contract, the Contractor shall keep an accurate record of the installation as work is
carried out, including length, size, number, location and depth of all conduits, pipe
ducts, and cables installed therein, and connections to all machines, plant
equipment, and terminal boxes, including all internal connections. Cooperate with
the suppliers of control centers, and annunciators to enable them to provide
accurate records of the internal connections and functions of the equipment
installed. Record drawings shall include, but not be limited to the following:
1. All amendments, additions, etc., to the location of outlets, equipment, and

sizes and routes of conduits and cables including lengths.
2. Amended drawings of all detailed circuit diagrams and cabling diagrams,
indicating conductor sizes, conduit numbers, all terminal numbers, and
sequence of operations.
3. New drawings of any extensively modified detail in the original Contract
drawings, and of further details provided or obtained during construction.
4. Schedules for all panelboards relating circuit breaker numbers to circuit
function and rating.
5. Schedules for all terminal boxes and terminal strips relating terminal numbers
to incoming and outgoing wires and general function (power or control).
1.4 QUALITY ASSURANCE
A Reference Standards
B International Standards: The design, Manufacture, installation practices and testing

of the materials, plant equipment and systems are to be supplied, constructed and
rated in accordance with the standards or approved International Standard of design
or manufacture unless otherwise specified. In all cases, the latest issue of
Publications, Specifications, Standards and/or Codes of Practice shall apply.
C Approved Standards include:
1. The Regulations for the Electrical Equipment of Buildings (IEE)

2. International Electro-Technical Commission (IEC)
3. International Organization for Standardization (ISO)
4. Commission Internationale de l'Eclairage (CIE)
D BS (UK) CENELEC (EUR), VDE (Germany), and NEC (USA) shall be considered with
regards to all matters that are not covered by IEC recommendations and ISO
documents.

E National Local Codes: The Work shall also consider local Codes, Regulations and
Standards such as:
1. Egyptian Building Codes and Regulations.

2. Requirements of the Egyptian Electricity Authority (EEA)
3. Egyptian Standard Specifications (ES)
F Hazardous Area Classification: The classification hazardous areas and suitable

electrical equipment, materials and methods for this purpose is based on
recommendations and standards from the International Electro-technical
Commission, IEC, CENELEC (Comité European de Normalization Electro-technique)
and VDE (Verband Deutschen Elektrotechniker).
G The use of IEC recommendations and accepted European practice and philosophy is
governed by the fact that all major production and process equipment shall be
manufactured in Europe.
H The equipment for each classified area shall be certified for the applicable zone or
better.
I The equipment used in the classified areas shall be approved, or otherwise

determined to be safe for use, by a recognized testing laboratory such as one of the
following:
1. PTB Germany
2. BASEFA England
J Equipment and machinery shall be furnished with approval certificates and be

marked as specified by IEC 79-VDE and CENELEC standards.
K Safety and Health Regulations: The requirements of the Egypt Industrial Safety and
Health Regulations and subsequent amendments are considered part of these
Contract Documents and shall be enforced during the installation and operations of
the Works. All applicable Local and/or International Standards shall be deemed as
minimum requirements under the Industrial Safety and Health Regulations. Where
higher standards are required, they shall be complied with.
L The Contractor shall be responsible for ensuring that all items of electrical systems
comply with the requirements of these Governing Standards; that the manufacturers
comply with all the necessary instructions and that these instructions are included in
the operating and maintenance instructions when submitted.
M The Contractor shall be responsible for providing all electrical equipment with the
necessary, warnings signs and instructions. These shall cover maintenance, working,
operating and access or egress. All electrical equipment rooms shall have a notice
permanently secured to all doors stating "No Admittance to Unauthorized
Personnel". Where the noise level is in excess of 80 dBA, there shall be installed a
warning notice on all doors in accordance with the Governing Standards for reducing
the exposure of noise to operating personnel.

N All notices shall be permanently engraved with the text in both Arabic and English.
O Factory Tests and Inspection: The Owner reserves the right to witness factory testing
and inspection of any equipment furnished under these Division 26, Electrical
specifications. The Contractor shall furnish the Engineer with any sketches, test
setups, and instrumentation and shall notify the Engineer at least 20 days in advance
of the time each shop test will be made.
P Inspection of the Works: The Engineer shall perform inspections of the work as he
requires from time to time, and shall witness the tests performed by the Contractor
as specified in Quality Control paragraphs of this section. Any work not acceptable to
the Engineer shall be removed and redone at the Contractor's expense.
Q Coordination Study: For the Medium-voltage and/or low voltage switchgear

manufacturer, the Manufacturer shall conduct a complete coordination study of
relays, circuit breakers, and all other protective devices. The coordination study shall
include the entire distribution system starting with the smallest 380/220 volt, 3-
phase and/or single phase, 50 Hz circuit’s protective device on the load end, to the
nearest protective device on the substation line side.
R The study shall include, but not be limited to, the following:
1. A tabulation of circuit breaker trip settings

2. Motor starting profiles for all motors sized 40 kilowatt and above
3. Transformer damage curves and protection evaluated in accordance with IEC,
ANSI/IEEE C57.109 (if applicable)
S The coordination study shall be bound in a standard paper size report. The study
shall be provided in accordance with the requirements set forth at the Conditions of
Contract. Final selection of all protective device settings or sizes shall be subject to
review and acceptance by the Engineer.
T Standardization: All materials and equipment supplied under this section of the
works shall wherever possible be standardized and of metric uniform design to
facilitate maintenance and operation and to limit storage of spare parts and tools.
All materials of the same kind of service shall be identical and made by the same
manufacturer.
U All components of the same size and rating used in the works shall wherever
practicable be interchangeable with one another. All circuit breakers, fuses,
contactors, relays, etc., shall be of the same make and design unless particular
location and duty make such standardization impracticable.
V Derating: All ratings given in the Contract Documents are standard ratings.
W For components and accessories for which no specific ratings or sizes are indicated,
the Contractor shall select rating and sizes that will be suitable for the site conditions.
Twenty percent (20%) shall be minimum derating factor for such items.

X The cable and wire sizes indicated on the drawings are the design sizes required for
the site conditions and for the ratings of the specified equipment. Therefore, for the
actual equipment, the sizes of cables need further selections. For wires or cables
where no specific sizes are indicated, the sizes shall be determined by suitably
derating the current ratings of those wires and cables as per the rating factors
indicated in the latest regulations of the country of origin.
Y Spare Capacity: Spare capacity shall be provided to allow for future expansion and
future loads. Where required in the contract drawings, there shall be spares for
conduits, spare space for installing future equipment, and spare circuits at
panelboards and switchgears. If during the field-testing prior to handing over the
Works, the required spare capacity is not available, the Contractor shall replace or
add to any component or equipment to the system at no cost to the Owner.
1.5 COORDINATION
A The drawings indicate the extent and general location and arrangement of electrical
equipment, conduit and wiring, poles, manholes, trenches, etc. All works shall be
carefully laid out in advance, coordinating electrical features with architectural,
structural and mechanical features of construction. Any conflicts which occur
necessitating departures from the drawings shall be submitted in the form of details
of departures and reasons therefore as soon as practicable for written approval.
B Where any of the electrical work may interfere with the work of other trades, assist
in working out space conditions to make a satisfactory adjustment. If requested by
the Engineer, the Contractor shall prepare, scaled working drawings and sections,
which clearly show how the work is to be installed in relation to the work of other
trades.
C Supervision: The Contractor shall provide competent supervision on the site at all
times to layout, check, coordinate and supervise the installation of all electrical work.
Where required, vendor’s representative for the equipment to also supervise the
work at site where deemed required by the Engineer. The Contractor shall plan the
installation of all electrical work, giving consideration to the work of other trades.
1.6 DELIVERY, STORAGE AND HANDLING
A Delivery: The equipment furnished under this section shall be prepared for
shipment, delivered, stored, and handled.
B Deliver electrical materials and equipment in original cartons or containers with seals
intact as applicable. Unless otherwise specified, deliver conductors in sealed cartons
or on sealed reels, ends of reeled conductor’s factory sealed. Deliver large multi-
component assemblies in sections that facilitate field handling and installation.
C Handling: All exothermal welding materials and molds shall be stored and protected
against absorption of moisture. Welding charges, which show signs of moisture
absorption during storage or during installation, shall be discarded and replaced.

Before making the first weld of the day or after a delay between welds, it is expected
that a charge may be fired in the empty mold to condition the mold.
D All grounding, insulating and electrolyte materials shall be protected from degrading
by any cause and from loss by any cause.
E Handle materials and equipment in accordance with best industry practices and
manufacturer's recommendations. Lift large or heavy items only at the points
designed by the manufacturer. Use padded slings and hooks for lifting as necessary
to prevent damage.
F The contractor shall inform the Engineer by the receiving of equipment to inspect
before installation.
G Store materials and equipment on the ground and under cover. Prevent corrosion,
contamination or deterioration. Unless the equipment item is specifically designed
for outdoor exposure in a non-operating mode, all items shall be stored in a
protected area.
1.7 PROJECT CONDITIONS
A Environmental Requirements: All equipment and materials shall be suitable for use
in an ambient temperature range from 5°C to 40C. Equipment and materials shall be
sized so that their ratings will not be exceeded nor their functional use degraded in
any way under these ambient conditions. Motor starters and other thermally-
sensitive equipment that is installed outdoors where exposed to sunlight shall be
provided with a sun screen or other provisions to avoid false tripping or damage due
to solar energy. Moreover, equipment shall be protected against corrosion, and
blowing sand and dirt.
B All services installed below grade on corrosive soil due to presence of moisture, salts,
acids and other substances that would cause corrosion, shall be protected with
acceptable treatment or encasement. Materials such as grounding cables, mats and
plates where meant to have electrical contact with earth shall be made of materials
resistant to corrosion while maintaining good electrical conductivity. Other means
such as grounding pits with provision for replaceable ground rods will be considered
where deemed necessary.
C All electrical equipment shall be rated for an ambient temperature of 45°C outside
and 40°C inside the building. The ground temperature at 75cm depth varies from
15°C in winter to 35°C in summer. It is the responsibility of the Contractor to take
into account the effects of any severe and arduous conditions in the design and
utilization of all electrical equipment.
D Underground Service: Underground service conductors shall be continuous from the

service entrance equipment to the indoor/outdoor power system connection at the
transformer substations and/or low voltage switchgear up to the main
switchboard/panelboard of the building. The underground portion of the conduit

shall be encased in a concrete envelope having a wall thickness of not less than 76
mm.
E Where a conduit enters through a concrete floor, the curved portion shall not be
visible above the finished floor and the entire conduit below the floor slab shall be
encased in a concrete envelope having a wall thickness of not less than 76 mm. Ends
of the underground conduit shall be protected by suitable caps until connections are
made.
F Electric Utility Service: The service feeders shall be at 22kV-380/220 volts, 3-phase,
4-wire, 50 Hertz unless otherwise specified.
1.8 WARRANTY
A All materials and equipment shall be warranted against workmanship defect or

failure for a period of time from date of acceptance as stipulated in the Conditions of
Contract.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A Subject to compliance with requirements, manufacturers offering products that may

be incorporated into the Work include, but are not limited to, the ones mentioned on
the attached list of manufacturers Section 01295.
2.2 MATERIALS
A The materials used in all systems shall be new, unused and as herein specified. All
materials where not specified shall be of the very best of their respective kinds in
accordance with the industry standard to which they are made.
B Standard Products: Materials and equipment to be provided by the manufacturers

shall be essentially the standard catalogued products of a manufacturer regularly
engaged in the manufacture of such products. Materials and equipment shall meet
the applicable requirements of the specification and shall essentially be in
satisfactory use for at least 3 years.
C Standard catalog items and IEC sizes, ratings, capacities, and voltages shall be given
preference.
D Prohibited Materials: Aluminum conduits, fittings, supports and conductors are not
acceptable unless specially approved for each use, or location, and Manufacturer
Standards.

E Equipment Enclosures: All equipment shall be properly de-rated for ambient heat,
altitude and similar climatic conditions, which shall affect the operation and
performance
F Outdoor electrical equipment enclosures (panels, luminaires, etc.) shall be corrosion

resistant, rainproof and dustproof, indoor electrical equipment enclosures shall be
dustproof, unless otherwise specified or indicated on related documents or drawings.
Minimum index of protection (IP) for outdoor wet areas shall be IP54 and for indoor
Surface mounted IP31 .
G Equipment located in damp or wet locations shall meet exterior requirements. Refer
to environment conditions (Item 1.7 above).
H Factory Finishes: Unless otherwise specified in a specific technical provisions section,

the sheet metal surfaces of electrical equipment enclosures shall be electro-statically
painted for interior and exterior metal surfaces. The color shall be medium light gray
or as per manufacturer’s standard. Hardware shall have a corrosion-resistant finish.
I Ratings: The required output ratings of all electric equipment shall be referred to a
continuous duty at a coolant temperature of 40C, Class F, for insulation and Class B
for temperature rise unless particularly specified elsewhere.
J Nameplates: Shall be as per manufacturer’s standard, and of durable quality.
K Common Requirements for Packaged Equipment: Where two or more units of the
same class of material or equipment are required, the Contractor shall provide
products of a single manufacturer.
L Deviations: The requirements laid down in this specification, drawings or requisition

orders, have to be strictly followed. Any deviation, arising during tendering, and
manufacturing of the relevant equipment for any reasons, must be submitted for
approval and confirmed in writing by the Engineer.
M Deviations in quality or quantity that are not listed or inspected shall in no way
relieve the Contractor from responsibility.
2.3 PERFORMANCE AND DESIGN REQUIREMENTS
A Suitability to Environment: Contractor shall be responsible to evaluate and assess all

ambient conditions where electrical equipment, devices and fixtures shall be
installed. Contractor is not relieved of the responsibility to replace any material with
prior approval if found unsuitable for the environment where it is to be installed.
B Design Criteria: The criteria for this project shall be taken as:
1. Ambient Air Temperature, C 40°

2. Ambient Ground Temperature, C 35 max
3. Relative Humidity, Range 10-70%
4. Altitude, meters (Not Exceed) 1000 m

C Electrical services shall enter the facility at 22kV-380/220 volts, three-phase, four-
wire, 50 Hz, unless otherwise specified or indicated on the drawings.
D The main grounding (earthing) arrangement is a TN-S System.
2.4 ACCESSORIES
A Nameplates: Shall be as manufacturer’s standard.
B Danger Signs: Provide danger signs on all electrical panelboards, switchboard, main
distribution panelboard, and other live energized equipment.
C All nameplates, signs and other notices shall conform to the requirements of IEEE, or
IEC Standards and shall be engraved (of durable quality) in both Arabic and English.
2.5 FABRICATION
A Surface Preparation: Remove all casting projections, weld flux or splatter, by hand
scraping, hand impact tools, etc., follow by wire brushing or power grinding. Sharp
corners or sheared edges shall be dulled and radiused with power grinder to improve
paint adherence.
B Exposed grooved surfaces shall be finished smooth by filling and thoroughly cleaned
as required to provide a smooth uniform surface for painting.
C Shop Painting: Unless otherwise specified, all iron and steel surfaces, except copper
and stainless steel shall be shop primed with a vinyl primer and then given two or
more shop coats of vinyl base light gray enamel finish. The shop coating, including
primer, shall have a dry film thickness of at least 0.155 mm.
2.6 SELECTION OF EQUIPMENT SUPPLIER
A The supplier of each equipment shall have a local representative or in the area
nearby. It shall be easy to get spare parts for all the equipment. The Owner’s
representative reserves the right to specify make and type to be supplied.
PART 3 EXECUTION
3.1 WORKMANSHIP
A All materials and equipment shall be installed in accordance with the

recommendations of each manufacturer as approved by the Engineer to conform to
the contract documents. The installation shall be done by workmen skilled in this
type of work. All electrical works shall be installed in a neat, workmanlike manner.
Exposed conduits shall be installed straight, plumb and level, parallel to or
perpendicular to beams and walls; where vertical shall be installed plumb.

3.2 ACCEPTABLE INSTALLERS
A Regulations for Electrical Installations: The Contractor shall plan methods of wiring
and installation of components into the Works in compliance with all regulations,
requirements and recommendations of the Governing Standards, and shall comply
with all local codes and ordinances. The Contractor shall be responsible for the full
compliance with the requirements of the applicable Standards and IEC 60364
"Electrical Installations in Buildings", throughout the installation of the Works
including any temporary works required.
B An installation or part thereof complying with the herein specified standards is one in
which:
1. Is suitable for its intended purpose

2. Has a supply adequate for its maximum possible demand
3. Comprises equipment suitable for the environment to which it will be
subjected
4. Comprises equipment correctly selected as regards to compatibility and
maintainability
5. Embodies protective measures for safety which remain effective over its
intended life
6. Has been constructed or installed so as to facilitate an efficient and safe
operation
7. Has been installed using good workmanship and proper materials
8. Is constructed so that periodic inspection, testing, maintenance and repairs
can be readily and safely carried out
9. Has been inspected, tested and certified as complying with the appropriate
standards and regulations
C The Contractor shall ensure that his employees are familiar with requirements of the
herein specified Governing Standards and the requirements of the "Industrial Safety
and Health" Regulations.
3.3 PREPARATION
A Before installing any materials, the Contractor shall make certain that there are
accepted shop drawings available in his files for the material being installed. All
electrical equipment furnished in this and other sections of the specification shall be
connected according to the schematic diagrams indicated on the drawings or on the
accepted drawings furnished by the Manufacturer of the equipment.
3.4 INSTALLATION
A Setting of Equipment: All equipment shall be installed level and plumb. Sheet metal
junction boxes, equipment enclosures, sheet metal raceways, etc., mounted on
water-bearing or earth-bearing walls, shall be separated from the wall by corrosion-
resistant spacers not less than 6mm.

B Sealing of Equipment: All distribution panelboards, power panels, disconnect
switches, lighting control panel and similar equipment shall be permanently sealed at
the base, and all openings into equipment shall be screened or sealed as required to
prevent the entrance of rodents and insects the size of wasps and mud daubers.
Sealing material at the base shall be non-shrink grout as specified in the Grout
section. Small cracks and openings shall be sealed from inside with silicone sealant,
specified in Section 07920, Joint Sealant.
C Repair of Existing Works: The work shall be carefully laid out in advance and where
cutting, channeling, chasing, or drilling of floors, walls, partitions, ceilings or other
surfaces necessary for the proper installation of supports or/and anchorage for
electrical works. This work shall be carefully done and any damage to building, piping
or equipment shall be repaired by skilled personnel of the trade involved, at the
satisfaction of and at no additional cost to the Owner.
D Thermal Expansion: Conduits and raceways crossing expansion joints or areas subject
to difference in temperatures shall be provided with approved factory-made fittings
to compensate for mechanical stress on raceways.
E Use of Different Materials: All metallic frames, structures and raceways used for
electrical installations shall be made of the same materials. Where deemed as of
absolute necessity, only approved compatible transition joints shall be used while
maintaining the cross-section of the Conduit System.
F Ducts: All ducts and conduit system shall be of the same materials. Where deemed
of absolute necessity, only approved compatible transition joints shall be used while
maintaining the cross-section of the Conduit System.
G Wiring: Install wiring for control systems, power feeder and branch circuits, lighting
branch circuits, communication and auxiliary systems such as fire alarm and security,
in separate raceways unless otherwise indicated. Install power system wiring for
“Emergency”, “Life Safety”, ”Critical”, systems in separate raceways.
H Wet, Damp, or Dry Location Work: Provide products as appropriate for wet, damp,
or dry location as defined by IEC.
I Manufacturer Installation Instructions: Install equipment in accordance with the

manufacturer‘s Installation instructions and recommendations.
J Fire and Smoke Barrier Penetrations: Install fire stopping to raceways, boxes and
electrical equipment installed in or penetrating fire – rated or smoked barrier
assemblies, in a manner which maintains the fire resistance rating or barrier intent.
K Field Painting: In a manner satisfactory to the Owner, touch-up or refinish factory –

applied paints or finishes which are chipped, defaced, scratched, or in any other way
disturbed due to handling, installation or general construction work.

3.5 CONSTRUCTION
A Sleeves and Forms: The Contractor shall provide and place all sleeves for conduits
penetrating floors, walls, partitions, etc. Locate all necessary slots for electrical work
and form before concrete is poured.
B Where exact locations are required by equipment for stubbing-up and terminating
conduit concealed in floor slabs, the Contractor shall request shop drawings,
equipment location drawings, foundation drawings, and any other data required by
him to locate the concealed conduit before the floor slab is poured.
C Where such data is not available in time to avoid delay in scheduled floor slab pours,
the Engineer may elect to allow the installation of such conduit to be exposed. No
additional compensation for such change will be allowed.
D All openings, sleeves, penetration, and slots shall be sealed as specified herein.
3.6 FIELD QUALITY CONTROL
A Field Service: All roughing in works for embedded items shall be subject to
inspection to the Engineer and cleared prior to concrete pouring, closing of
shuttering or closure of walls, ceiling and floors where electrical service shall be
concealed or embedded. The Engineer has the authority to stop any electrical work
found to be non-compliant with the project specification.
B Field Tests: In conjunction with the coordination study, the Contractor shall test and
calibrate all protective devices in accordance with the manufacturer's specification
prior to making the proper device setting before the initial energization of the
conductors and equipment. Field setting of adjustable protective devices shall be
indicated on electrical drawings that show the proper wiring of the protective devices
and the rating and wiring on non adjustable devices.
C The Contractor shall provide all test equipment and personnel and submit written
copies of all test results. As an exception to requirements that may be stated
elsewhere in the contract, the Engineer shall be given 15 working days notice prior to
each test.
3.7 PROTECTION
A Care of Equipment: During construction, all electrical equipment and cable insulation
shall be protected against absorption of moisture, and metallic components shall be
protected against corrosion by strip heaters, lamps, or other suitable means. This
protection shall be provided immediately upon receipt of the equipment and
maintained continuous until the equipment is put into operation.
END OF SECTION 260500

THIS PAGE IS A RECORD OF ALL SPECIFICATION REVISIONS. REVISED SHEETS ONLY ATTACHED
NORMALLY, EACH TIME THE SPECIFICATION IS CHANGED ONLY THE ENTIRE SPECIFICATION RE-ISSUED
NEW OR REVISED PAGES ARE ISSUED. ENTIRE SPECIFICATION REVISED
THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS

ISSUED FOR
BUT THESE REMARKS ARE NOT A PART OF THE SPECIFICATION. THE
REVISED PAGES BECOME PART OF THE ORIGINAL SPECIFICATION AND REVIEW/COMMENTS
SHALL BE COMPLETED WITHIN THEIR ENTIRELY. TENDER/QUOTATION X
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. MEDIUM VOLTAGE CABLES
CAIRO - EGYPT 260513 - 2874 0

CONTENTS
SECTION 260513
MEDIUM VOLTAGE CABLES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Design Criteria 4
1.6 Shipment 4
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 Construction Of Cables 5
2.3 Identification Of The Cable Phases And Marking 7
2.4 Multiple-Conductor Unarmoured Cables 7
2.5 Multiple-Conductor, Armoured Cables 7
2.6 Cable Supports And Fittings 7
2.7 Splice Kits 8
2.8 Solid Terminations 8
2.9 Cable Cleats 8
PART 3 EXECUTION 9
3.1 Installation 9
3.2 Inspection And Testing 12
3.3 Guarantee Tables 12
3.4 Field Testing 15
Medium Voltage Cables Section 260513

SECTION 260513 –MEDIUM VOLTAGE CABLE
PART 1 GENERAL
A Drawings and General Provisions of the Contract including General Conditions,

Conditions of Particular Application and other Sections of Division-1, apply to work of
this Section
1.2 SUMMARY
A This section covers the furnishing medium voltage cables, including armored and
unarmored single and multiple conductor power cables.
B The Contractor shall be responsible to deliver approved products, for cable

Manufacturer, color, insulation thickness, etc. from Electrical Distribution Company
and submit these approvals before delivering
1.3 SUBMITTALS
A Submit the following in accordance with the requirements set forth at the Conditions
of Contract.
B Tendering Submittals: Contractor to fill-in the ECG compliance data sheet (when
attached to a section) and stamp it by the proposed supplier and by the proposed
electrical sub-contractor (or himself if no sub-contractor).
C If the Contractor is assuming two suppliers for one material item in his bid, two data
D Data and Samples: Equipment, performance and Manufacturer’s catalog data,

samples, and identification tag shall be provided for the following items:
1. Multi-core XLPE/STA/PVC Direct Buried Armored Cable

2. Multicore XLPE/PVC Unarmored Cable
E Each sample shall show full data embossed on the sheath and shall be prepared for
easy investigation and measuring purposes.
F Instructions: Manufacturer's Instructions shall be provided showing the

recommended sequence and method of installation for the following:
1. Medium Voltage Power Cable Systems

2. Termination

G Statements: Listing of products installed shall be provided showing qualifications of
Cable Splices to the Engineer’s Representative prior to specified work.
H Reports: Test Reports for the following shall be in accordance with the paragraph
entitled, "Field Testing," of this section.
1. Dielectric Absorption Tests

2. High-Voltage Tests
3. Radiographic Tests
I Certificates: Certificates of Compliance shall be provided for the following showing

that the cable manufacturer has made the applicable factory-conducted tests on
each shipping length of cable. Certified copies of test data shall show conformance
to the referenced standards and shall be approved prior to delivery of cable.
1. Conductor Resistance
2. Thickness of Armour
3. Ionization
4. High-Voltage
5. Flammability
6. Mechanical Integrity
7. Bending Test
8. High-Voltage Time Test
9. Dielectric Power Loss
10. Power-Factor Tests
11. Qualifications of Cable Splices
12. Dielectric Pothead Tests
A. Reference Standards
1. Governing Standards:
a. Except as modified or supplemented herein, all equipment and

materials required in this section including their installation shall
conform to the applicable requirements of the Standards current at the
time of tender.
2. In addition to meet the requirements of this specification all cables provided

shall comply with the relevant latest standards published by the International
Electro Technical Commission (IEC) or approved equivalent including but not
limited to the following:
a. IEC 60228 Nominal cross-sectional areas and compositions of

Conductors of insulated cables
b. IEC 60229 Tests on anti-corrosion protective covering of metallic
Cable sheath
c. IEC 60230 Impulse on cables and their accessories

d. IEC 60270 Partial discharge measurement
e. IEC 60502-2 Extruded solid dielectric insulated power cables for
Rated voltages from 6 kV up to 30 KV (Vmax = 36kV)
f. IEC 60811 Test methods for insulations and sheaths of electric
Cables
g. IEC 60840 Power cables with extruded insulation and their
Accessories for rated voltages above 30 kV (Um = 36
KV) up to 150 kV (Um = 170 kV) – Test methods and
Requirements
B. Installer’s Qualifications: The Contractor shall submit data showing that he has
successfully installed systems of the same type and design as specified herein, or
that the Contractor has a firm contractual agreement with a subcontractor having
not less than five years’ experience in the design and installation of such systems.
Data shall include names and location of at least two installations of such systems,
he or his referenced sub-contractors has installed. The references shall indicate type
and design of each system and certification that each system has been performed
satisfactorily in the manner intended for not less than three years.
C. Engineer’s Acceptance and Contractor’s Responsibility: The Engineer’s acceptance of

the Contractor’s working drawings shall not relieve the Contractor from
responsibility for errors, omissions, or deficiencies in the work. The Contractor shall
verify actual conditions in the field and shall take all measurements necessary for
proper installation of this work.
1.5 DESIGN CRITERIA
A The cables shall be designed for the following environmental conditions:
1. Air ambient temperature at point of use (Refer to Section 260500)

2. Relative humidity (Refer to Section 260500)
3. Occasional sand storms
4. Salty air
5. Soil conditions vary from dry sand to wet silt or clay
6. In some areas the soil is alkaline, in others it is acidic or salt
B The cable shall be rated for 90°C continuous temperature, 130°C maximum
emergency temperature and 250°C short circuit temperature
1.6 SHIPMENT
A Cable shall be shipped on reels such that the cable will be protected from mechanical
injury. Each end of each length of cable shall be hermetically sealed and securely
attached to the reel.
B Minimum reel drum diameter shall be 14 times the overall diameter of the cable. A
pulling eye shall be installed by the manufacturer for each length of cable supplied
for installation in ducts, manholes, and utility trenches.

A Delivery: All cables shall be delivered to site with seals intact and bearing the
Manufacturer's label indicating classification, size, description, length and grade. All
labels shall be retained and kept in a logbook to be available for inspection by the
Owner’s Representative.
B Storage: Cables shall be stored at normal temperatures and out of direct sunlight.
Cables not on purpose-built cable reels shall be coiled neatly, allowing for any
limitations of bend radius and protected against mechanical damage. Cable ends
shall be sealed to prevent ingress of moisture.
C Care shall be taken to ensure that all cables are adequately protected while stored
on site prior to erection. No damaged cable shall be used.
D Handling: Whenever possible, cranes shall be used with suitable spindle through the
center of the reel. In the absence of hosting equipment, temporary ramp shall be
provided to move cable reels to and from storage area. Cable reels that have been
dropped will be subject to rejection by the Owner’s Representative, because of
flatting of the cable inner layers. Drums shall be rolled in the direction of indicating
arrows.
PART 2 PRODUCTS
2.1 MANUFACTURERS

be incorporated into the Work include, but are not limited to, the ones mentioned
on the attached list of manufacturers Section 01295.
2.2 CONSTRUCTION OF CABLES
A Medium voltage Cable 18/30 (36) kV Stranded compacted circular plain Aluminum
conductor, XLPE insulated in compliance with IEC 60502. The resistance of each
conductor shall be according to IEC 60228.
B Conductors: The cable shall have single conductor of plain aluminum Class 2, of
concentric strand wires. The conductor shall be of compacted circular shape.
C Conductor Screening: Each conductor shall be covered with an extruded semi-

conductive material layer. The screening shall be tightly fitted to the conductor but
shall be easily cold strippable. The conductor screens shall bond thoroughly to the
insulation but shall be easily distinguished from it by its different color.
D Insulation: Each conductor shall have ozone-resistant layer or cross-linked

polyethylene (XLPE) extruded on the conductor screen.

E Insulation Screening: A semi-conductive material layer, which shall have a different
color from that of the main insulation, shall be extruded on the core. The screening
layers shall be easily removable without damaging or scratching the main insulation
or leaving traces over it during splicing or terminating the cable.
F Copper Sheath: On each core insulation screening flat copper tape shall be applied
helically and overlapped comply with IEC 60502-2 standard. The number of copper
tapes and their percentage overlap for each core shall be selected in such a way to
obtain the specified effective cross section area of copper screen per phase.
1. The effective cross section area of copper screen per phase shall be not less
than the following:
Effective C.S.A of copper

NO. No. of cores X C.S.A of cable conductor mm2
screen/phase mm2
1 3X70, 3X95 ,3X120 mm2 16
2 3X150, 3X185, 3X240 mm2 25
3 300 mm2 30
G Filling and Inner Covering: The three cores shall be assembled together, the
interstice filled with non-hygroscopic; non–conductive material, which may be
extruded or not so, that the completed cable assembly is of substantial circular
cross-section.
H The inner covering wrapping the three cores together shall be of extruded corrosion
resistant material.
I The material is used for the filler and inner covering shall be suitable for the cable
operating temperature. The thickness of the inner covering shall be in accordance
with the attached table of dimensions.
J Metallic Armour: The metallic armor is of double tape type and shall be of steel. The
tapes shall be hot or cold rolled of commercial quality. The armor shall be applied
helically in two layers so that the outer type is approximately central over the gap of
the inner tape. The gap between adjacent turns of each tape shall not exceed 50% of
the tape width. Special consideration shall be given to the possibility of corrosion,
not only for mechanical safety, but also for electrical safety. It shall be applied on an
inner covering in accordance with IEC 60502 standard.
K The material and dimensions of the steel tapes shall be in accordance with IEC 60502
standard.
L The tape armour shall be helically applied in two layers so that the outer tape is
approximately central to cover the gap of the inner tape. The gap between adjacent
turns of each tape shall not exceed 50% of the width of the tape.
M Outer Jacket: The cable shall have an over sheath of extruded PVC st-2. The over
sheath shall be non-hygroscopic, sunlight resistant and suitable for soil conditions in
Egypt.

2.3 IDENTIFICATION OF THE CABLE PHASES AND MARKING
A Identification for phases shall be carried using colored plastic ribbon between the
semi-conducting layer and copper screen (RED, YELLOW, BLUE).
B The cable shall be marked throughout its length with the following items:
1. Voltage Rating
2. Size
3. Number of Conductors
4. Manufacturer’s Name
5. Cumulative Length
6. Year of Manufacture.
7. Compliance Standards
C Intervals of marking shall not exceed one meter and each mark shall serially indicate
the length of the cable remaining.
2.4 MULTIPLE-CONDUCTOR UNARMOURED CABLES
A Cross-linked polyethylene insulated IEC 60502:
B Cross-linked Polyethylene with PVC Jacket: Multiple-conductor, cross-linked

polyethylene-insulated, black sheath polyvinyl chloride-jacketed unarmored cable
shall conform to IEC 60502. Conductor screen shall be extruded, semi-conductor
compound, insulation screen (non-metallic part) shall be graphite layer with a
lapping tape or extruded semi-conductive material, and for metallic part shall be
copper tapes 0.10 millimeter thickness. Taped bedding shall be used.
2.5 MULTIPLE-CONDUCTOR, ARMOURED CABLES
A Cross-linked Polyethylene with PVC Jacket: Multiple-conductor, cross-linked

polyethylene-insulated, black sheath polyvinyl chloride-jacketed steel tape armored
(STA) cable shall conform to IEC 60502. Conductor screen shall be extruded semi-
conductor compound, insulation screen (non-metallic part) shall be graphite layer
with a lapping tape or extruded semi-conductive material and for metallic part shall
be copper tapes 0.10 millimeter thickness. Extruded PVC bedding shall be used.
Armour shall be galvanized steel tapes or steel wires applied helically over the PVC
bedding.
2.6 CABLE SUPPORTS AND FITTINGS
A Cable supports, related fittings, and accessories for use in corrosive underground
locations, such as manholes, shall be provided with a factory applied coating of
polyvinyl chloride of at least 0.51 millimeter thick. Polyvinyl chloride (PVC) coated
items shall have a uniform thickness and be free of blisters, breaks, and holidays.
PVC compound shall conform to IEC.

B Cable racks, cable tray supports and related fittings shall be IEC standard or heavy-
duty nonmetallic glass-reinforced nylon or polycarbonate.
2.7 SPLICE KITS
A Approved connectors shall be provided for splices and terminal connections of all
aluminum conductors. The connector shall fit the conductor to which it shall be
connected, and the assembly shall have joint contact surfaces not less than 50%. (As
recommended in writing by the splicing kit manufacturer for specific sizes, ratings
and configuration of cable conductor and splices specified). Include all components
required for complete splice with detail instruction. Comply with IEC Code.
2.8 SOLID TERMINATIONS
A Termination for medium voltage cable shall be in the switchgear or cable entrance
Compartment of transformers. Type of termination fitting shall be as required to
match conductor to equipment, built–up insulation and heat shrink stress cone as
manufactured by Raychem (or approved equal) for the type of cable specified.
2.9 CABLE CLEATS
A Cable Cleats shall be design and tested as per IEC 61914 and used to securing the
cables when installed at intervals along the length of the cables
B Where trays are not required metal rack with one or more pairs of cleats shall be
used to suit the formation of the cables.
C Cable cleats shall be of an approved non-corrosive material having no deleterious

effect on cable coverings or supporting steel work. Aluminum or aluminum alloy
cleats shall not be used. Cleats for carrying a single core cable shall be non-magnetic
and the arrangement shall not permit any closed magnetic circuit around the cable.
D Where single core cables in trefoil or quadrature formation are not secured in cleats,
binders of approved material and construction shall be fitted around the formation
to prevent the cables separating under fault conditions. The binders shall consist of a
nonferrous strap secured around the cables by means of a bolted connection. The
spacing of binders shall be approved by the Engineer. Single core and multicore
cables shall be clamped to the racks with smooth finish split packing pieces of non-
inflammable material or cleats with bores of the correct size for the cable diameters.
E The spacing of cable supports shall be approved by the Engineer

PART 3 EXECUTION
3.1 INSTALLATION
A Medium-voltage cables shall be installed in accordance with IEC.
B Cable shall be installed in underground duct banks; in conduit above and below
grade; inside buildings; by open wire method; on insulator hooks; on racks; in wall
and ceiling mounted cable trays and manholes; and by direct burial.
C Cables shall be secured with heavy-duty cable ties in trays mounted

horizontally, where cable rests on tray bottom. Cable ties shall be installed at
minimum of 3000-millimeter intervals.
D Cables shall be secured with PVC coated, metallic or non-metallic cable clamps,
straps, hangers, or other approved supporting devices, ceilings, and in cable trays
mounted vertically, where tray bottom is in a vertical plane. When field cuts or other
damage occurs to the PVC coating, a liquid PVC patch shall be applied to maintain
the integrity of the coating. After the installation is complete, an inspection shall be
performed to ensure the absence of voids, pinholes, or cuts.
E Contractor shall ensure that all cable trays are properly secured and supported prior
to installing new armored cable. Contractor shall add new permanent and/or
temporary tray support devices as required to preclude cable tray failure during
cable pulling or after cable is installed.
F Cable or conductors of a primary distribution system shall be rejected when installed

openly in cable trays or openly racked along interior walls; (in the same raceway or
conduit with AC/DC control circuits or AC power circuits operating at less than 600
Volts; or in a manner allowing cable to support its own weight).
G Moisture-testing Before Pulling: Contractor shall ensure that radii of bends,

potheads, fittings, cable risers, and other conditions are suitable for the cable and
conform to the recommendations of the cable manufacturer.
H Protection During Splicing Operations: Blowers shall be provided to force fresh air
into manholes or confined areas where free movement or circulation of air is
obstructed. Waterproof protective coverings shall be available on the work site to
provide protection against moisture while a splice is being made. Pumps shall be
used to keep manholes dry during splicing operations. Under no conditions shall a
splice or termination be made with the interior of a cable exposed to moisture. A
manhole ring at least 150 millimeters above ground shall be used around the
manhole entrance to keep surface water from entering the manhole. Unused ducts
shall be plugged and water seepage through ducts in use shall be stopped before the
splice is started.
I Duct Cleaning: Ducts shall be thoroughly cleaned before installation of power cables.
A standard flexible mandrel shall be pulled through each duct to loosen particles of
earth, sand, or foreign material in the line. Mandrel length shall be not less than 300

millimeter long, and shall have a diameter 13 millimeter less than the inside
diameter of the duct. A brush with stiff bristles shall then be pulled through each
duct to remove the loosened particles. Brush diameter shall be the same as or
slightly larger than the diameter of the duct.
J Pulling Cables in Ducts and Manholes: Medium-voltage cables shall be pulled into
ducts with equipment designed for this purpose, including power-driven winch,
cable-feeding flexible tube guide, cable grips, and lubricants. A sufficient number of
trained personnel and equipment shall be employed to ensure the careful and
proper installation of the cable.
K Cable reel shall be set up at the side of the manhole and above the duct, allowing the
cable to enter through the opening without reverse bending. Flexible tube guide
shall be installed through the opening in a manner that will prevent the cable from
rubbing on the edges of any structural member.
L Cable shall be unreeled from the top of the reel. Payout shall be carefully controlled.
Cable to be pulled shall be attached through a swivel to the main pulling wire by
means of a pulling eye or suitable cable grip permitted only on cables less than 60
meter long and less than 50 millimeter in diameter.
M Woven-wire cable grips shall be used to grip the cable end when pulling small cables
and short straight lengths of heavier cables.
N Pulling eyes shall be attached to the cable conductors to prevent damage to the
cable structure.
O Pulling eyes and cable grips shall be used together for PVC sheathed cables to
prevent damage to the cable structure.
P
P Minimum bending radius shall be in accordance with NEC article 300.34 and IEEE
1185 as the following:
Cable Type Minimum Bending Radius as a

Multiplier Times of overall Cable
Diameter
Single conductor cables with Armored, 12
>1000 V
Single or multiple conductor cables 8
Unarmored, >1000V
Multi-conductor cables with individually 12 times the individual conductor
shielded conductors, >1000 V diameter or 7 times the overall cable
diameter – whichever is greater
Q Cables shall be liberally coated with a suitable cable-pulling approved lubricant as it

enters the tube guide or duct. Grease and oil lubricants shall be used only on
armored cables. Unarmored sheathed cables shall be covered with wire-pulling

sheaves, or tube guides around which the cable is pulled shall conform to the
minimum bending radius of the cable.
R Cables shall be pulled into ducts at a speed not to exceed 0.25 meter per second and
not in excess of maximum permissible pulling tension specified by the cable
manufacturer. Cable pulling using a vehicle shall not be permitted. Pulling operations
shall be stopped immediately with any indication of binding or obstruction and shall
not be resumed until such difficulty is corrected. Sufficient slack shall be provided
for free movement of cable due to expansion or contraction.
S Cable splices made up in manholes shall be firmly supported on cable racks as

indicated. No cable splices shall be pulled in ducts. Cable ends shall overlap at the
ends of a section to provide sufficient undamaged cable for splicing. Cables to be
spliced in manholes shall overlap the centerline of the proposed joint by not less
than 600 millimeter.
T Cables cut in the field shall have the cut ends immediately sealed to prevent
entrance of moisture. Unarmored cables shall be sealed with rubber tape wrapped
down to 75 millimeter from the cable end. Rubber tape shall be cover-wrapped with
polyvinyl chloride tape. Armored cables shall be sealed with wiping metal making a
firm bond with the end of the sheath or with a disk of lead fitted over the end and
wiped to the sheath.
U Direct Buried Installation: Cable direct buried, unless otherwise specified furnish a
bed of soft clean sand 100 mm depth at the bottom of trench, and the same over
cable. Install concrete tiles to the whole route of the cable with 50 mm thickness
and covering at least 200 mm over the outer edge of the cable from both sides.
V Then storing in backfilling with selected soil and reach to 95% compaction minimum.
Before reaching to the finished grade level by 300 mm, install warning tape, in both
English and Arabic, to cover the whole routes indicating “DANGER ELECTRICAL
CABLES”.
W In road crossing, install UPVC pipe embedded in concrete encasement and install
warning tape and install spare pipes not less than 25 % of the same size.
X Permanent markers shall be installed at each 50 m of the cable runs, changes in

direction, buried splices and cable ends.
Y Cables shall be installed as required by drawing and manufacturer’s recommendation

and according to standard length of cable in case of long distance routes with one as
a maximum in certain route.
Z Use kits, which are compatible with conductor size, material and type and according
to the manufacturer’s recommendations.
AA Install terminations at ends of conductors and seal multi–conductor cable ends with
standard kits and glands.

BB Grounding: The armoring of metal sheathed cables grounding connection’s shall be
made by means of screw – type pressure connectors to grounding pads of
connections provided on the switchgear in accordance with IEC. All underground
connections shall be made by exothermic welding and then encapsulated in epoxy
resin (Jointing). A separate protective conductor shall connect the sheath, armoring,
ground metal bodies of terminators, splices and hardware according to
manufacturer’s
3.2 INSPECTION AND TESTING
A ENGINEER reserves its right to carry out inspection during fabrication stages and to
witness the testing of cables.
B Attendance of ENGINEER representative during fabrication stages and testing must

not relieve the Manufacturer of his full responsibility for furnishing the cables in
accordance with the requirements of this specification, and shall not give him the
right to invalidate any claim which ENGINEER may make because of defective
material or faulty workmanship.
C Unless otherwise specified or approved in writing by ENGINEER all cables shall be

tested at the factory in accordance with the latest applicable issues of the IEC
standards or approved equivalent. All routine and type tests shall be performed by
and at the expense of manufacturer. The type and routine test certificates shall be
delivered by ENGINEER.
D Quality control procedure shall be submitted with tender documents.
3.3 GUARANTEE TABLES
A The tenderer shall thoroughly fill in the attached guarantee tables (technical
particulars and performance) for guidance.
B The cable length on each reel shall be as long as possible to minimize the number of
joints and as shown in the attached tables.
C All cable ends shall be firmly secured to the reel and shall be covered by heat-
shrinkable end caps.
D The cable drum shall be covered with wooden slabs of suitable thickness.
E All cables shall be supplied on reels whose size is not to exceed 2.6 m diameter and
1.6 m width including protruded bolt length. The reels may be returnable as per
agreement between the tenderer and ENGINEER.
F On each reel the following data shall be printed on both sides:
1. Medium Voltage Power Cables

2. Manufactured by:
3. Voltage Class: kV

4. Number of Cores and Cross-section: mm2
5. Type of Insulation:
6. Length of Cable: Meters
7. Net Weight: kgs
8. Gross Weight: kgs
9. Reel No.:
G Important Note
The factory laboratory must be equipped with all modern instruments and
equipment required to perform all routine and special tests of IEC 60502 with
the accuracies mentioned in IEC 60502
1. Offers from tenderers having no such laboratories shall not be considered
2. Dimensions shall be measured by digital and microscopic instruments.
H Specified Dimensions of Cables
1. Table of Specified Dimensions of Cables according to IEC 60502-2 and EDC

requirements:
18/30 kV XLPE
Item
3*240 mm
Minimum thickness of conductor screening 0.8 mm
Nominal thickness of XLPE insulation 8 mm
Minimum thickness of insulation screening 1 mm
Nominal thickness of Armor tapes 0.8 mm
Nominal thickness of extruded PVC over sheath 4.1mm
The cable length on each reel shall be not more than 800 meters
2. The thickness of insulation at any place, may however be less than the
specified nominal value provided that the difference does not exceed 0.1 mm
+ 10% of the specified nominal value.
3. The dimension of the armour shall not fall below the specified nominal value
by more than 10%.
4. The measured smallest thickness of the PVC over sheath, at any point shall not
fall below 80% of the specified nominal value by more than 0.2 mm.
5. Guarantee Table (Similar data fills on typical manufacturer data sheets shall be
also accepted.
a. Technical Particulars
Maker’s Name:
1) Thickness of tape
2) Width of the tape
3) Percentage overlap of tape
4) Number of tapes
5) Effective cross-sectional area of screen per phase

6) Material of filling
7) Material of inner coverings
8) Minimum thickness of inner coverings
9) Material of armour tapes
10) Nominal thickness of armour tape
11) Minimum thickness of armour tape
12) Number of armour tapes Double tape
13) Material of over sheath
14) Thickness of over sheath
15) Nominal Value
16) Minimum Value
17) Maximum Value
18) Overall cable diameter
19) Minimum bending radius of cable
20) Cable weight per meter
21) Aluminum
22) Copper sheath
23) Finished cable
24) Length of cable per drum
25) Diameter of drum
26) Width of drum
27) Gross weight of charged drum
I Performance
1. Power Frequency Withstand Test Voltage: kV

2. Duration of Power Frequency Withstand Voltage: Minutes
3. D.C. Withstand Test Voltage: kV
4. Duration of D.C. Withstand Test Voltage: Minutes
5. 1.2/50 µs Impulse-withstand Test Voltage: kV
6. Insulation Resistance Measured by 5000 V mega ohm-meter for 10 meters of
Cable at 20°C: Mega-ohm
7. Minimum Bending Radius of Cable: cm
8. Thermal Conductivity of Finished Cable: w/cm/°C
9. Partial Discharge of Cable at 1.73 U0: pc
10. Maximum Equivalent Star Capacitance/km: µf
11. Maximum Loss Angle (Tan δ) at U0 and 20°C:
12. Maximum D.C. resistance of Conductor per km of cable at 20°C: ohm/km
13. Maximum A.C. Resistance of Conductor per km of Cable at 90°C: ohm/km
14. Inductance per Core per km of Cable: mH
15. Equivalent Star Reactance per km of Cable, 50 c/s: ohm/km
16. Impedance per km of Cable at 90°C and 50 c/s: ohm/km
17. Maximum Continuous Current Rating:
a. In Air, 40°C: Amps

b. In Ground, 30°C: Amps
18. Maximum One Second Short Circuit Current Capacity of:
a. Conductor: KA

b. Screen/One Phase: KA
c. Screen for 3 Phase: KA
19. Maximum Cable Temperature:
a. Continuous: °C
b. Emergency: °C
c. Short Circuit: °C
J Table of Specific Dimensions of Cables 18/30 KV XLPE 3*240 mm2
1. Minimum thickness of conductor screening (not less than) mm

2. Nominal thickness of XLPE insulation mm
3. Minimum thickness of inner covering (ST2) mm
4. Nominal thickness of steel tape armour mm
5. Nominal thickness of extruded P.V.C over sheath mm
6. The cable length of each reel shall be not less than. m
K We certify that the above mentioned data are guaranteed for the offered cable.
3.4 FIELD TESTING
A Each shall be subjected to dielectric-absorption and high-voltage tests after the

installation of power cables has been completed, including splices, joints, and
terminations, and before the cable is energized.
B The power frequency routine test voltage shall be 3.5 U0 values of single phase test
voltage for the standard rated voltage according to IEC 60502 and as given in the
following table:
Rated Voltage U0 (KV) 12 18

Test Voltage (KV) 42 63
C The partial discharge test shall be carried out in accordance with IEC 60885-3, except
that the sensitivity as defined in IEC 60885-3 and shall be 10 Pico-coulombs (P.C) or
better. The partial discharge test voltage shall be raised gradually to and held at 2 U0
for 10 seconds and then slowly reduced to 1.5 U0.
D Test equipment, labor, and technical personnel shall be provided as necessary to

perform the electrical acceptance tests.
E Arrangements shall be made to have tests performed by Electrical Distribution

Company and shall witnessed by the Engineer’s representative until all results are
satisfactory.
F Each power-cable installation shall be completely isolated from extraneous electrical

connections at cable terminations and joints. Safety precautions shall be observed.
G Each power cable shall first be given a full dielectric-absorption test. Test shall be
applied for a long enough time to fully charge the cable. Readings shall be recorded

every 15 seconds during the first 3 minutes of test and at 1 minute intervals
thereafter. Test shall continue until three equal readings, 1 minute apart, are
obtained. Minimum reading shall be 200 mega ohms at an ambient temperature of
16 degrees C. Readings taken at other than 16 degrees C ambient temperatures
shall be corrected accordingly.
H Upon successful completion of the dielectric absorption test, the cable shall be
subjected to a direct-current high-potential test for 5 minutes with test voltages
applied in accordance with IEC for cross-linked, polyethylene-insulated cable.
I Leakage current readings shall be recorded every 30 seconds during the first 2
minutes and every minute thereafter for the remainder of the test. When the
leakage current continues to increase after the first minute, the test shall be
immediately terminated and steps taken to find and correct the fault. When a
second test becomes necessary, this test procedure shall be repeated.
J Upon satisfactory completion of the high-potential test, the cable shall be given a
second dielectric-absorption test as before.
K Results of the second dielectric-absorption test shall agree with the first test and
shall indicate no evidence of permanent injury to the cable caused by the high-
potential test.
L Test data shall be recorded and shall include identification of cable and location,
mega ohm readings versus time, leakage current readings versus time, and cable
temperature versus time.
M Final acceptance shall depend upon the satisfactory performance of the cable under
test. No cable shall be energized until recorded test data have been accepted by the
Electrical Distribution Company and approved by the Engineer’s Representative.
N Radiographic tests may be performed on all potheads at the discretion of the

Engineer’s Representative to determine if voids exist in the pothead. Unacceptable
terminations shall be reworked at no additional expense to the Engineer.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. LOW-VOLTAGE ELECTRICAL POWER
CAIRO - EGYPT CONDUCTORS AND CABLES 260519 – 2874 0

CONTENTS
SECTION 260519
LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES

Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Delivery, Storage, And Handling 4
1.6 Coordination 5
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 Lv Wires And Cables 450/750 V Grade 5
2.3 Lv Cables 600/1000 (1200) V Grade 6
2.4 Control And Signal Cables 6
2.5 Connectors (Lv Power) 7
2.6 Performance And Design Requirements 8
PART 3 EXECUTION 11
3.1 Inspection 11
3.2 Preparation 11
3.3 Installation 13
Low-Voltage Electrical Power Conductors and Cables Section 260519

SECTION 260519 - LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including General and Supplemen-
tary Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This section covers the furnishing and installation of all insulated wires and cables in-
cluding control / (for power) cables voltages 600 volts nominal or lower; except wire
and cable for special applications, such as low-level circuits for analog signals, data
and supervisory control, Communication and Telemetering Systems.
1.3 SUBMITTALS
A. Submit the following in accordance with the requirements set forth at the Conditions
of Contract.
1. Tendering Submittals: Contractor to fill-in the compliance data sheet (when

attached to a section) and stamp it by the proposed supplier and by the
proposed electrical sub-contractor (or himself if no sub-contractor). If the
Contractor is assuming two suppliers for one material item in his bid, two data
2. Drawings and Data: Descriptive literature, catalogs, cable list, drawings and
test reports for cable shall be submitted. Literature submitted should be
marked on a typical data sheet to clearly indicate any particular specification
paragraph for which the material applies.
3. Samples: In addition to complete specifications and descriptive literature, a
sample of selected sizes of each type of cable, termination, gland,
identification tag and warning tape shall be submitted for review before
installation. Each sample shall have the manufacturer's full surface printing
identification data engraved and shall be prepared for measuring and
verification purposes. The samples shall be retained until completion of the
Contract. The Owner’s Representative reserves the right to subject any of the
samples submitted to tests and will be in no way responsible for damage or
breakage as a result of any such tests.
Manufacturing Data and Test Reports: Showing dimensioned sketches,
thickness of insulation and sheath, factory tests, drum data and shipping
details.
4. Shop and Construction Drawings: Submit drawings for approval including, but
not limited to, the following:
a. Exact routing layouts, sections and profiles of trays, feeder, sub feeder
cables and branch circuits, with indication of any equipment to show
and verify coordination between various trades.
b. Details of supports and fixings for buses, trays and cables.
c. Details of connections to transformers, switchboards, panelboards etc.
d. Details of terminations, splices and tapings where permitted, glands and
bushings at enclosures.
e. Number and size of conductors in conduit for all branch circuits in
accordance with final conduit routing.
f. Cable sizing calculations.
g. Cable schedule.
h. Cable termination schedule.
5. Governing Standards: Except as modified or supplemented herein, all equip-

ment and materials required in this section including their installation shall
conform to the applicable requirements of the following standards. Standards
current at the time of tender shall be used.
IEC 60228 Class 2
Bare copper cables for earthling (grounding)
PVC insulated or PVC Sheathed cables, 0.6/1 kV IEC 60502 or NEMA WC 7
XLPE insulated or PVC Sheathed cables, (90C) IEC 60502 or NEMA WC 7
0.6/1 kV
XLPE/SWA/PVC Direct Buried Armored Cable IEC 60502 or NEMA WC 7
Cable glands for single and multi-core PVC BS 6121, BS 5467 or BS
and/or XLPE cables 2874
Surge arrestors for cables IEC 60099 Part 1
Cable conductor identification by color or nu- IEC 60446
merals
Stranded copper cable Conductors IEC 60228 Part 1 and 2
Stranded copper wire IEC 60227 and BS 6004
Cable joints, encapsulated resin type IEC 60502 or IEC 60455
Cable joints, heat shrink type IEC 60502 or IEC 60684
6. British Standards (BS): 6004, BS 6007, BS 5467, BS 7676 and BS 7889

7. Egyptian Building Code
A. Installer Qualifications: Engage an experienced and certified cable splicer to install,

splice and terminate low-voltage cables.
B. Standards: Wires and cables are to comply with IEC or other equally approved stand-
ards and are to bear the mark of identification of the Standards to which they are
manufactured. Wires and cables not having this identification will be rejected.
C. Current carrying capacities of conductors have been determined in accordance with

the Regulations for specified type of insulation and expected conditions of installa-
tion. No change will be accepted in specified type of insulation unless warranted by
special conditions and approved by Engineer. Check various loads and current carry-
ing capacities and report any discrepancies or insufficiency of sizes indicated to Engi-
neer.

1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver wires and cables properly packaged in factory packed or fabricated contain-
ers, wound on factory reels.
8. Store wires and cables in dry areas, and protect from weather, fumes, water, debris,
etc.
B. Handle wire and cable carefully to avoid abrading, puncturing and tearing wire and
cable insulation and sheathing. Ensure that dielectric resistance integrity of
wires/cables is maintained.
C. Before dispatch, the manufacturer shall cap the ends of all cables so as to form a seal
to prevent the ingress of water during transportation, storage and installation. The
cable shall be supplied on stout wooden drums, which shall be designed so as to pro-
tect the cable from damage.
D. The lagging batten shall be secured at least with 2 nails of each end in addition to
steel bonding straps. No drum shall contain more than 1 length of the cable.
E. The cable shall be tightly wrapped on the cable drum and no turn shall be left loose.
Both ends of the cable shall be adequately secured to the cable drum. Inner end of
the cable shall be suitably fixed / gripped to the cable drum so that it will not come
out during cable laying operation. The cable shall be wrapped on drums of suitable
diameter such that the radius of bend of the innermost layers is not less than the
minimum radius of bend stipulated in relevant BS/IEC for installation of the cable.
F. No space shall exist between the adjacent layers of the cable and between the drum
flange and the cable.
G. Cable shall be wrapped with black polyethylene sheet inside the wood covering of
the drum.
H. Central lifting hole of the cable drum shall be provided with a steel pipe. The pipe
shall be welded with steel plates at both ends and these plates shall be duly secured
to the flanges of the cable drum with suitable size bolts. The pipe and the welded
end plates shall be of robust design to withstand the weight of the cable drum during
unrolling.
I. Each drum shall bear a distinguishing number on the outside of the flanges and par-
ticulars of the cable, i.e. voltage, length, conductor size, cable type and gross weight
shall also be clearly visible. The direction for rolling shall be indicated by an arrow.
J. Immediately after the Works tests, both ends of every length of metal sheathed ca-
ble shall be sealed by means of a metal cap fitted over the end and plumbed to the
sheath. All cables shall be sealed by enclosing the ends in approved caps, which shall
be tight fitting and adequately secured to prevent ingress of moisture.
K. The ends of factory lengths of cable shall be marked "A" and "Z", "A" being the end at
which the sequence of core numbers is clockwise and "Z" the end at which the se-
quence is anti-clockwise. The words "Running End "A"" or "Running End "Z"" shall be
marked on the flange and the direction for rolling shall be indicated by an arrow. The
method of drum marking shall be to the Purchaser's approval.

L. The cable end which is left projecting from the drum shall be adequately protected
against damage.
M. Cable drums shall be non-returnable and shall be made of timber, pressure impreg-
nated against fungal and insect attack or made of steel suitably protected against
corrosion. They shall be arranged to take a round spindle and be lagged with strong
closely-fitting battens of minimum 38 mm thickness.
N. All cables and accessories shall be carefully packed for transport and storage on Site
in such a manner that they are fully protected against all climatic conditions, particu-
lar attention being paid to the possibility of deterioration during transport to the Site
by sea or overland and to the conditions prevailing on the Site.
O. Wooden drums shall be suitably constructed to avoid problems due to shrinkage, rot
and attack by insects.
P. Drums, carts, cases, etc., for maintenance spares shall be non-returnable. Cable
maintenance lengths and spare lengths shall be wound onto steel drums inspected
and tested by the Engineer before they are handed over to the Purchaser's stores.
Particulars of the cable (as stated above) shall be clearly marked.
1.6 COORDINATION
A. Coordinate layout and installation of cables with other installations.
B. Revise locations and elevations from those indicated, as required to suit field condi-
tions and as approved by Engineer.
C. Ensure that cable twists, and crossings are avoided and sufficient bending radius is
maintained as per regulation.
PART 2 PRODUCTS
2.1 MANUFACTURERS

2.2 LV WIRES AND CABLES 450/750 V GRADE
A Single Core PVC Insulated Cables and Wires 450/750 V grade: single conductor cables
for wiring in conduit are to have soft annealed copper stranded conductors unless
otherwise indicated in the drawings, insulated with flame retardant, moisture and
heat resistant PVC according to IEC 60227 or BS 6004, suitable for wet locations and
for conductor temperature of 70 deg. C.
B Single Core PVC Insulated Cables and wires with Flexible Copper Conductors 450/750
V grade: Soft annealed Copper fine wires, bunched together in subunits or stranded
bunched groups into a main unit, twisted and Sheathed which forms the flexible
conductor. According to IEC 60227 or BS 6004. Shall be used where particular
flexibility is required for Electrical Panels connection and electrical apparatus they
can be laid in groups around steel sheets. Conductor temperature of 70 deg. C.
2.3 LV CABLES 600/1000 (1200) V GRADE
A Single Core PVC Insulated Cables (0.6/1 kV): Single-core circular stranded annealed,
copper conductors as indicated in the drawings, compacted, suitable filler and
sheathed with PVC according to IEC 60502, suitable for outdoor and indoor
installations in damp and wet locations. Conductor temperatures of 70 deg. C and
PVC over-sheath.
B Single Core XLPE Insulated Feeder Cables (0.6/1 kV): Single-core circular stranded,
annealed copper conductors as indicated in the drawings, compacted, insulated with
cross-linked polyethylene (XLPE), according to IEC 60502 or BS 7889 suitable for wet
locations and conductor temperatures of 90 deg. C.
C Multi-Core PVC Insulated Cables (0.6/1 kV): soft annealed, copper conductors as per
indicated in the drawings, compacted, suitable filler and sheathed with PVC
according to IEC 60502, flame retardant, moisture and heat resistant, suitable for
outdoor and indoor installations in damp and wet locations. Conductor temperatures
of 70 deg. C.
D Multi-Core XLPE Insulated Feeder Cables (0.6/1 kV): annealed copper conductors as
indicated in the drawings, compacted, XLPE insulated, for conductor temperature of
90 deg. C, laid up and bedded with suitable non-hygroscopic material compatible
with the insulation and PVC over-sheathed, color black according to IEC 60502 or BS
5467.
E Armored Multi-Core cables are to have single layer of steel wire or steel tape applied
helically over extruded PVC bedding (which may be an integral part of filling) and
over-sheathed with PVC, color black. PVC over-sheaths are to be type ST2 according
to IEC 60502. Armored cables shall be used where mechanical damages are expected.
F Armored Single-Core Cables, Single-conductor, cross-linked polyethylene-insulated,

polyvinyl chloride-jacketed cable 0.6/1 KV Single Core Cable with Copper Conductor,
XLPE Insulation, Aluminum Wire Armored (AWA) or Aluminum Tape Armored (ATA)
as indicated in the drawings, PVC Sheath with black color. Armored cables shall be
used where mechanical damages are expected or as specified on drawings
G Fire Resistance cable (0.6/1 KV): Plain annealed copper conductors class 2 according
to IEC 60228, with primary insulation of fire resistant MICA tape and secondary
insulation of 90°C. cross-linked polyethylene insulation, extruded LSHF bedding
compound and galvanized steel wires and robust LSHF sheath. Cable is to be rated at
600/1000 V, certified from a third party lab to passed the fire resistance tests
according to BS 6387 and Flame retardant tests according to IEC 60332-1 and 60332-
3. with Category CWZ according to BS 6387. Category C subject to fire at 950°C for 3
hours, category W (Resistance to fire with water) subject to fire at 650°C for 15
minutes, then at 650°C with water spray for a further 15 minutes and category Z
(Resistance to fire with mechanical shock) subject to fire at 950°C with mechanical
shock for 15 minutes.

H Fire Resistance Cable to be used for emergency/ life safety lighting circuits and Fire
Detection and alarm system: Solid or stranded plain annealed copper conductors to
BS 6360 (in sizes up to 4 mm2), cross linked damage resistant insulation, laminated
copper tape screen bonded to sheath and in contact with full size annealed copper
protective conductor. Cable is to be rated 300/500 V, It is to be certified to have
passed IEC 60331 and IEC 60332 flame resistance and fire retardant tests and BS
5839-1 for enhanced application area in addition to BS 7629-1 and BS6387 Category
CWZ. Cables must be supported by a fixing (recommended by the manufacturer) that
can withstand the same fire conditions as the cable.
2.4 CONTROL AND SIGNAL CABLES
A Multi-Core XLPE Insulated Control Cables: 0.6/1 kV rating, solid 1.5 mm2, 2.5 mm2 or
stranded 4 mm2 plain circular copper conductors, with heat resistive PVC/A to IEC
60502-1, rated for 90 deg. C, of 7, 12, 19, 24, 30 or 37 cores. Cores are to be laid up
together and filled with non-hygroscopic material, and covered with copper wire or
tape screen and over sheathed with flame retardant PVC/ST1, to form compact and
circular cable for use in switchgear, control gear and generally for control of power
and lighting systems. Armored cable is to have extruded PVC bedding which may be
an integral part of the filling, galvanized steel wire armoring, and over-sheath of
flame retardant PVC/ST1 to IEC 60502-1 and IEC 60332-1, color black. Core
identification is to be white printed numbers 1, 2, 3 etc. over black insulation.
B Cables are to be certified to have passed IEC 60331 fire resistance and IEC 60332-1 &
3 flame retardant and reduced flame propagation to category CWZ of BS 6387.
C PE insulated control and signal cables, for use on data systems, are to be generally
300 V rating, polyethylene insulated, color-coded, tinned copper conductors (0.6-mm
diameter), twisted together into pairs. Multi-pair core assembly is to be covered with
binder tape, spirally wound 0.075-mm bare copper shielding tape and provided with
drain wire and overall PVC sheath.
D Control and signal cables, enclosed in conduit and raceways with power cables, are
to be insulated for same voltage grade.
E Multi core PVC insulated cables (300/500 V) annealed copper conductors, solid
conductors, up to 4 mm2 unless otherwise indicated, insulated with moisture and
heat resistant PVC/C to IEC 60227 and with over sheath of flame redundant PVC type
ST1 to IEC 60227 and IEC 60332-1.
2.5 CONNECTORS (LV POWER)
A Connector - Type A-1: Pressure indent type, for terminating or making T-taps and
splices on conductors 10 mm2 and smaller. Connector is to be non-ferrous copper
alloy applied to conductor by mechanical crimping pressure, with vinyl insulating
sleeves or phenolic insulating covers.
B Connector - Type A-2: Bolted pressure split type for terminating or making T-taps and
splices on conductors 16 mm2 and larger. Connector is to be cast non-ferrous copper
alloy applied to conductor by clamping with minimum of two screws and provided
with phenolic insulating cover.
C Connector - Type B-1: Pre-insulated, spring type, for branch circuit and fixture wiring.
Connector is to be steel encased spring with shell, insulated with vinyl cap and skirt,
type Scotchlok brand, as manufactured by Minnesota Mining & Mfg. Co. or 3M or
other equal and approved.
2.6 PERFORMANCE AND DESIGN REQUIREMENTS
A Cable Design Criteria: All cables shall conform to the applicable provisions of the IEC
and local standard.
B Each type of cable used throughout the installation shall be supplied by one
manufacturer only.
C Cable Types: The following types of wiring systems shall be used for power circuits
and controls.
1. Armored/non-armored single/multicore XLPE Insulated PVC Sheathed, 90 C

flame retardant
2. Single/Multicore stranded PVC 70 C insulated and PVC sheathed, flame
retardant
3. The wires shall be PVC at rated voltage 450 / 750 V
4. Cables for critical loads shall be fire resistant sheathed such as:
a. Smoke Evacuation Fan (s)

b. Firemen Elevator (s)
c. Pressurization Fan (s)
d. Other life safety loads as shown on the drawings
5. Irrigation cables shall be moisture and heat resistant sheathed.

6. Steel wire armoring shall be galvanized type.
D The armour of single-core cables for use on a.c. systems shall consist of non-
magnetic material, unless a special construction is chosen.
E Cable Sizing and Selection: The applicable IEC or local regulations for Electrical
Installations shall be used as the basis for sizing cables and conductors.
F Minimum wire size shall be 4 mm2 for power circuits; 6 mm2 for current transformer
secondary circuits; 3 mm2 for potential transformer, digital signal, relaying, and
control circuits; 1.5 mm2 for annunciator circuits, analog signal and alarm circuits.
G Voltage drop on distribution cables for final branch circuit shall not exceed 5 percent.
H No cable shall be loaded to more than 80 percent of its current carrying capacity
after application of all the appropriate derating factors.
I The spacing of cables shall be as determined in the calculation of the derating factors
for the current carrying capacity of cables.
J When required, control cables shall be selected taking into account of the following:
1. Loop resistance shall be less than 50 ohms.

2. The environment through which the cable is to pass which will affect the
screening and conduit requirements.
3. Cable route to be used e.g. direct burial.
4. Electrostatic interference shall be reduced by using a conductive screen
around the signal wires and grounding the screen at one location only.
K Cable sizes shall not be less than the minimum size specified herein. Minimum
cables sizes for circuits outgoing from main switchboards, distribution panel board,
and main distribution boards shall be in accordance with the schedule set forth in
Table No. 1, indicating the nominal cross section area of PVC type cables.
L Circuits connecting lighting, power and miscellaneous equipment shall be sized in

accordance with NEC and IEC Governing Standards, but shall not be less than
1. PVC Cables 3 mm²
M Cables for motors above 2 kW, shall be sized to conform to the Governing Standards,
so that the current ratings are not less than 125 percent of the full load current of the
motor and that the cable is not smaller than
1. PVC Cables 4 mm²

2. Remote control circuits 2.5 mm²
N Cable and Conductor Identification
1. Power Cables: All conductors shall be identified by colored insulation. Mains,

sub-mains and final sub-circuit phase cables shall be identified by using their
respective phase colors, i.e., red, yellow and blue. The neutral conductors shall
be colored black, the ground conductors shall be colored green and/or green-
yellow.
2. The cables shall be marked throughout its length with the following items:
a. Voltage rating
b. Size
c. Number of conductors
d. Manufacturer’s name
3. All conductors shall be identified in distribution and panel boards by their

circuit numbers. Neutral and ground cables shall further be identified by their
respective circuit number and phase letter, i.e. R, Y and B. This identification
shall be made by permanent clip-on or push-on plastic identification bands. In
the case of larger conductors, the identification shall be by means of push-on
numbers or a suitable plastic bar that is tie-wrapped onto the cables.
4. At all outlet points, all phase and switch conductors are to be identified as
specified herein.
O Cables in Conduits and Trunking: All cables for lighting, small power, control and
auxiliary services, including low and extra low voltage services, shall be multistranded
single core (except for metal conduits shall be multicore) PVC, butyl, or silicone
insulated as required for 450/750 Volt grade as set forth in IEC and local specification
having stranded copper conductors. The minimum cable size shall be 1.5 mm2.

P All cables shall be color coded in accordance with the relevant IEC and local
Standards.
Q Marker sleeves shall be fitted to each end of cables and at suitable distances along its
length. Sleeves and markers shall be of the proprietary type manufactured for the
particular applications, and they shall be of the correct size to ensure a tight fit on
the cable. Where cables changed direction, or are routed through conduits, cables
identification sleeves shall be fitted.
R Cables shall be contained within a protective enclosure of a size not less than that
complying with IEC or local standards throughout its whole length.
S Cables installed in conduits, trunking shall be so grouped that the cables of all
phases, neutral and earth, are drawn into the same conduit. The lead and return
conductors shall always be drawn into the same conduit. Not less than three single
core cables shall be enclosed in any one conduit or trunking compartment.
T The grouping of cables fed from different distribution units shall not be permitted.
Also the grouping of cables of different service systems shall not be permitted.
U Where cables are installed in trunking, they shall be grouped in their respective
circuits or services and taped or bound by means of nylon cable straps at one-meter
intervals for purpose of identification.
V Flexible Cables: The use and type of flexible cables or cords shall suit the applications.
W Cables shall be butyl, silicone, PVC or impregnated glass fiber insulated as required
for the particular application. The cables shall be suitably sized, with a rating not less
than the protective device of the particular circuit, unless exempted by the
Governing Standards and, shall not be less than 0.75 mm² with a voltage rating of
300/500 volts.
X Flexible cables and cores shall be used for pendant luminaires, adjustable lamps,
portable appliances and certain items of special equipment such as air conditioning
terminal units.
Y The cables shall have the correct number of cores necessary for the particular
application and a strain cord shall be included where necessary to obviate any excess
weight being carried on the conductors. The grounding conductors shall be of
sufficient length to ensure that undue stress is not placed upon it.
Z No flexible cable, other than that enclosed in conduits, shall be in excess of two
meters in length.
AA Heat Resistant Cables: Where indicated, flexible cables for use with heating
appliances or luminaires shall be heat resistant of at least 105°C.
BB Cable Support Systems: For above ground installations the method of fixing
PVC/XLPE insulated and PVC sheathed cables shall be either laid on cable trays or
ladder rack or clipped to the building structure by suitable cable clamp. All single
core unsheathed cables shall be run in a non-metal conduit or trunking system.
CC Fasteners: Cable clamps shall be of either non-ferrous metal, or plastic material,

claw or split clamp type suitable for the size and type of cable and shall be so
selected so that all clamps can be tightened down without exerting undue pressure
or strain on the cables.
DD In the case of vertical cables, the clamps shall be so designed and of sufficient
number to grip the cable firmly to prevent creeping. No cable runs shall be without
fittings. All cable hangers and racks shall be submitted for inspection by the Owner’s
Representative prior to the installation of cables. Where cable routes are subject to
numerous changes in level and direction additional cable hangers shall be provided.
PART 3 EXECUTION
3.1 INSPECTION
A. The outside of each cable reel shall be carefully inspected and protruding nails, fas-
tenings, or other objects which might damage the cable shall be removed. A thor-
ough visual inspection for flaws, breaks, or abrasions in the cable sheath shall be
made as the cable leaves the reel, and the pulling speed shall be slow enough to
permit this inspection. Damage to the sheath or finish of the cable shall be sufficient
cause for rejecting the cable. Cable damaged in any way during installation shall be
replaced by and at the expense of the Contractor.
3.2 PREPARATION
A. Cable Protection: Cables shall be carefully handled during installation to avoid dam-
age of any kind. They shall be unreeled or uncoiled slowly in order to prevent dam-
age to the insulation or sheath due to sudden bending. Repeated bending shall be
avoided. Sharp links shall be avoided in unreeling, uncoiling and pulling.
B. The pulling of cables into conduits or ducts shall be carried out with all possible care.
The cable reels or coils shall be positioned so that the cable may be trained into the
conduit or duct as directly as possible, with the minimum of changes of direction or
of bending. The cable end shall be provided with a suitable protector to guard
against damage to the insulation or sheath. Where several cables are contained in
one conduit or duct, all cables shall be pulled-in together.
C. The pulling tension shall not exceed the maximum tension as recommended by the
cable manufacturer.
D. Long lengths of cable shall be laid using an adequate number of drum jacks, rollers
and other handling accessories. Make-shift-arrangements will not be acceptable.
Care shall be taken to break the rotation of the reel and cables shall not be dragged
over loose earth, concrete or any surface detrimental to the insulation. Cables shall
not be stretched but shall be adequately supported on rollers or manhandled into
position.
E. Before cables are pulled through ducts, the ducts shall be checked for cleanliness and
smoothness. Where ducting is longer than two meters, a cable wire mesh cable
stocking shall be used to attach the cable to the draw-in rope.
F. The minimum bending radii shall be not less than that recommended but the cable
manufacturer and contra twisting shall be avoided.
G. Spacing between cables shall be suitable for the derating factors applied to the cable
installation design.
H. Cables shall be installed using the loop-in principle, unless otherwise specified no
straight through or tee joints will be permitted.
I. Cable Routing: The general route of all cables shall be indicated on the drawings
and/or as directed by the Owner’s Representative if there are no drawings. The Con-
tractor shall include for all deviations required by the building structure and other
services. The final routes of all cables shall be submitted to the Owner’s Representa-
tive before any work in connection with the cable installation is commenced.
J. Cable shall be installed with a minimum of 300 mm clearance of any equipment or

pipework including lagging associated with other services. Where this condition is or
difficult to maintain, the Owner’s Representative consent shall be obtained prior to
the installation being commenced.
K. Where cables are situated below floor level in sub-stations and switch rooms, they
shall be run either in formed concrete open ducts, PVC or under fire resisting access
flooring. No cables shall be buried directly in concrete flooring or foundations.
L. Where cables pass through holes in panels or other metalwork, they shall be pro-
tected by rubber grommets, compression glands or their equivalent.
M. Where cables are run vertically heavy gauge sheet metal guards shall be supplied and
fixed where there is a possibility that the cable could sustain mechanical damage.
N. Single-core conductors or cables in metal conduits shall not be used.
O. Before commencing any part of the works, the Contractor shall submit for engineer
study and approval, drawings indicating conduit, trunking, ladders, trays and duct
sizes together with the proposed layout of the system.
P. Whenever cables have to pass through walls or slabs, special fire insulation should be
applied. The insulation shall have the same fire class as the wall or slab penetration.
Q. Both high, medium, low voltage and intrinsically safe cables shall be on separate ca-
ble runs.
R. All cable runs shall have minimum 30% spare space after all cables is installed.
S. Cable runs, supports and all its splices shall be conductive and be well earthed.
T. The main runs for cables between buildings shall be on the edge of the road, outside
the water ditch. If cables have to cross roads or concrete covers the cables must be
run in a drained cast ditch of concrete. The ditch must have covers that are to move.
U. Segregation: Cables of different voltages and duties shall be segregated and particu-
lar attention shall be paid to the avoidance of induced 'spikes' or ' electrical noise' on
adjacent circuits due to high currents and/or switches surges.
V. Grounding: All metal work which cannot be insulated as defined in the Governing
Standards and is associated with cable runs shall be bonded to earth or to the cable
armoring where this latter methods is approved.
W. Where steel tape armored cables are specified and the resistance of the armoring is
unsatisfactory, a supplementary earth (ground) cable shall be run with the affected
cable. This cable shall be sized to ensure compliance with the wiring regulations for
earthing.
3.3 INSTALLATION
A. Cable Installation: Cable shall be installed in accordance with IEC standards and local
code.
B. If single core cables are used they must not be installed separately through openings
of magnetic materials. They must be installed in 3 phase grouping to avoid current
heating”.
C. Cables for intrinsically safe circuits shall be routed on separate cable ladder or trays
or separated clearly from other cables. The tray shall be marked with a light blue
color.
D. Cable entries into all equipment shall be from below. When an entry has to be hori-
zontal a drip loop shall be performed in the cable immediately behind the cable
gland. Entries from above shall be avoided if possible, except for distribution board
in electrical rooms, top entry is allowed.
E. Cables shall not be buried in solid or hard setting building finishes unless prior ap-
proval has been given by the Owner’s Representative. The Contractor shall ensure
that cables when run in building finishes are immediately protected against mechani-
cal or any other damage. The Contractor shall also be in attendance when finishes
are applied and shall ensure that no damage or displacement occurs.
F. Cables shall be installed parallel to the building lines and shall not be run diagonally
in floor or ceiling finishes.
G. Single cable passing through walls and floors shall be protected by means of tubular
PVC or steel sleeves of sufficient size to give minimum 13 mm clearance all round the
cable. Sleeves passing through floors shall extend above the floor level a minimum
of 40 mm.
H. Where passing through walls the sleeve shall finish flush with the finished surface.
All sleeves shall be tightly packed with suitable fire resistant materials of an approved
type. All cables rising from floor level to equipment or in other locations where acci-
dental damage may occur shall be protected.
I. Cables shall be straightened and dressed neatly on the runs by approved methods.
All bends shall have an inside radius of not less than that recommended by the cable
manufacturer and in no case shall it be smaller than the bending radii shown in the
appropriate standards.
J. Where multi-runs of cables occur they shall be fixed to cable trays.
K. Cables shall be tagged at both ends, inside each panel, and every 15 m of the run.
Tag shall be metal type and shall read both the cable size and the target panels or
loads (From/To).

L. Megger conductor phase-to-phase and phase-to-ground for continuation and insula-
tion tests before connecting the utilization devices for 100% feeders, branch circuit
and motor circuit.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP GROUNDING AND BONDING FOR
CAIRO - EGYPT ELECTRICAL SYSTEMS 260526- 2874 0

CONTENTS
SECTION 260526
GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS
Page
PART 1 - GENERAL 2
1.2 Summary 2
1.3 Definitions 2
1.4 Submittals 3
PART 2 - PRODUCTS 5
2.1 Conductors 5
2.2 Connectors And Earthing Accessories 6
2.3 Earthing Electrodes 6
2.4 Soil Survey And Calculations 7
2.5 Fault Current And Duration 8
2.6 System Design 8
PART 3 - EXECUTION 12
3.1 Applications 12
3.2 Equipment Grounding 12
3.3 Installation 14
3.4 Connections 16
Grounding and Bonding For Electrical Systems Section 260526

SECTION 260526 - GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
B. The following Sections include requirements which relate to this section:
1. Division 26 Section "Ring Main Unit "

2. Division 26 Section "Switchboards "
3. Division 26 Section "Panelboards "
4. Division 26 Section "Motor Control Center "
5. Division 26 Section “Low Voltage Electrical Power Conductors and Cables".
6. Division 26 Section “Uninterrupted Power Supply"
7. Division 26 Section “Raceways and Boxes for Electrical Systems”
8. Division 26 Section “Engine Generator”
1.2 SUMMARY
A. This Section includes complete installations to earth every source of energy and to
provide protective earthing and equipotential bonding, based on the TN-S system ar-
rangement, including:
1. Ring Main Unit

2. LV Switchboards and Panelboards.
3. Main earthing terminals or bars in electrical, UPS, mechanical rooms, etc.
4. Exposed conductive parts of electrical equipment (light fittings, switches and
socket outlets, etc.).
5. Extraneous conductive parts (transformers, generators, Switchboards, motors,
etc.)
6. Transformer Neutral earthing.
7. Generator neutral earthing.
8. Building main ring system of electrodes and conductors.
9. Separate clean earth for the Telecommunication and security systems and con-
trol room (0.5 ohm).
B. Earthing requirements specified in this Section may be supplemented by special re-

quirements of systems described in other Sections.
C. In addition to, the common ground bonding for lightning protection system.
1.3 DEFINITIONS
A. The words "earth" and "earthing" as used herein are synonymous with the words
"ground" and "grounding" and may be used interchangeably within this specification.

B. The words "ground ring" as used herein is synonymous with the words "ground loop"
and may be used interchangeably within this specification.
C. Earth: Conductive mass of the Earth whose electric potential at any point is conven-
tionally taken as zero.
D. Earth Electrode: Conductor or group of conductors in initial contact with, and provid-
ing electrical connection to, Earth.
E. Exposed Conductive Part: Any part which can be readily touched and which is not a
live part, but which may become live under fault conditions.
F. Extraneous Conductive Part: Any conductive part not forming part of the electrical in-
stallation such as structural metalwork of a building, metallic gas pipes, water pipes,
heating tubes etc. and non-electrical apparatus electrically connected to them i.e. ra-
diators, cooking ranges, metal sinks etc. and non-insulating floors and walls.
G. Protective Conductor: Conductor used for some measure of protection against elec-
tric shock and intended for connecting together any of the following parts:
1. Exposed conductive parts.

2. Extraneous conductive parts.
3. Earth electrode(s).
4. Main earthing terminal or bar(s).
5. Earthed point of the source(s).
H. Main Earthing Terminal or Bar: The terminal or bar provided for the connection of
protective conductors, including equipotential bonding and functional earthing con-
ductors if any to the means of earthing.
I. Equipotential Bonding: Electrical connection to put exposed and extraneous conduc-

tive parts at a substantially equal potential.
J. Earthing Conductor: Protective conductor connecting main earthing terminal or bar
of an installation to earth electrode or to other means of earthing.
1.4 SUBMITTALS
A. Product Data and Sample: Submit for each type of product indicated including manu-
facturer’s catalogue sheets with catalogue numbers marked for the items furnished,
which shall include:
1. Exothermal welding materials, kits and tools.

2. Terminal lugs, clamps, etc.
3. Copper ground cable.
4. Ground rods, test pits, etc.
5. Earthing conductors, protective conductors, and bonding conductors.
6. Connectors and other accessories.
7. Samples of conductors, or any other accessories as requested by the Engineer.
B. Qualification data for firms and persons specified in "Quality Assurance" Article to
demonstrate their capabilities and experience. Include lists of completed projects

with project names and its locations, Engineer/Consultant and Owner. The firm
should have at least two years of success full installation experience.
C. Field inspection reports indicating compliance with specified requirement and submit
written test reports to include the following:
1. Test procedures used and test conditions (Method statements for testing of
the earthing system for each building/structure and the measurement of soil
resistivity).
2. Test results that comply with requirements.
3. Results of failed tests and corrective action taken to achieve test results that
comply with requirements.
D. Calculations: Grounding calculations detailed enough to reach the required overall

earthing resistance. However, the final test report results after installation shall re-
main the effective proof of reaching the requested earthing resistance value.
E. Shop Drawings: Submit drawings for approval including, but not limited to, the fol-
lowing:
1. Manufacturer's Instruction for Grounding system.

2. Exact location of earth pits, rods and details of installation and connections.
3. Exact routing of buried earthing conductors with indication of cross-section,
depth of laying and covering.
4. Cross sectional area of all earthing, protective and bonding conductors.
5. Layout and details of earthing provisions at substations, generator rooms,
switchgear, distribution panel-boards etc., indicating fittings used, insulation,
plates, passage and routing of earthing conductors, conduit, sleeves, grooves,
niches etc., giving sizes and dimensions of component parts.
F. As-Built Drawings: Scaled drawings, showing actual layout and specification of all
components of earthing system include the number of rods driven and their depths
at each location, indicate nature of soil, special earthing arrangements, date and par-
ticulars of additives to soil or in bore-holes if used, test conditions such as weather
and other phenomena that may effect on the tests and results obtained.
G. Compliance Sheet: Contractor to fill-in the compliance data sheet (when attached to
a section) and stamp it by the proposed supplier and by the proposed electrical sub-
contractor (or himself if no sub-contractor). If the Contractor is assuming two suppli-
ers for one material item in his bid, two data sheets should then be filled and
stamped, as mentioned, for the same item.
H. Operation and Maintenance Data: For grounding to include the following in emer-
gency, operation, and maintenance manuals:
1. Instructions for periodic testing and inspection of grounding features at inspec-

tion pits.
a. Tests shall be to determine if ground resistance values remain within

specified maximums, and instructions shall recommend corrective action
if they do not.
b. Include recommended testing intervals.

A. Installer Qualifications: Engage an experienced installer who has specialized in in-

stalling earthing and bonding systems similar in material, design and extent to those
indicated for this project and whose work has resulted in installations with a record
of successful in service performance.
B. Standards: Except as modified or supplemented herein, all materials required in this

section including their installation shall conform to the applicable requirements of
the following standards. Standards current at the time of tender shall be used.
1. International Electro-Technical Commission-IEC.

2. British Standard-BS.
3. American Welding Society (AWS) - AWS A5.8/A5.8M Specification for Filler
Metals for Brazing and Brazed Welding.
4. US Department of Defense (DOD) - MIL-STD-889 Dissimilar Metals.
5. Local Codes and Regulations.
PART 2 - PRODUCTS
2.1 CONDUCTORS
A. Insulated Conductors: Copper wire or cable PVC insulated in green and/or green-
yellow color for 380 V unless otherwise required by applicable Code and indicated on
the drawings.
B. Bare Copper Conductors:
1. Stranded Conductors: Soft drawn annealed bare copper with 98% conductivity
and shall conform ASTM B3 and/or BS EN 60228 and/or IEC 60228.The cross
section shall be 120 mm2 unless otherwise indicated on the drawings.
2. Flexible braided cable strap: Copper, 250 mm by 35 mm thick ground post
clamps. Clamps shall be of the anti-electrolysis type.
3. Grounding plates: Copper, minimum 600 mm by 600 mm by 3 mm thick.
C. All conductor fittings shall be manufactured from high strength copper alloys with
phosphor bronze nuts, bolts, washers and screws. All fittings shall be designed for the
specific application and shall not be permanently deformed when correctly installed.
D. Protective Bonding Conductors: Bare copper strip conductor, annealed stranded cop-
per cable or flexible strap (flexible braid) of cross-sectional area as mentioned in item
2.7 (b)-12.
E. Exothermic welds: Molds, cartridges, materials and accessories as recommended by

the manufacturer of the molds for items to be welded. Molds and powder shall be
furnished by the same Manufacturer.

2.2 CONNECTORS AND EARTHING ACCESSORIES
A. Copper or copper alloy, of approved design, compatible with points of connection,

and of adequate cross-section and current carrying capacity.
B. Connections to metallic structures for earthing conductors and bonding conductors

between electrically separate parts of a structure shall be either by direct exothermic
welding or by bolting using a stud welded to the structure. Drilling of a structural
member for a directly bolted connection shall only be carried out to the approval of
the Engineer.
1. Bolted Connectors and Clamps: Bolted-pressure-type or compression type

connectors and clamps. Bolts, nuts and washers are to be high quality phos-
phor bronze or copper silicon alloys. Bolted connections are not permitted in
run of the earthing conductors unless approved by the Engineer.
2. Welded Connectors: Exothermic-welded type, in kit forms, and selected per
manufacturer's written instructions. Welded connectors are to be used only in
inaccessible locations and at “T” joints and it shall be subject to the approval of
the Engineer.
C. Bi-metallic connectors shall be used between conductors of dissimilar materials and

insulating material shall be interposed between metallic fittings and structures of dis-
similar materials to prevent corrosion.
D. When the reinforcing in concrete is used as a part of the earthing system the fittings
used to provide a connection point at the surface of the concrete shall be exothermi-
cally welded to a reinforcing bar. This fitting shall be provided with a bolted connec-
tion for an earthing conductor. The main bars in the reinforcing shall be welded to-
gether at intervals to ensure electrical continuity throughout the reinforcing.
E. No connections shall be made to reinforcing bars and other steelwork, which do not
form part of the earthing system and are completely encased in concrete.
2.3 EARTHING ELECTRODES
A. Earth Electrode: The earth electrodes shall comprise a system of bare conductors
forming a loop/ring buried near the surface of the ground supplemented, by one or
more of the following electrodes:
1. A system of interconnected copper-clad steel rods driven into the ground.

2. Structural steel metalwork in direct contact with the ground.
3. Reinforcing steel in buried concrete.
B. Ground/Earth Rods: Copper-clad steel rods and shall not less than 20mm in diameter
by not less than 3000 mm in length per section and shall conform to the require-
ments of NFPA 70 and UL 467 and/or BS. Ground rods must be clean and smooth and
have a cone-shaped point on the first section and be die-stamped near the top.
C. Reinforcing Steel:
1. The reinforcing steel in the foundations of buildings containing the primary

electrical equipment may be used as auxiliary electrodes subject to the ap-
proval of the Engineer. The Contractor shall show in the design calculations
that the fault currents and D.C stray currents will not damage the structure.
2. Steel reinforcing mesh in the floors of the building may also be used for the
control of step and touch potentials within the building subject to the approval
of the Engineer.
D. Earth Pit: Precast, square or circular section concrete hand-hole (minimum 450 mm
internal diameter), with concrete cover, with ultra-heavy-duty cover for areas where
heavy vehicles cross and extending to about 150 mm below top of earth rod. Earth
pit is to be provided for each earth rod where connected to an earthing conductor.
Cover is to have inset brass plate with inscription 'Earth Pit No. # & Earth pit ID - Do
Not Remove'.
E. Earth pit with Sealing Kit: shall be installed within the building itself. The pit shall be
provided with a suitable sealing mechanism around the earth electrode.
The pit shall be of high performance lightweight polymer, corrosion resistance pres-
sure tested, compliant to BS EN 62305-3 standard and tested according to BS EN
50164-5. The sealing mechanism shall consist of high density polyethylene molding
flange and housing to accommodate the sealing kit and protective tube for the earth
rod.
F. Power Systems (transformer, medium voltage switchgear, generator, and main dis-
tribution board) Main Earthing Bar: Consisting of hard drawn annealed copper bar
conforming to ASTM B3, 50 x 6 mm. Earth bar is to be labeled 'Main Earth Bar' and is
to be drilled, for connection of conductors, at a spacing not less than 75 mm, and is
to be supplied with copper alloy bolts, nuts and washers and wall mounting insula-
tors.
G. Telecommunication Systems Main Earthing Bar: similar to above but with minimum
dimensions 100 x 6 mm for the main grounding busbar of the main telecommunica-
tion room, and 50 x6 mm for equipment rooms grounding busbars.
H. Disconnecting links shall comprise a high conductivity copper PVC insulated link sup-
ported on two insulators mounted on a galvanized steel base for bolting to the sup-
porting structure. The two conductors shall be in direct contact with the link and shall
not be disturbed by the removal of the link. Links for mounting at ground level shall
be mounted on bolts embedded in a concrete base.
I. Disconnecting links mounted at ground level and the connections at the earth rods
shall be enclosed in concrete inspection pits, with concrete lids, installed flush with
the ground level.
J. Testing joints (Test links): Copper or copper alloy, with bolted end connections, dis-
connect able by use of a tool, and suitably sized for earthing conductors or earth bar
connection. Links are to be fixed to porcelain or other approved insulating supports.
Contact surfaces are to be tinned.
2.4 SOIL SURVEY AND CALCULATIONS
A. The Contractor shall carry out an earth resistivity survey on each site and report in

writing to the Engineer in accordance with the approved program. The report shall
detail the methods and instruments used and the results of the surveys. Based on the
results the Contractor shall include in the report his proposals for the resistivity’s to
be used in the design of the earthing system.
B. The value of resistivity’s to be used in the design of the earthing system shall be sub-
ject to the Engineer’s approval.
C. The surveys shall show the variation of resistivity across the site and with the depth
below the site. The Contractor shall consider if there is a need to model the resistivity
in two layers and if there is any advantage in the use of long rods. The surveys shall
also determine the depth and nature of any underlying rock, which may limit the
depth for driving earth rods or if boring will be necessary for installing earth rods.
D. The weather conditions prior to and at the time of the surveys shall be recorded in
the report and an assessment made of the seasonal variations in resistivity based on
meteorological data for the area. The program for the project should, as far as possi-
ble, time the resistivity surveys to take place during a dry season.
E. The report should also state if there are any indications that the ground is corrosive
to copper or if there is any risk of galvanic corrosion on other metal structures in the
neighborhood.
F. The report shall be approved by the Engineer before proceeding with the design of
the earthing system.
G. The calculations shall be submitted for approval prior to commencing the design of
the earthing systems.
2.5 FAULT CURRENT AND DURATION
A. The earthing system design calculation by the Contractor shall be based on earth
fault withstand current.
B. The estimated maximum duration of the fault current shall not be less than 1.0 sec-
onds for the 11 KV system.
2.6 SYSTEM DESIGN
A. Design Calculations:
1. The design of the earth electrode systems shall be based on the approved
earth resistivity data and the system’s fault currents and their duration.
2. The design calculations shall be submitted to the approval of the Engineer and
shall be based on the methods given in the standards listed. The calculations
shall include the following parameters: -
a. Earth resistance of the whole system and its components.

b. Earth potential rise.
c. Step, touch and mesh potentials inside and outside the perimeter

fence.
d. Requirements for a high resistance surface layer.
e. Conductor ratings.
f. Step, touch and mesh potentials shall be within the limits calculat-
ed in accordance with the standards given in IEEE 80 and BS 7430
for the proposed surface layer. The formula for allowable body cur-
rent shall be used for 50 Kg body weight.
B. General Requirements
1. Component parts of earthing system are to include the following:
a. Earth electrode (rods, tapes etc.)

b. Main earthing terminals or bars.
c. Earthing conductors.
d. Protective conductors.
e. Equipotential bonding conductors.
f. Electrically independent earth electrodes for special systems.
g. Accessories and termination fittings, bonding, welding kits and
other materials.
2. Provide a common earth termination network for all services, consisting of
bonding earthing networks of all individual services. The resistance to earth
should, in this case be the lowest value needed for any of the individual ser-
vices.
3. Ground Electrode: Provide one or a combination of the following arrange-
ments as necessary
a. Earth electrode is to consist of one or more earth rods, intercon-

nected by buried earthing tape or cable; distance between two
rods is not to be less than twice the length of one rod driven
depth.
b. Loop/Ring type earth electrode consisting of earthing conductors,
in a closed loop, buried in exterior wall foundations underneath
the water-proofing, or alternatively buried at a depth of 600 mm
and a distance of about 100 mm around external walls. Connect all
earthing conductors to this ring. Additional earth rods connecting
with the earth ring are to be provided, as necessary, to bring down
earth electrode resistance to the specified value.
c. Functional earth electrode is to be provided separately from, but
interconnected to, other earth electrode(s) through suitably rated
(470 V) spark gap. Functional earth electrodes are to be used for
earthing electronic equipment (communication equipment, digital
processors, computers etc.) as required by the particular Section of
the Specification and recommendation of the manufacturer.
4. Main earthing bar is to be provided at point of service entrance or medium

voltage, transformer, generator, low voltage, low current, and mechanical dis-
tribution rooms; as described in the Specification. Connect all earthing conduc-
tors, protective conductors and bonding conductors to the main earthing bar.
Provide two insulated main earthing conductors, one at each end of the bar,
connected via testing joints to the earth electrode at two separate earth pits.

Conductor is to be sized to carry maximum earth fault current of system at
point of application with final conductor temperature not exceeding 160 deg. C
for at 1 second for medium voltage systems and 0.4 seconds for low voltage
systems. Main earthing conductors’ sizes are to be minimum 120 mm2.
5. The main earth bar shall be in the form of a ring or rings of bare conductors
surrounding
or within an area in which items to be earthed are located. Where 2 or more
rings are installed they shall be interconnected by at least two conductors,
which shall be widely separated.
6. Testing joints (test links) are to be provided, in an accessible position, on each
main earthing conductor, between earthing terminal or bar and earth elec-
trode.
7. Protective conductors are to be separate for each circuit. Where protective
conductor is common to several circuits, cross-sectional area of protective
conductor is to be the largest of the conductor sizes. Selection of sizes is to be
in accordance with IEE Wiring Regulations (BS 7671).
8. Protective conductors are not to be formed by conduit, trunking, ducting or
the like. Where armored cable is specified and armor is steel, it may be used as
a protective conductor, if approved by the Engineer.
9. Continuity of Protective Conductors: Series connection of protective conductor
from one piece of equipment to another is not permitted. Extraneous and ex-
posed conductive parts of equipment are not to be used as protective conduc-
tors, but are to be connected by bolted clamp type connectors and/or brazing
to continuous protective conductors which are to be insulated by molded ma-
terials. Conductor sheaths shall be of yellow-green colored PVC to meet the
requirements of BS 6004 or IEC 60502-1 Grade ST1 with a minimum thickness
of 1.5 mm.
10. Ensure by calculation that Earth Fault Loop Impedance values for final circuits
are to satisfy the requirements of BS 7671 regulations.
11. Earth Fault Loop Impedance: For final circuits supplying socket outlets, earth
fault impedance at every socket outlet is to be such that disconnection of pro-
tective device on over-current occurs within 0.4 seconds. For final circuits sup-
plying only fixed equipment, earth fault loop impedance at every point of utili-
zation is to be such that disconnection occurs within 1 second.
12. Supplementary Equipotential Bonding: Connect all extraneous conductive
parts of the building such as metallic water pipes, drain pipes, other service
pipes and ducting, metallic conduit and raceways, cable trays and cable armor
to nearest earthing terminals by equipotential bonding conductors. Cross-
section of protective bonding conductor shall not be less than half of the pro-
tective conductor connected to respective earthing terminal with a minimum
of 4-mm2.
a. Individual components of metallic structures of plant shall be

bonded to adjacent components to form an electrically continuous
metallic path to the bonding conductor.
b. Small electrically isolated metallic components mounted on non-
conducting building fabric need not be bonded to the main earth
bar.
c. Bolted joints in metallic structures including pipework, which do
not provide direct metallic contact shall be bridged by a bonding
conductor or both sides of the joint shall be separately bonded to

earth unless the joint is intended to be an insulated joint for ca-
thodic protection or other purposes.
13. Main Equipotential Bonding: Main incoming and outgoing water pipes and any
other metallic service pipes are to be connected by main equipotential bond-
ing conductors to main earth terminal or bar. Bonding connections are to be as
short as practicable between point of entry/exit of services and main earthing
bar. Where meters are installed, bonding is to be made on the premise side of
the meter. Cross-sections of conductors are not to be less than half that of the
earthing conductor connected thereto, and minimum 6 mm2.
14. Identification: Connection of every earthing conductor to earthing electrode
and every bonding conductor to extraneous conducting parts is to be labeled in
accordance with the Regulations, as follows:
a. Safety Electrical Connection - Do Not Remove.
15. Identification: Protective and earthing conductors are to be identified by com-

bination of green-and-yellow colors of insulation or by painting bar conductors
with these colors, as approved.
16. Exposed external earth / grounding conductor connection joints are to be pro-
tected from corrosion with grease caps or bituminous tape or approved equal.
17. In general earthing conductor connections to structures, connections within
the lightning protection system conductors, are to be exothermic copper-weld
type unless stated otherwise.
18. Ground wires for equipment receptacles for noncurrent carrying hardware, in-
stalled in conduit must be soft drawn copper, in accordance with ASTM B 3,
stranded, with green insulation.
19. Grounding and bonding fasteners and connectors must conform to the re-
quirements of UL 467, and Section 26 27 26 “WIRING DEVICES”.
20. Grounding and bonding fasteners must be copper/bronze.
21. Bonding straps and jumpers for shock-mounted devices with pivot, hinged &
swivel joints must be made of flat tinned-copper woven-wire braid flexible
stranded wire.
C. Patient Care Areas Requirements
1. Patient care areas shall be provided with retardant ground (earthing) path. Re-
tardant ground paths will be provided via equipment ground conductors and
raceway systems.
2. The equipment ground busses in different panel-boards serving the same pa-
tient care areas will be bonded together.
3. Provide an equipotential grounding system in each operating room. All metal
objects likely to become energized in the OR room shall be grounded via a ded-
icated, insulated grounding conductor to the room ground bus.
4. Room ground bus shall consist of an isolated ground bar mounted in a re-
cessed metal junction box with stainless steel cover
5. Each patient room shall include two Patient Equipment Grounding Points on
both sides of bed installed in the bed head unit. Each Patient Equipment
Grounding Point shall include one grounding jack.

PART 3 - EXECUTION
3.1 APPLICATIONS
A. Conductors: Install solid conductor for 10mm2 and smaller, and stranded conductors
for 16 mm2 and larger, unless otherwise indicated on the drawings.
B. Underground Grounding Conductors: Install bare copper conductor, 120mm2 mini-

mum unless otherwise indicated on the drawings.
1. Bury at least 600 mm below grade at a distance not less than 1000mm and not
more than 3000 mm from the edge of walkways and not more than three me-
ters from the structure.
2. Duct-Bank Grounding Conductor: Bury 300 mm above duct bank when indi-
cated as part of duct-bank installation.
C. Isolated Grounding Conductors: Green-colored insulation with continuous yellow

stripe. On feeders with isolated ground, identify grounding conductor where visible
to normal inspection, with alternating bands of green and yellow tape, with at least
three bands of green and two bands of yellow.
D. Grounding Resistance: The completed installation when a ground loop is not used
shall have a maximum total resistance to ground using the fall-of-potential method
described in IEEE 81 or equivalent method as per BS and/or IEC of 5 ohms, under
normally dry conditions. Use a ground loop when two of any three (3) ground rods,
driven not less than three meters into the ground, a minimum of three meters apart
and equally spaced around the perimeter, give a combined value exceeding 50 ohms
immediately after having been driven.
E. Unless indicated otherwise on drawings and/or as a special requirement, maximum

grounding resistance values shall be as follows
1. Secondary distribution systems (Neutral) and non-current carrying metal parts
and enclosures associated with Secondary distribution system: 2 ohms.
2. Clean earthing for electronic equipment: 0.5 ohm.
F. Make connections between ground conductors and grounds or ground loop and be-
tween ground loop and grounds electrically continuous. Where so indicated, provide
an alternate method for grounding electrodes in shallow soil by digging trenches ra-
dially from the building. A 120 mm2 bare copper cable (or as shown on the drawings)
arranged in a star pattern with the structure at the center for radial systems shall be
installed.
3.2 EQUIPMENT GROUNDING
A. Transformer Substation Earthing
1. Ring Main Unit is to have a separate main earthing bar connected to RMU
room earth bar by two insulated earthing conductors, one at each end of bar,
via testing joints. Earthing Conductors is to be minimum not less than 120mm2

(unless otherwise indicated on the drawings) for each switchgear.
2. LV switchgear (main distribution board) is to have separate main earthing bar
connected to LV room earth bar by two insulated earthing conductors not less
than 120 mm2 (unless otherwise indicated on the drawings), via testing joints.
3. Transformer room is to have a separate MV main earthing bar, to which the
transformer
body earthing terminal is to be connected by insulated copper earthing con-
ductor not less than 120mm2(unless otherwise indicated on the drawings).
4. Transformer neutral (star point) is to be connected by insulated earthing con-
ductor (color black) to transformer room LV main earthing bar. Where a neu-
tral is directly connected to earth electrode, an insulated disconnecting device
is to be provided at the transformer. Neutral earthing conductor is to be sized
for maximum earth fault current for 1 second with final conductor tempera-
ture not exceeding 160 deg. C or sized not less than 120 mm2 for transformer
ratings below 500 kVA and 300 mm2 for higher ratings up to 2500kVA.
B. Earthing of Main Distribution Boards, Panelboards, Lighting Installations And Wiring

Accessories
1. For earthing of main distribution boards, refer to item 3.2.(A)-2

2. Distribution, lighting and power panel boards are to be connected by protec-
tive conductors run together with incoming feeder cable, connecting earth
terminals in panel boards with respective main distribution board earthing bar.
3. Socket outlets are to be earthed by protective conductor looped around with
the branch circuit and connected to earth terminal within socket outlet box
and to which socket outlet terminal is to be connected.
4. Lighting fixtures and other exposed conductive parts of electrical installations,
such as switches, heaters, air conditioning units, etc. are to be connected by
protective earth conductors to earthing terminals of respective panel boards.
C. Generator Plant Earthing
1. Generator room is to have a separate main earthing bar, to which the genera-
tor neutral (star point) is to be connected by insulated earthing conductor
through the neutral earthing link or device. Neutral earthing conductor is to be
suitably sized to carry maximum earth fault current for time it takes the system
protection to operate with final conductor temperature not exceeding 160
deg. C, but not less than 120 mm2 for LV generator ratings below 500 kVA and
300 mm2 for higher LV generators’ ratings.
2. Generator earthing terminal is to be connected to the generator room main
earthing bar by insulated copper conductor of cross section not less than 120
mm2 unless otherwise indicated on the drawings.
3. Automatic Transfer Switch (ATS) and Control Gear: Earthing terminals or bars
of switchgear and control gear are to be connected by separate protective
conductors to respective normal and emergency main distribution board earth
bars.
4. Extraneous conductive parts including steel frames, battery racks, day-tank,
pumps and piping are to be connected by bare copper earthing conductors to
main earth bar in compliance with bonding regulations.
D. Electrical / Mechanical Plant Rooms and Fixed Machinery

1. Electrical / Mechanical room is to have separate earthing bar(s) or loop con-
veniently located, and connected by earthing conductors to exposed conduc-
tive parts of motor control center at its earthing bar, and to motors, switches
and other electrical equipment etc. at their earthing terminals, using copper
conductor with half size of the protective earth conductor and not less than 6
mm2.Conductors are to be securely fixed, recessed in floor grooves or niches,
or fixed to walls by appropriate staples. Earth bar or loop is to be securely fixed
to building wall with copper or brass saddles.
2. Earthing bar is to be connected by two insulated earthing conductors, one at
each end of the bar, through testing joints to the earth electrode at two sepa-
rate earth pits, or to the main LV earth bar.
3. Motor and other equipment earth terminals are to be connected also by pro-
tective earth conductors of each branch circuit to earth terminal/bar at motor
control center, panel or distribution unit.
E. Road Lighting
1. Earthing Cables: separate protective earthing cables for lighting column circuits
are to be run with power circuit, terminated at LV supply position in lighting
control panel and looped into column earthing terminals. The last column is to
be bonded via an earthing bolt to a single 16 mm diameter copper covered
steel rod, 2.4 m long, driven into ground adjacent to column. Bonding is to be
16 mm2 stranded bare copper conductor.
2. Connections between rods and earthing conductors are to be made by the cad
weld process producing a fused joint. Bolted connections may be used for con-
nection to removable items of equipment only.
F. Clean Earth Grounding
1. Clean earth grounding or low noise earth shall be provided as required, to en-
sure that the level of induced or conducted interference from external sources,
including the facility power grounding system, does not produce incidence of
malfunction of the equipment, which is unacceptable for the operating system.
2. Clean earth grounding system shall not be connected to any other earthing or
grounding system.
3. Clean earth grounding cables shall not be run parallel with other grounding ca-
bles or power cables.
4. Clean earth grounding system shall comply with IEC 60950 and BS EN 50310.
5. Clean earth grounding pits shall be separated from other earthing pits by a dis-
tance of at least 1800mm.
6. In general clean earth grounding shall be provided for data system, telephony
and other communication systems, and UPS unless otherwise recommended
and required by systems providers.
7. Clean earth grounds shall have an earth impedance of less than 0.5 ohm unless
otherwise indicated.
3.3 INSTALLATION
A. Coordination: All works below grade shall be thoroughly coordinated with all under-
ground services and structures. Grounding and bonding works must, in all circum-

stances prevent any dissimilar metal contact that will cause galvanic corrosion.
Bonding shall be made only after thorough inspection of metal parts to be bonded.
Grounding conductors shall be run with all three phase feeders, and all single and
three phase branch circuits.
B. Continuity: Ensure that complete earthing system is electrically continuous and me-
chanically secure.
C. Grounding Conductors: Route along shortest and straightest paths possible, unless
otherwise indicated or required by Code. Avoid obstructing access or placing con-
ductors where they may be subjected to strain, impact, or damage.
D. Common Ground Bonding with Lightning Protection System: Comply with code when
interconnecting with lightning protection system. Bond electrical power system
ground directly to lightning protection system grounding conductor at closest point
to electrical service grounding electrode. Use bonding conductor sized same as sys-
tem grounding electrode conductor, and install in conduit.
E. Ground Rods: Drive rods until tops are 50 mm below finished floor or final grade, un-
less otherwise indicated.
1. Interconnect ground rods with grounding electrode conductor below grade.

Make connections without exposing steel or damaging coating, if any.
2. For grounding electrode system, install at least three rods spaced at least three
meters apart from each other and located at least the same distance from oth-
er grounding electrodes, and connect to the service grounding electrode con-
ductor or as indicated on the drawings.
3. While sitting earth rods, ensure that resistance areas associated with individual
rods do not overlap. Earth rods are to be located at a distance greater than 1 m
horizontally from foundations of buildings. Where rock is encountered, a hole
of sufficient size is to be drilled before lowering the rod. Conductive filler will
not corrode is to be provided around the rod.
4. The rods shall be installed by driving into the ground with a power hammer of
suitable design to ensure the minimum of distortion to the rod. Where it is not
possible to drive rods to the full depth required due to the presence of a stra-
tum of rock, and then holes shall be drilled or blasted in the rock. The holes
shall be filled with bentonite or other approved material prior to inserting the
rod.
5. Spacing between earth rods shall not be less than that stipulated by the IEC.
F. Test Pits: Install at least one test pit for each service, unless otherwise indicated on
the drawings. Set top of test pit flush with finished grade or floor.
G. Bonding Straps and Jumpers: Install in locations accessible for inspection and
maintenance, except where routed through short lengths of conduit.
1. Bonding to Structure: Bond straps directly to basic structure, taking care not to
penetrate any adjacent parts.
2. Bonding to Equipment Mounted on Vibration Isolation Hangers and Supports:
Install so vibration is not transmitted to rigidly mounted equipment.
3. Use exothermic-welded connectors for outdoor locations, but if a disconnect-

type connection is required as per the project specifications, use a bolted
clamp.
H. Bonding shall be provided where necessary to assure electrical continuity and the ca-
pacity to conduct safely any fault current likely to be imposed. Non-current-carrying
metal parts of service equipment shall be effectively bonded together.
I. Conduits stubbed-up below a switchboard or motor control center shall be fitted

with insulated grounding bushings and connected with the equipment ground bus.
J. Care shall be taken to ensure good ground continuity, in particular between the con-
duit system and equipment frames and enclosures. Where necessary, jumper wires
shall be installed.
K. Grounding and Bonding for Piping:
1. Water Meter Piping: Use braided-type bonding jumpers to electrically bypass

water meters. Connect to pipe with a bolted connector.
2. Bond each aboveground portion of gas piping system downstream from
equipment shutoff valve.
L. Bonding Interior Metal Ducts: Bond metal air ducts to equipment grounding conduc-
tors of associated fans, blowers, electric heaters, and air cleaners. Install bonding
jumper to bond across flexible duct connections to achieve continuity.
M. Grounding for Steel Building Structure: Install a driven ground rod at base of each
corner column and at intermediate exterior columns at distances not more than 18 m
apart unless otherwise indicated on the drawings or required by the codes.
3.4 CONNECTIONS
A. Protection against Corrosion: Protect bolted connections against corrosion either by

filling with Vaseline or coating with a special anti-corrosion compound and proper
capping.
B. Earth connections are to be readily accessible. If inaccessible earth connection is

permitted, approved exothermic welding or brazing technique is to be employed.
C. Where earth connections between dissimilar metals must be made, use bimetallic fit-
tings and protect by coating with moisture resisting bituminous paint or compound,
or by wrapping with protective tape to exclude moisture.
D. Exothermic-Welded Connections: Comply with manufacturer's written instructions.
E. Tighten screws and bolts for grounding and bonding connectors and terminals ac-
cording to manufacturer's published torque-tightening values. If manufacturer's
torque values are not indicated, use those specified in applicable Standards.
F. Connection of earthing conductors to ground pit earth rods, shall utilize multiple
connectors as required. More than one cable shall not be connected through one
connector clamp unless specifically permitted.

A. Testing Agency: Owner or his representative will engage a qualified testing and in-
specting agency to perform field tests and inspections and prepare test reports.
B. Perform the following tests in addition to the tests required by IEC and/or BS and in-
spections and prepare test reports:
1. After installing grounding system but before permanent electrical circuits have
been energized, test for compliance with specifications and drawings require-
ments.
2. Test completed grounding system at each location where a maximum ground-
resistance level is specified, at service disconnect enclosure grounding termi-
nal. Make tests at ground rods before any conductors are connected.
a. Measure ground resistance not less than two full days after last
trace of precipitation and without soil being moistened by any
means other than natural drainage or seepage and without chemi-
cal treatment or other artificial means of reducing natural ground
resistance.
C. Report measured ground resistances that exceed the maximum ground resistance
value required.
D. Excessive Ground Resistance: If resistance to ground exceeds specified values, modi-

fy the grounding system to install and connect additional rods as directed by the En-
gineer until the required value is obtained.
E. Check the operation of residual current protective devices.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. RACEWAY AND BOXES FOR ELECTRICAL
CAIRO - EGYPT SYSTEMS 260533 – 2874 0

CONTENTS
SECTION 260533
RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Coordination 3
PART 2 PRODUCTS 3
2.1 Manufacturers 3
2.2 General 3
2.3 Application Considerations 3
2.4 Electrical Metalic Tubing 4
2.5 Flexible Metal Conduit 4
2.6 Rigid Heavy Gauge Pvc Conduit 4
2.7 Under Groung Upvc Conduits 5
2.8 Flexible Pvc Conduit 5
2.9 Steel Conduit Accessories 5
2.10 Wiring And Cable Trunking 6
2.11 Weatherproof Wiring And Cable Trunking 6
2.12 Outlet Boxes, General 7
2.13 Metallic Outlet Boxes 7
2.14 Moulded Plastic Outlet Boxes 7
2.15 Floor Outlet Box 8
PART 3 EXECUTION 8
3.1 Examination 8
3.2 Equipment Installation Requirements 8
3.3 Installation And Wiring 8
3.4 Outlet Boxes 10
3.5 Junction, Pull 11
3.6 Grounding And Bonding 11
3.7 Connections 11
3.8 Protection 11
3.9 Cleaning 12
Raceway and Boxes for Electrical Systems Section 260533

SECTION 260533 - RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS
PART 1 GENERAL
1.2 SUMMARY
A. This section covers raceways, fittings, boxes, enclosures, and cabinets for electrical
wiring:
1. Raceways include all types of conduits, trunking and duct bank systems, such
as Electrical Metal Tubing (EMT), Rigid PVC Conduit, Flexible Conduit, wire
ways, Surface Raceways, galvanized trunking, rigid PVC trunking, etc.
2. Boxes, enclosures, and cabinets include the following devices: floor boxes,
pulling and junction boxes, cabinets and hinged cover enclosures.
B. Related Sections include the following
1. Division 26 Section “Grounding and Bonding”.

2. Division 26 Section “Low Voltage Electrical Power Conductor and Cables”.
3. Division 26 Section “Medium Voltage Cable”
4. Division 26 Section “Cable Trays for Electrical Systems”.
5. Division 26 Section “Wiring Devices”.
1.3 SUBMITTALS
A. Material lists and equipment data.
B. Boxes, cabinets, conduits and duct assignments for application.
C. Shop Drawings showing components and wiring as to ensure clearances and access
provisions. Refer to cable sections (260513, 260519) for more details on cable laying,
segregation and bundling inside raceways, trunking and trays.
D. Proof of conformance to applicable codes and standards.
E. Samples.
A. Products specified in this section should comply with IEC & local Egyptian regulations
for components and installation.

B. Provide products specified in this section that are listed and labeled according to IEC
Standards.
C. Where specified in other sections of Division 26, electrical equipment manufacturer

shall furnish the services of an authorized representative especially trained and expe-
rienced in the installation of his equipment.
1.5 COORDINATION
A. Coordinate layout and installation of raceways and boxes with other construction el-
ements to ensure adequate heady room, working clearance, and access.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Raceway and boxes Approved Manufacturers:
1. Subject to compliance with requirements
2.2 GENERAL
A. Materials and equipment to be provided shall be new and essentially the standard
catalogued products of a manufacturer regularly engaged in the manufacture of the
products.
2.3 APPLICATION CONSIDERATIONS
A. The specified products for raceways, boxes, and cabinets shall be used as suitable to
the environment. The following table shall be a general guide and shows a complete
list of environments and permissible products.
RACEWAY APPLICATION TABLE

Boxes, Enclosures,
No. Environment Raceways
Cabinets
1. Dry locations, concealed (above UPVC NEMA 1 (IP20)
false ceiling not used as a free
air return ”)
2 Dry locations, concealed (above EMT, FMC NEMA 1 (IP20)
false ceiling used as free air re-
turn)
4. Dry locations, exposed, not sub- UPVC NEMA 1 (IP20)
ject to damage.
6. Outdoor locations, embedded UPVC --

RACEWAY APPLICATION TABLE
Boxes, Enclosures,
No. Environment Raceways
Cabinets
in concrete, under concrete slab
7. Underground, direct burial UPVC --
B. Legend:
1. EMT Electrical metal tubing.

2. FMC Flexible metal conduit.
3. PVC Polyvinyl chloride (flame retardant).
2.4 ELECTRICAL METALIC TUBING
A. Electrical Metallic Tubing (EMT): Welded steel, non-threaded type galvanized exter-
nally and protected internally with corrosion resistant enamel, according to U.S. Fed-
eral Specifications, UL 797 and ANSI C80.3.
B. EMT Fittings: Generally, thread less pressure type, galvanized or cadmium plated
malleable cast iron. Fittings used in corrosive atmospheres are to be specially treat-
ed. Factory made bends are to be provided where site bending is not possible.
C. Corrosion Resistance: Conduits used in corrosive atmospheres are to be copper sili-

con alloy, highly resistant to corrosion.
2.5 FLEXIBLE METAL CONDUIT
A. Material: Steel, cold rolled and annealed, non-threaded type, formed from continu-
ous length of helically wound and interlocked strip steel, with fused zinc coating on
inside and outside, and to IEC 61386-1, BS EN 50086-1.
B. Liquid-tight flexible conduit is to have PVC jacket extruded over core.
C. Fittings: Generally Thread less, hinged clamp type, galvanized or cadmium plated
malleable cast iron. Fittings used in corrosive atmospheres are to be specially treat-
ed.
D. Straight Connectors: One-piece body, female end, having hinged clamp and deep
slotted machine screws for securing to conduit, male end having thread and locknut.
E. Angle connectors of 45 or 90 degree and terminal connectors are to be as specified

for straight connectors, except that body is to be two-piece with removable upper
section.
2.6 RIGID HEAVY GAUGE PVC CONDUIT
A. Material: Rigid un-plasticized polyvinyl chloride with high impact and high tempera-

ture resistance, flame retardant, non-hygroscopic and non-porous, to CEE 26, BS
4607 and BS EN 50086-1, IEC 61386-1, IEC 61386-21, DIN 49016 or other equal and
approved standards conforming to IEC 60423.
B. Fittings: Generally unbreakable, non-inflammable, self-extinguishing, heavy molded

plastic. Expansion couplings are to be telescoping double tube type, with at least two
inner water-tight neoprene rings.
C. Assembly: Conduits, boxes and accessories are to be assembled by cementing, using

manufacturer's recommended products and appropriate connectors or spouts.
Where no spouts are available use smooth bore male PVC bushes and sockets.
2.7 UNDER GROUNG UPVC CONDUITS
A. UPVC conduits with diameter greater than 32 mm used for electrical low voltage and
medium voltage Cables ducts shall comply with DIN Standard 8061/8062 or BS 3506.
B. Conduits installed in concrete encased duct bank shall be UPVC Class-2 (4 bar) ac-
cording to DIN standard, unless otherwise indicated.
C. Conduits installed direct-buried duct in non-traffic areas shall be UPVC Class-3 (6 bar)
according to DIN standard, unless otherwise indicated
D. Conduits installed direct-buried duct in traffic area shall be UPVC Class-4 (10 bar) ac-
cording to DIN standard, unless otherwise indicated.
2.8 FLEXIBLE PVC CONDUIT
A. Material: Flame retardant, heat resistant, non-hygroscopic PVC, high resistance to

impact, ribbed on circumference for flexibility to IEC 61386-1 or other equal and ap-
proved standards.
B. Fittings: Generally unbreakable, non-inflammable, self-extinguishing, heavy molded

plastic. Expansion couplings are to be telescoping double tube type, with at least two
inner water-tight neoprene rings.
2.9 STEEL CONDUIT ACCESSORIES
A. Sleeves Through Outside Walls: Cast iron, with end and intermediate integral flanges,
and internal diameter larger than diameter of through-conduit. Length is to corre-
spond to wall thickness. Space between sleeve and conduit is to be packed with
backer rod/oakum to within 50 mm of both faces of wall, remainder of sleeve packed
with plastic compound or lead, held in place by heavy escutcheon plates bolted at
both ends to flanged ends of sleeve. Alternatively, sleeves are to be O.Z/Gedney,
Type WSK or other equal and approved, with cable or conduit bolted pressure sealing
components.
B. Supports and Hangers: Galvanized malleable cast iron straps or structural steel sec-
tions with hot dip galvanized bolts and nuts.

C. Expansion Joint for Embedded Steel Conduits - Type A: Watertight, flexible conduit
with end fittings to receive fixed conduits. Length is to allow movement within range
of joint and is not to be less than 20 times diameter of conduit. Conduit is to be cov-
ered with thick rubber tubing with 5 mm minimum gap all around tube. Bonding
jumper with earth clamp is to be electrically connected both sides of joint.
D. Expansion Joint for Exposed Steel Conduits - Type B: Sleeve with fittings to permit
telescoping of one conduit into sleeve. Movable conduit is to be fitted with water-
tight bushing. Joint is to be weatherproof, of galvanized malleable iron or steel.
Bonding jumper with earth clamp is to electrically connect both sides of joint. Expan-
sion fitting is to be O.Z/Gedney, Type DXX or other equal and approved.
E. Expansion Joint for Exposed Steel Conduits - Type C: PVC sheathed flexible steel con-
duit terminating in pull boxes and securely fixed on each side of structural expansion
joint. Bonding jumper is to electrically connect both sides of joint.
F. Tags: 50 mm diameter steel with indented lettering, rust inhibiting treatment and
baked enamel finish.
2.10 WIRING AND CABLE TRUNKING
A. Components are to include wire way base, clip-on covers, couplings, end plates, wall
flanges, panel to trunking rubber grommets, elbows, tees, adaptor plates and neces-
sary hangers, supports and accessories.
B. Steel Trunking: To BS EN 50085-1 and BS EN 50085-2-1, galvanized sheet steel, mini-

mum 1.5 mm thick, protected internally and externally with corrosion resistant finish
such as zinc or cadmium with top coat of enamel.
C. PVC Trunking: To BS 4678 part 4 high impact, heavy duty, self-extinguishing, rigid PVC
with grooved double locking action of the clip-on cover. Design is to be approved by
Engineer before ordering materials. Trunking is to be capable of receiving functional
slot-in hangers and demountable separators to segregate wiring systems as needed.
D. Sizes: As required to accommodate number of conductors permitted by the Regula-

tions.
2.11 WEATHERPROOF WIRING AND CABLE TRUNKING
A. Type: Hot-dip galvanized sheet steel trunking of 1.5 mm thickness (minimum) with 1
mm thick cover to BS EN 50085-1 and BS EN 50085-2 for trunking and BS EN ISO 1461
for galvanizing.
B. Construction: Trunking is to have outwardly turned flanges to receive cover, and in-
ternal sleeve coupling between sections, permitting cutting of trunking on site.
C. Gaskets: Neoprene bonded cork gaskets are to be fitted throughout, between any
two attached surfaces.

D. Screws: Removable flanged covers are to be secured with galvanized steel holding
screws.
2.12 OUTLET BOXES, GENERAL
A. Surface or recessed boxes are to be suitable for type of related conduit or cable sys-
tem. Shapes and sizes of boxes are to be of compatible standards as switches and
socket outlets specified under Division 26 Section "Wiring Devices", and lighting fix-
tures selected and of various types and mounting methods required.
B. Unused openings in outlet boxes are to be closed with molded caps or knock-out
closers manufactured for the purpose.
C. Floor outlets and plates are to be water-tight and impact resistant.
2.13 METALLIC OUTLET BOXES
A. Recessed and Concealed Boxes: Galvanized pressed steel, with knock-outs for easy
field installation. Special boxes are to be punched as required on Site.
B. Exposed Surface Mounted Boxes: Galvanized cast iron with threaded hubs.
C. Outdoor Surface or Recessed Boxes: Galvanized cast iron with threaded hubs and
PVC gaskets to ensure water tightness and with stainless steel or non-ferrous, corro-
sion resistant screws.
D. Floor Boxes - Type A: Watertight, cast iron or cast metal alloy with corrosion resistant
finish, adjustable mounting, standard duty, round or square, factory drilled and
tapped for required conduit sizes, and with brass cover and flange with brushed fin-
ish free from markings other than required for mounting screws.
E. Floor Boxes - Type B: non-standard size, flush floor mounted, cast metal alloy, with
watertight neoprene gasket and hinged cover for each service. Box to be ready with
factory drilled and tapped conduit entries and adjustable mounting fittings. Metal
barriers are to separate services for power and low current.
F. Flame-Proof Boxes: Malleable iron or cast iron, with gas threaded hubs, special co-
vers with silicon rubber gaskets, gas tight, and water-tight. Boxes are to comply with
the Regulations for explosive areas.
2.14 MOULDED PLASTIC OUTLET BOXES
A. Type: Boxes and covers used with PVC conduit systems are to be heavy gauge pres-
sure molded plastic, minimum 2 mm thick, self extinguishing, with softening point
not less than 85 deg. C. Boxes are to have provision for securely terminating conduits
and are to be manufacturer's standard for required application.
B. Fittings: Boxes are to have brass inset threads to receive cover screws and for mount-
ing devices or accessories, push-fit brass earth terminals, and steel insert clips to

provide additional support for pendants or for heat conduction. Neoprene gaskets
are to be provided for weatherproof installations.
2.15 FLOOR OUTLET BOX
A. Floor service waterproof boxes shall be a steel recessed floor box with four wiring
compartments. Fully adjustable mounting hardware with degree of protection not
less than IP 44.
B. Wiring compartments shall be interconnected within the box with removable divid-
ers. Each floor box shall use flush activation. The cover shall be suitable for the appli-
cation, specifically a flush access hatch with carpet trim or flush furniture partition
feed. The exact type of cover for each box will be determined by the owner in con-
junction with the interior finishes.
C. Boxes with no connections shall be equipped with the flush access hatch. The covers
shall not be installed until the floor coverings or tile is installed. The boxes shall be
protected from damage during construction.
D. Covers shall be steel. 7 cm depth boxes shall be used in elevated applications; 10 cm

depth boxes shall be used for slab-on-grade applications. Each box shall be equipped
with two 16-amp duplex receptacles as specified in the drawings.
E. Install two brackets for mounting receptacles with provision for snap-in connector
modules unless indicated otherwise on the drawings.
PART 3 EXECUTION
3.1 EXAMINATION
A. Examine surfaces to install raceways, boxes enclosures and cabinets for compliance
with installation tolerances and other conditions affecting performance of the race-
way system. The Contractor shall not proceed with installation until unsatisfactory
conditions have been corrected.
3.2 EQUIPMENT INSTALLATION REQUIREMENTS
A. General: Provide all the equipment installation and wiring installation, including
connections as indicated, specified and required. Assure proper fits for all equip-
ment and materials in the space as shown on the Drawings. Conduits installed un-
derground shall be provided with preformed long radius PVC elbows encased in con-
crete. Liquid-tight lengths of flexible conduit shall be used for connections to all mo-
tors and equipment subject to vibration. Maximum conduit fill shall not exceed 40%.
3.3 INSTALLATION AND WIRING
A. Conduits shall be concealed either within false ceiling plenums or embedded in slabs,

walls and floors. Conduits shall be installed in accordance with the requirements of
IEE Building Regulations. Conduit runs shall be determined by the Contractor and
agreed by the Engineer before commencing work.
B. A minimum clearance of 300 mm shall be maintained for conduits that are installed
in the vicinity of uninsulated hot pipes or hot surfaces.
C. Sleeves and inserts shall be furnished and installed as required for electrical work.
Open conduit ends shall be carefully closed during construction to prevent foreign
materials from entering the conduit.
D. Conduit buried in concrete shall have 35 mm depth of cover over its entire length.
Conduit shall not be installed in plastering layers.
E. A draw in (Pull) box shall be provided in all conduit runs exceeding 10 m or contain-
ing more than two right angled bends. Any unused opening shall be plugged.
F. The length of thread (for galvanized steel conduits) at the ends shall suit the length
of the internal thread of the fitting or accessory. Excess length shall not be allowed.
G. Fixings for surface mounted conduit boxes, accessory boxes and saddles to concrete,
brick, building blocks and similar materials shall be by means of cadmium-plated
steel screws and raw plugs.
H. The ends of conduits shall be cut straight and the length of screw thread (for the gal-
vanized steel conduits) shall be sufficient only to allow the ends of the conduit to
butt solidly in all couplings and against the shoulders provided in conduit boxes.
I. The ends of galvanized conduits shall be carefully reamer to remove all burrs or
sharp edges after the screw threads have been cut. All dirt, paint or oil on the
screwed threads of the conduit and accessories shall be carefully removed immedi-
ately prior to erection.
J. The number of running joints in conduit shall be kept to a minimum and where in-
stalled locknuts shall be used to secure the sockets.
K. Where space permits their use, plain bends are preferred than elbows. Maximum
number of bends is 3 as total.
L. Draw-in boxes with wide flanged robust covers shall be used.
M. All joints in an assembly of conduit shall be painted after assembly with two coats of
moisture resisting paint. Arrangements shall be made, where necessary to prevent
the collection of moisture in conduit fittings.
N. Runs terminating in flexible conduit shall have the latter fitted with special adaptors
in accordance with the Manufacturer's recommendations to ensure a weatherproof
connection and where applicable, earth continuity.
O. Where equipment is provided with a plain entry only, the conduit shall be fixed by
means of flanged couplings, lead washers and male brass brush.

P. All conduits shall be swabbed through before wiring is commenced and cable shall
not be drawn into any section of the system until all conduits and draw boxes for
that particular section are fixed in position.
Q. Deep boxes or extension rings on standard circular conduit boxes shall be used
where necessary in order to bring the front face of each box flush with the surface of
the ceilings.
R. Nails shall not be used for fastening the boxes installed in concrete slabs.
S. The box shall be so constructed as to prevent contact between the conductors in the
box and the supporting screws.
T. Flush-mounted boxes shall be cast in concrete walls or grouted into hollow masonry
walls. Metal boxes threaded to raceways in exposed installations shall be separately
supported. Boxes installed in concealed conduit or raceway systems shall be set
flush with the finished surfaces. The location of all boxes shall be easily accessible
and any interference with mechanical equipment or structural features shall be relo-
cated as directed by the Engineer.
U. All circuit wires shall be tagged to indicate clearly the circuit number and panel des-
ignation at each pull box or access point. Circuit wires in excess of 600 V shall have
voltage identification.
V. Device plates shall be installed with all four edges in continuous contact with finished
wall surfaces without the use of mats or similar devices. Device plates shall be in-
stalled vertically with an alignment tolerance of 2 mm.
3.4 OUTLET BOXES
A. Location of outlets shown on wiring plans shall be considered as approximate and

they shall be incumbent upon the Contractor, before installing outlet boxes, to study
all pertinent Drawings and obtain precise information from the architectural sched-
ules, scale drawings, large scale and full size details of finished rooms, approved shop
drawings of other trades or from the Engineer.
B. Outlet boxes for similar equipment shall be mounted at uniform heights within the
same or similar areas. Without any restrictions by Drawings or instructions on Site,
and except where they are located 250 mm above work benches or positioned to suit
a particular piece of equipment, switches and socket outlets shall be mounted at
1.25 m and 300 mm from finished floor level, respectively.
C. All outlet boxes shall be securely fastened. Exposed outlet boxes shall be attached to
permanent inserts or lead anchors with machine screws.
D. All unused openings in outlet boxes shall be closed with knockout closers manufac-
tured for such purpose.
E. Blank plates for wall outlets shall be attached by a bridge with slots for horizontal
and vertical adjustment.

F. Outlet boxes shall be of shape and dimension suitable for their application as used
with switches, socket outlets, and lighting fixtures of the various types and mounting
methods applicable.
3.5 JUNCTION, PULL
A. Junction and pull boxes shall be located where required to facilitate pulling of wires.
B. Boxes of adequate capacity shall be provided at every junction of the conduit system
and as required by the "IEE Building Regulations".
C. Pull-boxes shall be placed at a maximum spacing of 10 meters.
D. Concealed surfaces of hot dip galvanized steel junction, pull boxes shall be given a
heavy field application of emulsified asphalt prior to installation.
3.6 GROUNDING AND BONDING
A. Grounding type insulated bushings shall be provided on steel conduits at all distribu-
tion boards. The grounding bushings shall be bonded together and to the equipment
enclosure or, where provided, to the equipment ground bus. This type of installation
shall also be used at pull boxes to ensure ground continuity.
B. Effectiveness of grounding shall not be dependent upon the continuity of the metal
and a separate earth conductor shall run throughout the conduit for this purpose.
C. Cable or conduit terminations at equipment shall be bonded to the equipment by

means of an earthing clip and suitable section of copper wire or strip. This shall not
be required where an item of electrical equipment is provided with screwed entries.
The bonding can be omitted (unless otherwise indicated on Drawings or supplemen-
tary specifications) providing the screwed connections are clean low-resistance
joints.
D. Sizes of installed earthing conductor shall not be less than those indicated in relevant
regulations, codes of practice etc.
3.7 CONNECTIONS
A. All conduit connections shall be made up tight to provide good electrical conductivity
throughout the entire length of the conduit run including flexible conduits.
3.8 PROTECTION
A. The contractor shall exercise the necessary precautions to prevent the lodgment of
dirt, plaster or trash in conduit, fittings and boxes during the course of installation. A
run of conduit, which has become clogged, shall be entirely freed of these accumula-
tions or shall be replaced. Open conduit ends shall be carefully closed during con-
struction to prevent foreign materials entering the conduit. Conduits, which have

been crushed or deformed in any way, shall not be installed; or if so deformed after
installation, shall be replaced.
B. In Case of coatings and finishes damage:
1. Repair damage to galvanize finished with what is recommended by Manufac-

turer.
2. Repair damage PVC or paint finishes layer with matching touchup coating rec-
ommended by the Manufacturer.
3.9 CLEANING
A. Upon completion of installation of system including outlet fittings and devices, in-
spect exposed finished and remove burrs, dirt and construction debris and repair
damage finish including clips, scratches and abrasions.
B. Repair damage using matching touch-up coating recommended by the Manufacturer.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. CABLE TRAYS FOR ELECTRICAL SYSTEMS
CAIRO - EGYPT 260536 – 2874 0

CONTENTS
SECTION 260536
CABLE TRAYS FOR ELECTRICAL SYSTEMS
Page
PART 1 - GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Sequencing And Scheduling 3
1.6 Delivery,Storage And Handlines 3
PART 2 - PRODCUTS 3
2.1 Materials And Finishes 3
2.2 Sizes And Configurations 4
2.3 Cable Tray Accessories 4
2.4 Fire Stopping 5
2.5 Wiring Signs 5
2.6 Perforation Engineering 5
2.7 Cable Saddles 5
2.8 End Caps 5
2.9 Source Quality Control 5
3.1 General 5
3.2 Installation 6
3.3 Grounding 7
3.4 Warning Signs 7
3.6 Cleaning 7
3.7 Protection 7
Cable Trays for Electrical Systems Section 260536

SECTION 260536 - CABLE TRAYS FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.2 SUMMARY
A. This Section covers cable trays and accessories as required by the contract.
B. Related Sections.
1. Division 26 Section “Low Voltage Electrical Power Conductor and Cables”.
1.3 SUBMITTALS
A. Product Data: Show tray types, dimensions, and finishes.
1. Show the applicable reference code (IEC or similar)

2. Show the loading curves
3. Show the recommended fixing and supporting intervals
4. Show the recommended accessories for each specific mounting with proper
screw sizes and similar
5. Show the perforation details at bottom and inside of cable tray
6. Submit proof of conformance to the applicable code as source quality control
B. Samples: For the following items:
1. Sample for trays, fittings and cover.

2. Sample for fire barriers.
3. Sample for tray warning signs.
4. Sample for cable saddles.
C. Shop Drawings: To scale 1:50 detailing the installation of main cable trays, including
plans, sections, and attachment to other construction elements, to show the sup-
porting intervals and inside clearances as suitable to actual assigned cables and
weights as per selected manufacturer’s recommendations.
D. In general:
1. Where multi-core cables are installed in ventilated cable trays, the sum of the
diameters of all cables installed shall not exceed 90 percent of the cable tray
width and the cables shall be installed spaced in a single layer.

2. Where multi-core cables are installed in solid bottom cable trays, the sum of
the diameters of all cables installed shall not exceed 80 percent of the cable
tray width and the cable shall be installed spaced in a single layer.
E. Coordination Drawings: Floor plans drawn to accurate scale. Show accurately scaled
cable tray layout and relationships between components and adjacent structural and
mechanical elements.
A. All cable tray and components shall be the product of a single manufacturer.
B. Supplier should be experienced in manufacturing cable trays similar to those indicat-

ed for this project and has a record of successful in-service performance. Those
products shall be listing and labeling as per IEC 61537, NEMA VE1 and ISO 1461 /
ASTM A123.
C. Comply with local Egyptian code.
1.5 SEQUENCING AND SCHEDULING
A. Contractor should coordinate layout and installation of cable trays with other trades
and installation. Revise location and elevations as required to suit field condition and
as approved by the Engineer.
1.6 DELIVERY, STORAGE AND HANDLINES
A. Store indoors to prevent water or other foreign materials from staining or adhering
to cable tray.
B. Unpack and dry wet materials before storage.
PART 2 - PRODCUTS
2.1 MATERIALS AND FINISHES
A. Cable trays, fittings and accessories shall be post fabricated heavy gauge hot-dip gal-
vanized, manufactured from mild steel sheets of thickness not less than 2 mm for
above 400 mm width. Trays shall not present sharp edges, burrs or projections inju-
rious to the insulation or jackets of cables. Fixing brackets shall be hot-dip galva-
nized.
B. All cable tray sections shall be close return flange type, legibly and durably marked to
show the manufacturer name or logo.
C. Successful manufacturer shall have his logo engraved or bossed to the tray and a
strengthen means along the tray width by forming smooth left and right corrugation
in its base (not just 4 shape).

D. Cable tray sections, fittings and connected raceways shall be bonded using bolted
mechanical connectors or bonding jumpers sized in accordance with (IEE) regula-
tions.
2.2 SIZES AND CONFIGURATIONS
A. Sizes and configuration shall be as per table below and comply with IEC Code. Cable
trays shall carry the installed cable weight with an allowance for future cable load of
about 25% of the existing cable plus the weight of a tradesman standing at mid-span
on tray (about 80 kg) at the expected locations.
B. Ladder-Type Trays:
1. Width:
a. 100 mm
b. 150 mm
c. 200 mm
d. 300 mm
e. 400 mm
f. 600 mm
g. 800 mm
h. 900 mm
i. 1000 mm
2. Inside Depth: 100 mm

3. Cross-Rung Spacing: 300 mm
C. Perforated-Type Trays:
1. Width:
a. 100 mm
b. 150 mm
c. 200 mm
d. 300 mm
e. 400 mm
f. 600 mm
g. 800 mm
h. 900 mm
i. 1000 mm
2. Inside Depth: 100 mm
2.3 CABLE TRAY ACCESSORIES
A. Cable tray fittings, bends, tips, etc., shall be supplied by the same cable tray manufac-
turer and from the same material and finishing as cable trays. Site fabricated acces-
sories shall not be accepted.

2.4 FIRE STOPPING
A. Provide suitable internal asbestos-free fire-resisting barriers (mortar type) where

trays pass through floors, walls, or partitions, for not less than 120 min. retarding and
according to international standards.
B. In selecting materials for use as fire stops, some important factors such as gas tight-
ness, poisonous gases or fumes developed during installation or during a fire, and
heat dissipation are to be considered. Spray coating of fire resisting material (30 min.
retarding) shall be applied on cables for at least 1.5 meter on both sides of the fire
stop barrier.
2.5 WIRING SIGNS
A. All visible cable trays shall have approved durable type conspicuously located warn-
ing signs reading "WARNING! NOT TO BE USED AS WALKWAY, LADDER, OR SUPPORT
FOR LADDERS OR PERSONNEL", and shall be readable at 8-meter distance. All warn-
ing signs shall be in Arabic / English. Sign's lettering shall be black on yellow back-
ground and 40 mm high.
2.6 PERFORATION ENGINEERING
A. The perforation details shall provide both adequate heat dissipation and adequate
strength or rigidity to the bottom and sides of cable trays.
2.7 CABLE SADDLES
A. Cable installed on trays shall be secured by means of PVC covered metal saddles.
Cable should be clamped to the tray at 3m intervals horizontally or 0.9m vertically.
2.8 END CAPS
A. Plastic end caps for cable trays and tray support shall be provided, to avoid personnel
injury.
2.9 SOURCE QUALITY CONTROL
A. Where materials are specified to be constructed and/or tested in accordance with

the standards of International Electro-Technical Commission (IEC), or other approved
standards, proof of such conformance shall be submitted for approval.
PART 3 - EXECUTION
3.1 GENERAL
A. Provide cable trays with the indicated types and sizes as per the approved shop

drawings, complete with manufacturer's recommended covers, fire barriers, strips,
dropouts, fittings, bolts, conduits adapters, hold-down devices, supports, connectors,
bonding jumpers, etc.
3.2 INSTALLATION
A. General: Cable trays shall be installed (level and plumb) as indicated and according
to manufacturer's written instructions and reference standard. Cable tray shall be
supported at not more than 1.5 m intervals, and/or in accordance with Manufactur-
er's instructions and Engineer's approval. Supports for horizontal elbow trays fittings
shall be placed within 0.2 m of each fitting extremity. Remove burrs and sharp edges
of cable trays. Unless otherwise indicated, cable tray supports shall be securely fas-
tened to the building structure.
1. Cable trays shall be installed as a complete system.

2. Cable trays shall be fixed to the purpose made brackets which shall be fixed to
channel inserts where they are provided and/or direct to the structure by
means of sheradised steel rawlbolts.
3. Trays shall be supported every 1.5 m and not more than 200 mm from bends
or intersections. Elbows shall be provided and no sharp bends are accepted.
4. Each run of cable tray shall be completed before the installation of cables.
5. Cables shall not be bent at a radius of less than ten times their overall diame-
ter.
6. Sufficient space shall be provided and maintained above cable trays to permit
adequate access for installing and maintaining cables.
7. Cable trays shall be installed at a vertical distance not less than 300 mm from
ceiling, from each other and from other pipe runs.
8. Before installation, the Contractor shall submit to the Engineer for his approval
mounting detail drawings to scale of 1:50 in plans and sections for all cable
tray runs.
9. In any case site fabrication is not accepted.
10. All vertical runs or outside installation of perforated cable trays should be
covered by suitable cover of same material of cable tray.
B. Installation Requirements:
1. Supports shall be designed to carry the greater of the calculated loads with an
allowance for future load about 25% of the existing weight plus a tradesman
standing at mid span on tray about 80 kg at the expected locations
2. Make connections to equipment with flanges fittings fastened to the tray and
to the equipment. Support the tray independently of fitting. Do not carry
the weight of the tray on the equipment enclosure.
3. Provide adequate supports for cables leaving or entering the tray individually
to prevent stress on cables.
4. Install expansion connectors in cable tray runs that exceed 30 m. Space con-
nectors and set gaps according to IEC.
5. Change in direction, elevation and cable tray connection shall be in accordance
with manufacturer's instruction and by standard fittings, of same manufactur-
er.
6. Locate cable tray above piping except as required for tray accessibility and

otherwise indicated and providing sufficient space to permit access for in-
stalling cables.
7. Cable trays for different systems (for power, communications and data pro-
cessing cables), and different insulation levels (600 V and 11 kV) to be installed
separately.
3.3 GROUNDING
A. All cable trays shall be properly grounded by means of a low-resistance conductor of

sufficient capacity (but in no case smaller than 16 mm2 copper). The effective
grounding shall be permanent and continuous, with impedance sufficiently low to
limit the potential above ground and to facilitate operation of over current devices in
the associate circuit. Groundings and bondings of cable trays shall be in accordance
with IEC.
3.4 WARNING SIGNS
A. After installation of cable trays is completed, install warning signs in a visible location
on or near cable tray according to the engineer instructions.
A. Provide checking, and testing on the installations including the following:
1. Check: All routes shall be checked to assure connections and supports.

2. Grounding: Test cable tray to ensure electrical continuity of bonding and
grounding connections.
3. Anchorage: Test pull-out resistance of one of each type, size and anchorage
material toggle bolts and powder-driven threaded studs.
4. Defects: Correct malfunctioning units at site, where possible, and retest to
demonstrate compliance, otherwise, remove and replace with new units and
retest.
3.6 CLEANING
A. Upon completion of installation of system, including fittings, inspect exposed finish.

Remove burrs, dirt, and construction debris and repair damage in quality and color to
the original factory finish and with Manufacturer's recommendations.
3.7 PROTECTION
A. Provide final protection and maintain conditions in a manner acceptable to manufac-

turer to ensure that cable tray is without damage or deterioration at substantial
completion.
B.Repair damage to galvanized finishes with paint recommended by the tray Manufac-
turer.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. IDENTIFICATION FOR ELECTRICAL
CAIRO - EGYPT SYSTEMS 260553 - 2874 0

CONTENTS
SECTION 260553
IDENTIFICATION FOR ELECTRICAL SYSTEMS
Page
PART 1 - GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Coordination 3
PART 2 - PRDOCUTS 3
2.1 Power Raceway Identification Materials 3
2.2 Power and Control Cable Identification Materials 4
2.3 Conductor Identification Materials 4
2.4 Underground-Line Warning Tape 5
2.5 Warning Labels and Signs 5
2.6 Instruction Signs 5
2.7 Equipment Identification Labels 6
2.8 Cable Ties 6
2.9 Miscellaneous Identification Products 6
3.1 Installation 7
3.2 Identification Schedule 7
Identification For Electrical Systems Section 260553

SECTION 260553 - IDENTIFICATION FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
A. Drawings and general provisions of the Contract, including General and

Supplementary Conditions and Division 01 Specification Sections, apply to this
Section.
1.2 SUMMARY
A. Section Includes:
B. Identification for raceways.
C. Identification of power and control cables.
D. Identification for conductors.
E. Underground-line warning tape.
F. Warning labels and signs.
G. Instruction signs.
H. Equipment identification labels.
I. Miscellaneous identification products.
1.3 SUBMITTALS
A. Product Data: Submit product data for each electrical identification product
indicated.
B. Samples: Submit sample for each type of label and sign to illustrate size, colors,
lettering style, mounting provisions, and graphic features of identification products.
C. Identification Schedule: Submit an index of names of electrical equipment and

system components used in identification signs and labels.
A. Comply with IEC and/or BS.
B. Comply with NFPA 70.

C. Comply with Local Codes.
D. Comply with IEC 61310 for safety signs and labels.
E. Adhesive-attached labeling materials, including label stocks, laminating adhesives,

and inks used by label printers, shall comply with relevant codes and standards.
1.5 COORDINATION
A. Coordinate identification names, abbreviations, colors, and other features with

requirements in other Sections requiring identification applications, Drawings, Shop
Drawings, manufacturer's wiring diagrams, and the Operation and Maintenance
Manual; and with those required by codes, standards. Use consistent designations
throughout Project.
B. Coordinate installation of identifying devices with completion of covering and

painting of surfaces where devices are to be applied.
C. Coordinate installation of identifying devices with location of access panels and

doors.
D. Install identifying devices before installing acoustical ceilings and similar

concealment.
PART 2 - PRDOCUTS
2.1 POWER RACEWAY IDENTIFICATION MATERIALS
A. Comply with IEC and/or BS for minimum size of letters for legend and for minimum
length of color field for each raceway size.
B. Colors for Raceways Carrying Circuits at 600 V or Less:
1. Black letters on an orange field

2. Legend: Indicate voltage and system or service type.
C. Colors for Raceways Carrying Circuits at More Than 600 V:
1. Black letters on an orange field.

2. Legend: "DANGER CONCEALED HIGH VOLTAGE WIRING" with 75-mm high
letters on 500-mm centers.
D. Raceways Carrying Circuits at 600V or Less:
1. Self-Adhesive Vinyl Labels: Preprinted, flexible label laminated with a clear,

weather- and chemical-resistant coating and matching wraparound adhesive
tape for securing ends of legend label.
2. Snap-Around, Color-Coding Bands for Raceways Carrying Circuits at 600 V or
Less: Slit, pretension, flexible, solid-colored acrylic sleeve, 50 mm long, with

diameter sized to suit diameter of raceway or cable it identifies and to stay in
place by gripping action.
E. Raceways Carrying Circuits more than 600V:
1. Tape and Stencil for Raceways Carrying Circuits More Than 600 V: 100 mm
wide black stripes on 250mm centers diagonally over orange background that
extends full length of raceway or duct and is 300 mm wide. Stop stripes at
legends.
F. Metal Tags: Aluminum, 50 by 50 by 1.3 mm, with stamped legend, punched for use
with self-locking cable tie fastener.
2.2 POWER AND CONTROL CABLE IDENTIFICATION MATERIALS
A. Comply with IEC and/or BS for minimum size of letters for legend and for minimum
length of color field for each raceway and cable size.
B. One or combination of both of the following identification materials shall be used

according to Engineer instructions.
1. Self-Adhesive Vinyl Labels: Preprinted, flexible label laminated with a clear,

weather- and chemical-resistant coating and matching wraparound adhesive
tape for securing ends of legend label.
2. Metal Tags: Aluminum, 50 by 50 by 1.3 mm, with stamped legend, punched
for use with self-locking cable tie fastener.
2.3 CONDUCTOR IDENTIFICATION MATERIALS
A. Color Codes for conductors shall be specified in Section 260513” and

Section”260519”. Factory –apply color to the entire length of conductor shall be
applied.
B. Field –applied color coding method shall be used in addition to the factory code for
all the electrical cables and wires according to cover the following.
1. Conductors to be Extended in the Future: Indicate source and circuit numbers

2. Power or Lighting Circuits in the Same Enclosure: Identify each conductor with
source, voltage, circuit number, and phase. Use color-coding for voltage and
phase indication of secondary circuit
3. Control and Communication Circuits in the Same Enclosure: Identify each
conductor by its system and circuit designation. Use a consistent system of
tags and color-coding
C. One or combination of both of the following identification materials shall be used

according to Engineer instructions.
1. Color-Coding Conductor Tape: Colored, self-adhesive vinyl tape not less than
0.08 mm thick by 25 to 50 mm wide.

2. Snap-Around, Color-Coding Bands: Slit, pretensioned, flexible, solid-colored
acrylic sleeve, 50 mm long, with diameter sized to suit diameter of raceway or
cable it identifies and to stay in place by gripping action.
2.4 UNDERGROUND-LINE WARNING TAPE
A. Tape:
1. Recommended by manufacturer for the method of installation and suitable to

identify and locate underground electrical and communications utility lines.
2. Printing on tape shall be permanent and shall not be damaged by burial
operations.
3. Tape material and ink shall be chemically inert, and not subject to degrading
when exposed to acids, alkalis, and other destructive substances commonly
found in soils.
B. Color and Printing:
1. The color shall comply with IEC and /or BS.

2. Inscriptions: The statement stamped on the tape should indicate the type of
utility (HIGH VOLTAGE, TELEPHONE CABLE, CATV CABLE, etc).
2.5 WARNING LABELS AND SIGNS
A. Comply with IEC and /or BS.
B. Self-Adhesive Warning Labels: Factory-printed, multicolor, pressure-sensitive

adhesive labels, configured for display on front cover, door, or other access to
equipment unless otherwise indicated.
C. Baked-Enamel Warning Signs:
1. Preprinted aluminum signs, punched or drilled for fasteners, with colors,

legend, and size required for application.
2. 6.4-mm grommets in corners for mounting.
3. Nominal size, 180 by 250 mm.
D. Warning label and sign shall include for example, but are not limited to, the following
legends in English and Arabic languages:
1. Multiple Power Source Warning: "DANGER - ELECTRICAL SHOCK HAZARD -

EQUIPMENT HAS MULTIPLE POWER SOURCES."
2. Workspace Clearance Warning: "WARNING - OSHA REGULATION - AREA IN
FRONT OF ELECTRICAL EQUIPMENT MUST BE KEPT CLEAR FOR 915 MM."
2.6 INSTRUCTION SIGNS
A. Engraved, laminated acrylic or melamine plastic, minimum 1.6 mm thick for signs up
to 129 sq. cm and 3.2 mm thick for larger sizes.

1. Engraved legend with black letters on white face.
2. Punched or drilled for mechanical fasteners.
3. Framed with mitered acrylic molding and arranged for attachment at
applicable equipment.
2.7 EQUIPMENT IDENTIFICATION LABELS
A. Engraved, Laminated Acrylic or Melamine Label: Punched or drilled for screw

mounting. White letters on a dark-gray background. Minimum letter height shall be
10 mm.
2.8 CABLE TIES
A. According to the location of the installations and Engineer instructions one of the
following cables ties shall used.
B. General-Purpose Cable Ties: Fungus inert, self extinguishing, one piece, self locking,
Type 6/6 nylon.
1. Minimum Width: 5 mm.

2. Tensile Strength at 23 deg C, 82.7 MPa.
3. Temperature Range: Minus 40 to plus 85 deg C.
4. Color: Black except where used for color-coding.
C. UV-Stabilized Cable Ties: Fungus inert, designed for continuous exposure to exterior
sunlight, self extinguishing, one piece, self locking, Type 6/6 nylon.

4. Color: Black.
D. Plenum-Rated Cable Ties: Self extinguishing, UV stabilized, one piece, self locking.

4. Color: Black.
2.9 MISCELLANEOUS IDENTIFICATION PRODUCTS
A. Paint: Comply with requirements in Division 09 painting Sections for paint materials
and application requirements. Select paint system applicable for surface material
and location (exterior or interior).
B. Fasteners for Labels and Signs: Self-tapping, stainless-steel screws or stainless-steel

machine screws with nuts and flat and lock washers.

PART 3 - EXECUTION
3.1 INSTALLATION
A. Verify identity of each item before installing identification products.
B. Location: Install identification materials and devices at locations for most convenient
viewing without interference with operation and maintenance of equipment.
C. Apply identification devices to surfaces that require finish after completing finish
work.
D. Self-Adhesive Identification Products: Clean surfaces before application, using

materials and methods recommended by manufacturer of identification device.
E. Attach signs and plastic labels that are not self-adhesive type with mechanical
fasteners appropriate to the location and substrate.
F. System Identification Color-Coding Bands for Raceways and Cables: Each color-
coding band shall completely encircle cable or conduit. Place adjacent bands of two-
color markings in contact, side by side. Locate bands at changes in direction, at
penetrations of walls and floors, at 15-m maximum intervals in straight runs, and at
7.6-m maximum intervals in congested areas.
G. Aluminum Wraparound Marker Labels and Metal Tags: Secure tight to surface of
conductor or cable at a location with high visibility and accessibility.
H. Cable Ties: For attaching tags. Use general-purpose type, except as listed below:
1. Outdoors: UV-stabilized nylon.

2. In Spaces Handling Environmental Air: Plenum rated.
I. Underground-Line Warning Tape: During backfilling of trenches install continuous

underground-line warning tape directly above line at 300 mm below finished grade.
Use multiple tapes where width of multiple lines installed in a common trench or
concrete envelope exceeds 400 mm overall.
J. Painted Identification: Comply with requirements in Division 09 painting Sections for

surface preparation and paint application.
3.2 IDENTIFICATION SCHEDULE
A. Concealed Raceways, Duct Banks, More Than 600 V, within Buildings: Tape and
stencil 100-mm wide black stripes on 250-mm centers over orange background that
extends full length of raceway or duct and is 300 mm wide. Stencil legend "DANGER
CONCEALED HIGH VOLTAGE WIRING" with 75-mm high black letters on 500-mm
centers. Stop stripes at legends. Apply to the following finished surfaces:
1. Floor surface directly above conduits running beneath and within 300 mm of a
floor that is in contact with earth or is framed above unexcavated space.

2. Wall surfaces directly external to raceways concealed within wall.
3. Accessible surfaces of concrete envelope around raceways in vertical shafts,
exposed in the building, or concealed above suspended ceilings.
B. Accessible Raceways, and Cables, More Than 600 V: Install labels at 3-m maximum
intervals.
C. Accessible Raceways and Cables, 600 V or Less, for Service, Feeder, and Branch
Circuits More Install labels at 3-m maximum intervals.
D. Accessible Raceways and Cables within Buildings: Identify the covers of each junction
and pull box of the following systems with self-adhesive vinyl labels with the wiring
system legend and system voltage. System legends shall be as follows:
1. Emergency Power.
2. Power.
3. UPS.
E. Power-Circuit Conductor Identification, 600 V or Less: For conductors in vaults, pull

and junction boxes, manholes, and handholes, use color-coding conductor tape to
identify the phase.
F. Power-Circuit Conductor Identification, More than 600 V: For conductors in vaults,

pull and junction boxes, manholes, and handholes, use nonmetallic plastic tag holder
with adhesive-backed phase tags, and a separate tag with the circuit designation.
G. Install instructional sign including the color-code for grounded and ungrounded
conductors using adhesive-film-type labels.
H. Conductors to Be Extended in the Future: Attach marker tape to conductors and list
source.
I. Auxiliary Electrical Systems Conductor Identification: Identify field-installed alarm,

control, and signal connections.
1. Identify conductors, cables, and terminals in enclosures and at junctions,

terminals, and pull points. Identify by system and circuit designation.
2. Use system of marker tape designations that is uniform and consistent with
system used by manufacturer for factory-installed connections.
3. Coordinate identification with Project Drawings, manufacturer's wiring
diagrams, and the Operation and Maintenance Manual.
J. Locations of Underground Lines: Identify with underground-line warning tape for

power, lighting, communication, and control wiring and optical fiber cable.
1. Limit use of underground-line warning tape to direct-buried cables.

2. Install underground-line warning tape for both direct-buried cables and cables
in raceway.
K. Warning Labels for Indoor Cabinets, Boxes, and Enclosures for Power and Lighting :
Self-adhesive warning labels or Baked-enamel warning signs according to the
Engineer instructions.

1. Identify system voltage with black letters on an orange background.
2. Apply to exterior of door, cover, or other access.
3. For equipment with multiple power or control sources, apply to door or cover
of equipment including, but not limited to, the following:
a. Power transfer switches.

b. Controls with external control power connections.
L. Operating Instruction Signs: Install instruction signs to facilitate proper operation

and maintenance of electrical systems and items to which they connect. Install
instruction signs with approved legend where instructions are needed for system or
equipment operation.
M. Emergency Operating Instruction Signs: Install instruction signs with white legend on
a red background with minimum 10-mm high letters for emergency instructions at
equipment used for power transfer, load shedding and other emergency operations.
N. Equipment Identification Labels: On each unit of equipment, install unique

designation label that is consistent with wiring diagrams, schedules, and the
Operation and Maintenance Manual. Apply labels to disconnect switches and
protection equipment, central or master units, control panels, control stations,
terminal cabinets, and racks of each system. Systems include power, lighting,
control, communication, signal, monitoring, and alarm systems unless equipment is
provided with its own identification.
1. Labeling Instructions:
a. Indoor Equipment: Engraved, laminated acrylic or melamine label.

Unless otherwise indicated, provide a single line of text with 13-mm high
letters on 38-mm high label; where two lines of text are required, use
labels 50 mm high.
b. Outdoor Equipment: Engraved, laminated acrylic or melamine label
c. Elevated Components: Increase sizes of labels and letters to those
appropriate for viewing from the floor.
d. Unless provided with self-adhesive means of attachment, fasten labels
with appropriate mechanical fasteners that do not change the enclosure
protection degree.
2. Equipment to Be Labeled:
a. Panelboards: Typewritten directory of circuits in the location provided

by panelboard manufacturer. Panelboard identification shall be self-
adhesive, engraved laminated acrylic or melamine label.
b. Enclosures and electrical cabinets.
c. Access doors and panels for concealed electrical items.
d. Switchgear.
e. Switchboards.
f. Transformers: Label that includes tag designation shown on Drawings
for the transformer, feeder, and panelboards or equipment supplied by
the secondary.
g. Substations.

h. Emergency system boxes and enclosures.
i. Motor-control centers.
j. Enclosed switches.
k. Enclosed circuit breakers.
l. Enclosed controllers.
m. Variable-speed controllers.
n. Push-button stations.
o. Power transfer equipment.
p. Contactors.
q. Remote-controlled switches, dimmer modules, and control devices.
r. Battery-inverter units.
s. Battery racks.
t. Power-generating units.
u. Monitoring and control equipment.
v. UPS equipment.
w. Telephone switching equipment.
x. Clock/program master equipment.
y. Call system master station.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. MEDIUM-VOLTAGE DRY TYPE
CAIRO - EGYPT TRANSFORMER 261202 – 2874 0

CONTENTS
SECTION 261202
MEDIUM-VOLTAGE DRY TYPE TRANSFORMER
Page
PART 1 - GENERAL 2
1.2 Summary 2
1.3 Related Sections 2
1.4 Submittals 2
1.5 Warranty 3
1.8 Coordination 4
PART 2 - PRODUCTS 4
2.1 Dry-Type Distribution And Power Transformers 4
2.2 Identification Devices 6
3.1 Examination 7
3.2 Installation 8
3.3 Identification 8
3.4 Connections 8
3.6 System Validation 9
Medium-Voltage Dry Type Transformer Section 261202

SECTION 261202 - MEDIUM-VOLTAGE DRY TYPE TRANSFORMER
PART 1 - GENERAL

Section.
1.2 SUMMARY
A. This Section includes the Dry type transformers with medium-voltage primary 24kV
and secondary no-load low- voltage at principle tap is 400 V, 50 HZ and according to
IEC 60076-11.
B. The Contractor is responsible to supply and install the transformer (s) according to
the latest requirements of the Electrical Distribution Company. This shall require
from the contractor’s manufacturer to obtain the approval (before delivering) for the
type, voltage, losses, etc. from Electrical Distribution Company. Any additional
requirements shall be considered without any extra cost to the Contract even if these
requirements are not clearly mentioned in these specifications.
C. The contractor is responsible to supply and install the transformer (s) with the rating
indicated on the drawings at the ambient conditions mentioned in the specifications
without applying any derating factors.
1.3 RELATED SECTIONS
A. The following sections include, but not limited to, requirements which relate to work
of this section:
1. Division26 Section “Grounding and Bonding “

2. Division26 Section “Low Voltage Switchboards”
3. Division26 Section “Enclosed bus assemblies”
4. Division25 Section “Building Management System (BMS) “
1.4 SUBMITTALS
A. Product Data: Include rated nameplate data, capacities, weights, dimensions,

minimum clearances, installed devices and features, location of each field
connection, and performance for each type and size of transformer indicated.
B. Shop Drawings: Diagram of power signal and control wiring.
C. Coordination Drawings: Floor plans, drawn to scale, on which the following items are
shown and coordinated with each other, based on input from installers of the items

involved:
1. Room layout and cable routing.

2. Dimensioned concrete base, outline of transformer, and required clearances.
3. Ground rod and grounding cable locations.
D. Source quality-control test reports.
E. Field quality-control test reports.
F. Operation and Maintenance Data: For transformer and accessories to include in

emergency, operation, and maintenance manuals.
G. Certification: Compliance certificate with IEC or BS or NEMA.
H. Spare parts: Manufacturer recommended spare parts list.
1.5 WARRANTY
A. The Maintenance Period for the equipment and appurtenances shall begin when the
performance test on the equipment and appurtenances has been successfully
completed and preliminary accepted as stipulated in the Conditions of Contract.
B. Warranty: One year from date of substantial completion.
A. Comply with IEC, IEEE.
B. Reference Standards
C. Except as modified herein, the equipment shall be designed, manufactured and

tested in accordance with IEC Standard Publication No.
1. IEC 60076-1
2. IEC 60076-3: Part 3: Insulation levels, dielectric tests
3. IEC 60076-10: Part 10: Determination of sound levels
4. IEC 60076-11: Part 11: Dry Type Transformer
5. IEC 60076-12: Part 12: loading guide for Dry Type Transformer
6. IEC 60085 Thermal evaluation and classification of electrical insulation.
7. IEC 60137 Bushings for alternating voltages above 1000V
8. IEC 60364: Electrical Installations.
D. Local Egyptian code and standards.
A. Store transformers protected from weather and so condensation will not form on or
in units. Provide temporary heating according to manufacturer's written instructions.

B. Transformers shall be crated, as required. Auxiliary devices shall be designed for
easy installation on Site and shall be packed and shipped separately.
C. Handling shall be in accordance with manufacturer's instructions. Use factory

installed lifting provisions.
1.8 COORDINATION
A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases.
Concrete, reinforcement, and formwork requirements are specified in Division 03.
B. Coordinate installation of louvers, doors. Coordinate installation so no piping or

conduits or ventilation ductworks are installed in space allocated for medium-voltage
transformers except those directly associated with transformers.
PART 2 - PRODUCTS
2.1 DRY-TYPE DISTRIBUTION AND POWER TRANSFORMERS
A. Description: Dry-type, 2-winding transformers, three phase, 50Hz
1. Cast coil/encapsulated coil, with primary and secondary windings individually

cast in epoxy-resin.
B. Primary Connection: Fully enclosed cable end box on high voltage side.
C. Secondary Connection: Transition terminal compartment with connection pattern to

match switchgear and/or bus duct as shown on the drawings.
D. Insulation Class: Class F (155°C)
E. Ambient Temperature: 45°C
F. Average winding Temperature Rise above ambient temperature at rated current: 100°C
G. Basic Impulse Level: 125 kV for 22 kV transformer nominal voltage.
H. Rated 1 minute power frequency withstand for (22 kV winding): 50 kV
I. Rated 1-minute power frequency withstand for (400 V winding): 5 kV
J. Partial discharge ≤ 10 P.C
K. Climate Class: C1
L. Environmental Class: E2
M. Fire Class: F1

N. Full-Capacity Voltage Taps (22 kV): Total fife taps, four nominal 2.5 percent taps, 2
above and 2 below rated primary voltage; with tapping links on HV windings suitable
for de-energized operation. Tap changer shall be gang-operated and capable of
withstanding full transformer short circuit without damage
O. Cooling System: AN/AF, self-cooled, and with forced-air-cooled rating.
1. Automatic forced-air cooling system controls, including thermal sensors, fans,

control wiring, temperature controller with test switch, power panel with
current-limiting fuses, indicating lights, alarm, and alarm silencing relay.
P. Vector Group: Dyn11 unless otherwise indicated on the drawings.
Q. Core: The cores of the transformer shall be built-up from best quality, low losses,
high permeability cooled rolled grain-oriented stress relieved steel laminations non-
aging silicon steel, insulated on both sides as per Electrical Distribution Company
requirements.
R. Windings: HV and LV Windings shall be of Aluminum conductors with low losses and
then cast separately in molds as per Electricity Company requirements according to
transformer rating. Conductors insulated with high dielectric strength tapes having
very good temperature stability and be firmly braced so as not be loosen due to short
circuit.
S. The insulation material shall be based on an epoxy-resin/ powdered quartz mixture,

which makes the windings maintenance-free, humidity-resistant and suitable for
tropical areas as well as fire-resistant (in accordance with IEC 60076-11, class F1) and
self-extinguishing. The insulation material of windings and connections shall be free
from insulation compounds subject to shrinking or collapse during service.
T. Transformer Losses: The maximum acceptable values for transformer losses shall be
according to the following tables:
Power Iron losses Load Losses Noise Level % Impedance

(KVA) (W) (W) DB At 75°C
1600 3100 14000 62 6
2000 4000 17500 63 6
U. Capability of withstanding short circuit: transformer should be capable of

withstanding without damage the thermal and mechanical effects of short circuit at
the terminal for two seconds duration.
V. Permissible Overload: 10% for 1 hour without undue heating and without any forced
cooling fans support.
W. Enclosure: Protection enclosure IP21 with anti-corrosion treatment. Enclosure

thickness in all side shall be not less than 2.5 mm before electro static painting and
the enclosure shall be according to IEC 62271-202 and the manufacturer shall assure
the temperature rise will be within limits.

X. High-Temperature Alarm: Sensor at transformer with local audible and visual alarm
and contacts for remote alarm.
Y. in case of installing any equipment within the transformer room a wire mesh gate
access shall be installed to make a separation between the transformer and any live
equipment) and according to engineer approval.
Z. Accessories:
1. Lifting lugs for complete transformer.

2. Skid base with jacking and pulling provisions.
3. Two grounding pads on diagonally opposed sides for the base with bolt type
cable clamp adjustable for copper ground cables ranging from 95mm2 to
240mm2 for chassis grounding. One of the pads shall be located at the side
where the secondary neutral busing is mounted.
4. Cooling fans automatically operated to increase the permissible loading of the
transformer.
5. Relaying and protection as manufacturer’s standard practice at least 2 NO and
2 NC points.
6. Diagrammatic weatherproof stainless steel engraved or etched nameplate.
The nameplate shall show full rating of transformer, voltage and tap ratios,
impedance, weight, vector diagram, temperature class and temperature rise,
etc. and shall bear a connection diagram showing studs, tap changers and
other parts. Nameplate shall be in English.
7. Thermal Monitoring: shall be provided with electronic controller for thermal
protection and temperature monitoring ready to interface and connect to
BMS.
8. Temperature sensors PTC sensing thermistors shall be mounted in each LV coil
as close as practicable to its hot spot.
9. The thermistors shall be wired back to the electronic controller fitted on the
transformer.
10. The thermistors shall be used to indicate winding temperature, and provide
alarm and trip indications, and to operate forced cooling fans and trip HV
circuit breakers where specified.
11. In addition to items listed hereinbefore, provide relaying and protection as
manufacturer’s recommendation.
12. The Cooling fan shall be automatically switched on and off by means of
sensors and fan control unit.
13. Transformer shall be fitted with control unit for temperature monitoring and
fan control unit, the unit shall have sufficient number of inputs and outputs for
sensors, Alarms, Trip, fault and fans.
2.2 IDENTIFICATION DEVICES
A. Nameplates: Engraved, laminated-plastic or metal nameplate for each transformer,

mounted with corrosion-resistant screws. The nameplate shall show full rating of
transformer, voltage and tap ratios, impedance, vector group, insulation class,
temperature rise, weight, etc.

A. Reference Standards:
1. Except as modified herein, the equipment shall be designed, manufactured

and tested in accordance with IEC 60076 and IEC 60726, latest editions or
equivalent BS and IEEE.
B. Factory Tests: Perform the following factory-certified tests on each transformer

according to the IEC or BS or IEEE:
1. Measurement of transformation ratio on rated voltage and on all tap

connections and checking of voltage vector relationship.
2. Insulation tests between windings and between windings and earth.
3. Induced over voltage withstand test.
4. Measurement of no load losses at rated voltage and rated frequency.
5. Measurement of no load losses and current.
6. Measurement of load losses.
7. Measurement of winding resistance.
8. Measurement of short circuit impedance.
C. Certifications: A certificate for the following type tests shall be submitted
1. Impulse voltage test.

2. Measurement of maximum temperature rise.
3. Audible sound level measurement.
4. Vector group test.
5. Audible sound level measurement.
D. Prior to shipment the Contractor should submit all test certificates mentioned in item
A and B for review and approval.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Inspect each transformer and related accessories for damage, defects and
completeness before installing.
B. Examine areas and conditions for compliance with requirements for medium-voltage
transformers.
C. Examine roughing-in of conduits and grounding systems to verify the following:
1. Wiring entries comply with layout requirements.

2. Entries are within conduit-entry tolerances specified by manufacturer and no
feeders will have to cross section barriers to reach load or line lugs.
D. Examine walls, floors, roofs, and concrete bases for suitable mounting conditions
where transformers will be installed.

E. Verify that ground connections are in place and that requirements in Division 26
Section "Grounding and Bonding for Electrical Systems" have been met. Proceed
with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A. Install transformers on concrete bases with the dimensions as indicated on the

structural drawings and as per manufacturer instructions.
B. Maintain minimum clearances and workspace at equipment according to

manufacturer's written instructions and as per IEC and/or BS.
3.3 IDENTIFICATION
A. Identify field-installed wiring and components and provide warning signs as specified
in Division 26 Section "Identification for Electrical Systems."
3.4 CONNECTIONS
A. Ground equipment according to Division 26 Section "Grounding and Bonding for

Electrical Systems."
B. Connect wiring according to Division 26 Section "Low-Voltage Electrical Power

Conductors and Cables."
A. Manufacturer's Field Service: Engage a factory-authorized service representative, at

no additional cost, to inspect field-assembled components and equipment
installation, including connections. Report results in writing.
B. Perform the following field tests and inspections and prepare test reports:
1. After installing transformers but before primary is energized, verify that

grounding system at substation is tested at specified value or less.
2. After installing transformers and after electrical circuitry has been energized,
test for compliance with requirements.
3. Perform visual and mechanical inspection and electrical test.
4. Test and adjust controls and safeties. Replace damaged and malfunctioning
controls and equipment.
C. Remove and replace malfunctioning units and retest as specified above.
D. Test Reports: Prepare written reports to record the following:
1. Test procedures used.

2. Test results that comply with requirements.

3. Test results that do not comply with requirements and corrective actions taken
to achieve compliance with requirements.
3.6 SYSTEM VALIDATION
A. Provide the services of approved trained and field experienced engineers, at no

additional cost to the Employer. This is to validate each system and verify that each
system is operational and performing its intended function within system tolerances
as specified hereinafter and detailed in the approved post- installation test
procedures. Validate each system by simulating inputs.
B. Simulate malfunctions to sound alarms. Check all systems thoroughly for correct
operation. Test equipment for this function shall be furnished by the Contractor.
C. Immediately correct all defects and malfunctions disclosed by tests. Use new parts
and materials as required and approved and retest. Provide a report certifying
completion and validation of each system.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. RING MAIN UNIT
CAIRO - EGYPT 261301 - 2874 0

CONTENTS
SECTION 261301
RING MAIN UNIT
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Coordination 3
1.7 Warranty 5
1.8 Instructions And Training On Operation And Maintenance 5
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 Performance And Design Requirement 5
2.3 Components 5
2.4 Accessories 10
2.5 Fabrication 10
2.6 Voltage Presence Indicators (Vpi) 10
2.7 Fault Passage Indicator 11
PART 3 EXECUTION 11
3.1 Installation 11
Ring Main Unit Section 261301

SECTION 261301 – RING MAIN UNIT
PART 1 GENERAL
A Drawings and general provisions of the Contract, including General Conditions,

Conditions of Particular Application and Division-1 Specification Sections, apply to
this Section.
B Division 25: Section 250000 “Building Management System (BMS)”
1.2 SUMMARY
A This section covers Ring Main Unit which shall be furnished and installed as specified
herein and as indicated on the drawings.
B Equipment furnished and installed under this section shall be fabricated, assembled,
erected, and placed in proper operating condition in full conformity with the
drawings, specifications, engineering data, instructions, and recommendations of the
equipment manufacturer unless exceptions are noted by the Engineer.
C During tendering, the Contractor shall select one of the manufacturers whose is
capable of delivering Ring Main Unit which fulfill the requirement of electrical
distribution company (EDC) and had previous approvals of similar types. By this
awareness the manufacture shall give the correct quotation for the required
Equipment including EDC requirements during tendering.
D Before delivery, the Contractor is responsible to obtain the approval for the
manufacturer, type, voltage, protection devices, meters, etc. from the electrical
distribution company whose additional requirements shall be considered even if
these requirements are not clearly mentioned in these specifications.
1.3 SUBMITTALS
A Drawings and Data: Complete drawings, details, and specifications covering the
equipment furnished under this section shall be submitted.
B Complete and accurate drawings of the equipment, including plan, front, and
sectional or side views, and base plans showing anchor bolt locations and base
details, shall be provided.
C Within 90 days after the Notice to Proceed, the Contractor shall furnish outline
drawings and dimensional data which fully describe the projected floor space
required for the equipment; the absolute minimum working space required at the
front, rear, and sides of the equipment; the equipment height; and the equipment
weight.

D Operations and Maintenance Manuals/Charts and Spare Parts Data: Complete
operations and maintenance manuals/charts including spare parts data and wiring
diagrams of all equipment furnished under this section.
A References: Except as modified or supplemented herein, all equipment and materials

required in this section including their installation shall conform to the applicable
requirements of the following standards. Standards current at the time of tender
shall be used.
B International Electro-Technical Commission IEC No.
1. 62271-200 A/C Metal Enclosed Switchgear and Control Gear for Rated
Voltages Above 1 kV and up to and Including 52 kV
2. 62271-102: Alternating current and earthing switches
3. 62271-103: Switches for rated voltage above 1 KV up to and including 52 KV.
4. 62271-1: Common Specifications for HV Switchgear & Control Gear Standards
5. 62271-105: Alternating current switch-fuse combination).
6. 60255: Measuring relays and Protection equipment’s
7. 60529: Degree of Protection
C Manufacturer’s Experience: Each Ring Main Unit (RMU) shall be a product of RMU
manufacturer who has designed, fabricated, and furnished equipment of the type
and size specified which has been successfully installed for a period of not less than
five or ten years.
D Shop Tests: All standard factory tests, including quality control tests, shall be
performed on the RMU. Four certified copies of test results shall be submitted to
the Owner Representative before the equipment is shipped.
1.5 COORDINATION
A All equipment specified under this section shall be furnished by or through a single
manufacturer who shall be responsible for the design, coordination, testing, and
satisfactory performance of all the components.
B Manufacturer’s Field Services: An experience, competent, and authorized

representative of the substation manufacturer shall visit the site of the Work and
inspect, check, adjust if necessary, and approve the installation of the substation.
The manufacturer’s representative shall be present when the equipment is energized
and placed in operation. The manufacturer’s representative shall revisit the job site
as often as necessary until all deficiencies are corrected and the substation
installation and operation are satisfactory in the opinion of the Engineer.
C The manufacturer’s representative shall furnish to the Engineer, a written report

certifying that each substation has been properly installed and adjusted; and that is
operates satisfactorily.

D All costs for these services shall be included in the Contract Price as stated in the Bill
of Quantities.
E Coordination Study: When required, a coordination study of the power distribution

system will be conducted in accordance with Section 260500, Electrical Materials
and Method. The equipment manufacturer shall provide the following information
to the Engineer with the initial equipment shop drawings:
F Protective relay coordination curves for each relay provided as a part of the unit
substation assembly.
G Protective fuse curves for each current-limiting fuse provided as a part of the RMU
assembly.
H Within 28 days after the return of the initial equipment shop drawing submittal, the
equipment manufacturer shall provide the above information to the Contractor in
accordance with Section 260500, Electrical Materials and Method.
A Delivery Schedule: Delivery schedule of the RMU shall be coordinated with the
Engineer and the Contractor. A copy of all correspondence and memoranda
regarding delivery of each RMU beyond point of manufacture to the construction
sites shall be submitted as required at the Conditions of Contract.
B Storage: Supplementing the storage requirements described in Section 260500,

General Equipment Stipulations the manufacturer shall acknowledge storage
conditions at the time of submitting his Tender. The equipment may not be
operational within 90 days after manufacture, and the manufacturer shall crate and
prepare the equipment for export transportation and long-term storage.
Precautionary measures for prolonged storage shall be provided by the
manufacturer at the factory. The Contractor shall be responsible for storage and
maintenance of the protective measures as recommended and instructed by the
manufacturer while stored at the storage site.
C Electrical equipment controls and insulation shall be protected against moisture or

water damage. All space heaters provided in the equipment shall be kept connected
and operating at all times until equipment is place in service.
D In additions to the protection specified for prolonged storage, the packaging of spare
parts (If Any) shall be prepared for export packing and shall be suitable for long-term
storage in a damp location. Each spare item shall be packed separately and shall be
completely identified on the outside of the container.
E Instructions for the servicing of equipment while in long-term or prolonged storage

shall accompany each item of equipment. Advisement of enclosed instruction with
each package shall be noted on the exterior of the package and shall be in the Arabic
and English languages.

1.7 WARRANTY
A The Maintenance Period for the equipment and appurtenances shall begin when the
1. Warranty Period: one year from date of Substantial Completion
1.8 INSTRUCTIONS AND TRAINING ON OPERATION AND MAINTENANCE
A Contractor shall provide instructions and training for the staff to be assigned in the
operation and maintenance of the equipment specified under this section. Training
and instructions shall be in accordance with the requirements set forth at the
PART 2 PRODUCTS
2.1 MANUFACTURERS

be incorporated into the Work.
2.2 PERFORMANCE AND DESIGN REQUIREMENT
A System Characteristics: The system will be rated at (24) KV, 3-Phase, 50 Hz. The
approximate fault current shall be 750 MVA unless otherwise as shown on the
drawing.
B Station Criteria:
1. Four cells R.M.U (2+1) with metering comprise of :
a. Two incoming with SF6 Load break switches with earthing switch
mechanically interlocked. With rating as indicated in the drawings.
b. One outgoing with SF6/Vacuum Circuit breaker for feeding the
transformers with rating as indicated in the drawings.
b. Earth leakage indicator with Ferranti C.T.
c. Complete with bus bars and supporting insulators
d. Metering cell ready to install all meters required by Electrical
Distribution Company (EDC).
2.3 COMPONENTS
A RMU Enclosure: Enclosure shall be made of steel sheet 2.5 mm thick before paint
and treated against rust and provided with priming, intermediate and finishing coats
of electrostatic painting powder from inside and outside.

B Each switch shall be enclosed in a special compartment with its own door which have
device to prevent self-closing. The door shall be interlocked with the LBS such that it
can’t be opened unless the LBS is open. Door shall have a rubber sealing gasket.
C Degree of protection shall be at least (IP3x)
D Loss of Service Continuity LSC: 2A class PI complying with IEC 62271.
E All bus bars shall be electrical copper, Air insulated, mounted on support insulators
enough to withstand mechanical forces which may happen due to short circuit 20 kA
R.M.S for 3 sec.
F Each switch compartment shall be equipped with suitable clamp or any other mean
for supporting and fixing the cable or end box.
G Each switch board shall be supplied with a detachable insulated operating handle ≥
650 mm.
H Switchboard design according to IEC 62271 standards.
I Detailed drawings and technical specifications shall be attached with the offer.
J Load break Switches:
1. Load break switch and its mechanically interlocked earthing switch shall be SF6
insulation.
2. Shall be maintenance -free, the position of the power contacts and earthing
contacts shall be clearly visible on the front of the switchboard. The position
indicator shall provide positive contact indication.
3. The switches shall have 3 positions, open-disconnected, closed and earthed,
and will be constructed in such a way that natural interlocking prevents
unauthorized operations.
4. The switches shall be fully mounted and inspected in the factory.
5. Manual opening and closing will be driven by a fast-acting mechanism,
independent of operator action.
K Circuit-breakers:
1. The SF6/Vacuum circuit breakers shall be of the maintenance-free, (i.e. to be

of the Sealed Pressure System according to IEC 62271-100). the position of the
power and earthing contacts shall be clearly visible on the front of the
switchboard. The position indicator shall provide positive contact.
2. The circuit breakers shall have 3 positions: open-disconnected, closed and
earthed and shall be constructed in such a way that natural interlocks prevent
all unauthorized operations.
3. They shall be fully mounted and inspected in the factory.
4. An operating mechanism shall be used to manually close the circuit breaker
and charge the mechanism in a single movement.
5. Circuit breakers shall be fitted with a local system for manual tripping by an
integrated push button. There will be no automatic reclosing.
6. The circuit breaker shall be associated with a protection unit that will operate
with auxiliary DC power supply.
7. The protection system will ensure circuit breaker tripping as of a minimum
operating current (Is) which is the rated current of the transformer being
protected and may be set to certain ratings (adjustable).
8. Phase to phase protection shall be provided.
9. Ground fault protection shall also be provided.
10. Circuit breaker shall be with time delay relay or harmonic current restraint
relay to prevent false operation of the circuit breaker in case the transformer
draws inrush current from the supply.
11. Periodic mechanism lubrication shall require at the most not less than every
10000 cycles or five years.
12. Circuit breakers shall be equipped with an electrical spring stored energy
operating mechanism, including at least:
a. One electrical motor, recharging the mechanism as soon as the breaker

is closed or opened.
b. One anti-pumping relay to prevent the closing the breaker if the closing
coil being fed continuously while the opening coil is energized.
c. One shunt trip opening coil.
d. One closing coil.
13. Circuit breaker shall be rated at 750 MVA at 22kV rating nominal 3-phase class
with a normal continuous current rating as sown on Drawing’s bus. Breaker
shall be rated at least 20 kA RMS symmetrical at 22 KV and shall have a closing
and latching capability of 62.5 kA. Rates shall be referred to withstand short
circuit for three (3) seconds. Operating cycle shall be as a follow (0-0.3 sec-
CO-15 secs-CO). Automatic reclosure shall not be required.
14. Padlocking facilities
a. Circuit breakers shall be locked in the open or closed position by 1 to 3

locks
M Voltage and Current Ratings
1. Rated Voltage Un (24) kV

2. Continuous operating voltage (22) kv
3. Basic Impulse Level U1 (125) kV
4. Power Frequency Withstand Voltage (50) kV
5. Rated Current as indicated in the drawings
6. Rated Short-time Withstand Current 3 sec (20) kA
7. Rated Making Withstand Current peak (50) kA
N Specifications and tests shall comply with IEC 62271 for cable switch disconnectors
(L.B.S.).
O There shall be an earthing switch with each cable L.B.S.
P The earthing switch shall be manual operated with mechanical lock which prevents
its switching while the main switch is on.

Q When fuse LBS switches are used then two earthing switches shall be used. One
above fuse and one below fuse. All LBS shall be equipped with permanent voltage
presence lamps.
R The rated short-time withstand current of the earthing switch shall be at least equal
to that assigned to the disconnectors (L.B.S.)
S The peak withstand current of the earthing switch shall be at least equal to that
assigned to the disconnectors (L.B.S.)
T Cable L.B.S. shall also fulfill the conditions for isolating distance acc. To IEC 62271-
102 prescribed for isolators.
U At the side of the fused switch compartment shall be the outlet of 3 single or multi
core XLPE cables. That side shall be equipped with an insulating backelite plate with
three holes to pass the XLPE cables outside to the transformer. The level of this
backelite plate shall be ≥ 200 mm over the bottom, from outside, the place of the
backelite plate shall have a cover of the same sheet steel bolted with detachable
bolts. Depth of cover ≥ 22 cm.
V Contractor shall submit type tests certificates for the offered equipment’s according
to IEC.
W Routine tests shall be in accordance with IEC and shall be attended by Employer’s
representative(s).
X Earth Fault Indicators: 220 V, 50Hz, Automatic reset type complete with Ferranti
current transformer which will be erected around the cable sheath, according to the
specification.
1. Shall be mounted inside a metal or fiber-glass box with an opening to show

the indicator flag.
Y Current Limiting Fuses: (22) according to project KV H.R.C. FUSES (if required)
1. Conditions in Normal Services

2. Maximum ambient air temperature 45°C
3. Mean temperature measured over 24 hours 35°C
4. Average value of relative humidity:
5. Measured during a period of 24 hours < 95%
6. Measured during a period of a month <90%
Z To withstand effect of humidity and occasional condensation outdoor fuses shall be

used indoor.
AA A powder filled fuse-link shall not emit flame or powder although a minor emission
of flame from a striker is permissible, provided this does not cause breakdown or
significant electrical leakage to earth.
BB After the fuse has operated, the components of the fuse apart from these intended
to be replaced after each operation shall be in the original state. It shall be possible
to remove the fuse-link in one piece after operation.
CC Strikers shall comply with the requirements specified in Sub-clause 18.3 of IEC
60282-1.
DD The values of cut-off current corresponding to each prospective breaking current

shall not exceed the values corresponding to the cut-off characteristics given by the
manufacturer.
EE After operation, the fuse shall be capable of withstanding the power frequency
recovery voltage across its terminals.
FF Fuse Ratings:
1. Rated Voltage (22) according to project kV

2. Rated Frequency 50 Hz
3. Rated Current As shown on drawings
4. Rated Breaking Capacity ≥ 50 kA
GG Features Required:
1. The fuse links shall have the dimensions as per attached spec.
2. The fuse link contacts shall be silver plated.
3. The fuse link body shall be of porcelain.
4. On each fuse link the badge of the Employer shall be printed.
5. Each fuse link shall be equipped with a striker which complies with Sub-clause
18.13 of IEC 62271
HH Time-current characteristics shall be in compliance with IEC 62271 and shall be

offered with tender.
II Instrument Transformers and Control Switches: Instrument transformers shall be

sized for burden requirements of connected meters with accuracy Class as follows:
1. Current Transformers (CT's): Class 0.5 for metering and class 5P10 for
protection n10.
2. Potential Transformers (PT's): Class 0.5 for metering (first core) and class 3P
for protection (second core).
JJ All potential transformers shall be provided with current limiting fuses. Voltage
rating for the secondary winding shall be of ratios:
22000 / 110 / 110

3 3 3
KK The thermal rating of the transformers shall be sufficient to provide the total current
required to operate the burdens on the secondaries without exceeding the rating of
transformer as indicated on nameplate. PT's (1 per phase) shall be installed either as
a unit drawout assembly or with an isolating switch in a separate compartment so
that the transformers, primary fuses and secondary circuits may be inspected and
tested in a completely de-energized condition.
LL CT's shall have mechanical and thermal rating equal to the rating of the LBS.
Secondary rating shall be 5 amperes and primary ratings shall be as shown on one-
line diagram. Transformer shall be capable of carrying 120 percent of rated current
for one hour. Ground current sensing transformers shall have a one ampere
secondary current.
MM Control switches shall be the rotary enclosed type with positive means for
maintaining contact position.
2.4 ACCESSORIES
A Signage: Each RMU shall have engraved laminated nameplates screwed to the doors
of each individual compartment and wiring diagrams pasted inside each door.
B Each RMU shall be furnished with a sign marked “DANGER - HIGH VOLTAGE”. Letters
shall not be less than 25mm high, 6 mm stroke. Signs shall be laminated plastic, red
letters with a white background.
C All compartments with voltages from sources outside of the compartment shall have
a sign on the compartment door marked “CAUTION - THIS UNIT CONTAINS A
VOLTAGE FROM A SOURCE OUTSIDE OF THIS UNIT”. Letters shall be black on a high
visibility yellow background. Signs shall be adhesive backed vinyl approximately
75mm by 125mm.
D All nameplates and signage shall be printed in both English and Arabic.
2.5 FABRICATION
A Surface Preparation: Remove all casing projections, weld flux, or splatter by hand
scraping, hand impact tools, etc., followed by wire brushing or power grinding.
Sharp corners or sheared edges shall be dulled and radiused with power grinder to
improve paint adherence.
B Exposed grooved surfaces shall be finished smooth by filling and thoroughly cleaned
as required to provide a smooth uniform surface for painting.
C Shop Painting: Unless galvanized surfaces are provided, all ferrous metal surfaces
shall be painted with a prime coat and given two or more finish coats of paint.
2.6 VOLTAGE PRESENCE INDICATORS (VPI)
A Each RMU function shall be equipped with a Voltage Presence Indicator (VPI) on the
front cover to indicate whether there is voltage in the cables.
B The voltage indicator shall be in compliance with IEC 62271-206 standard.
C Cable connection bushings shall be equipped with capacitive dividers that will supply
low voltage power to the voltage presence lamps.
D The lamps shall be of high performance LED technology to insure high visibility and
long life duration. Three voltage sensing inlets shall be provided on each function to
allow checking the phase concordance.
E It shall be possible to replace the voltage presence indicator while unit remains
energized, guaranteeing the safety of people.
2.7 FAULT PASSAGE INDICATOR
A Each of the two Incoming Load break switches shall be equipped with a fault Passage
indicator
B The voltage signal shall be taken from the Voltage Presence Indicator (VPI)
connected to capacitive divider in each load break switch cable bushing.
C The voltage detection device shall display the MV network voltage. It is not allowed
to use a voltage measuring tool to calibrate the device.
D The fault passage indicator function is used to detect and localize the faulty part of
the network.
E It shall indicate short circuit and earth faults with a high performance red LED on the
front panel.
F It shall indicate permanently the load currents of each phase and memories the maxi
meters of each phase.
G It shall indicate both phase-to -phase and phase-to earth faults.
H In order to guarantee a fault validation on cable with low load value, a validation by
voltage presence shall be provided.
I It shall be equipped with both automatic and manual setting modes.
J It shall indicate permanently that it is in operation, it could be by means of the

permanent load indication.
PART 3 EXECUTION
3.1 INSTALLATION
A The RMU base assembly comprises the preformed concrete sump to which are fixed
2 opposing sheet steel support trays. The steel support trays, which overhang the
concrete sump, serve to support and secure RMU together with the external
extremities of the cable entry compartments.
A Test and Checks: The following minimum test and checks shall be performed before
energizing the substation.
B Megger terminals and buses for grounds after disconnecting devices sensitive to
megger voltage.
C Remove all current transformer shunts after completing secondary circuit.
D Check all mechanical interlocks for proper operation.
E Vacuum-clean all interior equipment.
F Arrangements shall be made to have tests performed/witnessed by Electrical

Distribution Company and handing over to local authorities.
G Tests Certificate
1. Type test certificates shall be submitted with the offer (if not before
submission) including:
a. Type tests of cable L.B.S. acc. IEC 62271-103

b. Type tests of earthing switch acc. To IEC 62271-102
for above mentioned requirements
H OWNER may require its representative(s) to attend some or all of the routine tests
acc. to same above IEC publications.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. LOW VOLTAGE SWITCHBOARDS
CAIRO - EGYPT 262413- 2874 0
ECG Form No. E409 Rev. 5/0 Sheet of 16

CONTENTS
SECTION 262413
LOW VOLTAGE SWITCHBOARDS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.4 Warranty 4
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 General 5
2.3 Connection To Building Management System (Bms) 7
2.4 Communication 7
2.5 Switchgear 7
2.6 Incoming Supply And Outgoing Circuits 9
2.7 Circuit Breakers 9
2.8 Power Air Circuit Breakers (Pacbs) 11
2.9 Instrumentation And Controls 13
2.10 Mcc Special Requirements 14
2.11 Surge Protection Device (Spd) 14
2.12 Factory Testing 14
PART 3 EXECUTION 15
3.1 Inspection 15
3.2 Preparation 15
3.3 Electrical Work 15
3.4 Mounting 15
3.5 Installation Supervision 15
3.6 Field Testing 16
3.7 System Validation 16
Low Voltage Switchboards Section 262413

SECTION 262413 - LOW VOLTAGE SWITCHBOARDS
PART 1 GENERAL
A. Drawings and General Provisions of the Contract, including General Conditions, Con-
ditions of Particular Application and Division-1 Specification Sections, apply to work
of this Section.
1.2 SUMMARY
A. This section covers low voltage metal enclosed switchgear as indicated on the Draw-
ings and required by the Contract and shall include the following items:
1. Switchboard
2. Distribution Boards
3. Branch Circuit Panelboards
B. Related Sections
1. The following sections of work contain requirements that relate to this Sec-
tion:
a. Division 25 Section “Building Management System”
b. Division 26 Section “Basic Electrical Materials and Methods “
c. Division 26 Section “Grounding and Bonding “
d. Division 26 Section “Package Engine Generator “
e. Division 26 Section “Power Factor Correction Equipment “
f. Division 26 Section “Panelboards “
1.3 SUBMITTALS
A. Submit the following in accordance with the Conditions of the Contract and Division-
1 Specification Sections.
B. Verification and Compliance:
1. Room Layout diagrams and general arrangement showing dimensions and

weights of the subject equipment inside.
2. Certificates of compliance of equipment to codes
3. Spare parts list recommended by the manufacturer for normal operation and
maintenance of 3 years
4. 3 complete original sets of manufacturer operation and maintenance manuals
for each board
Studies:
5. Provide thermal stress limitation checks for all breakers and cables as per

manufacturer’s data
6. Short circuit calculations
7. Provide full discrimination and relay coordination studies for all breakers as
per manufacturer’s data according to the calculated short circuit currents
shown on the drawings.
Test Programs:
8. Standard and optional factory tests program

9. Post-installation test procedure
10. Final test reports procedure
C. Equipment Data: The equipment data to be provided by the Contractor prior to or-
dering any material covered by this Section shall include but not be limited to:
1. Complete technical data on circuit breakers, contactors and other switchgear

protection and switching devices, including data on operating characteristics,
compliance to standards, dimensions and weights and detailed description of
operating mechanism.
2. Complete technical data on instrument transformers protective and auxiliary
relays, measuring instruments, including manufacturer's catalogue operating
characteristics - operating curves with detailed description.
3. Complete technical data on the construction of switchboards with bus-bars,
equipment plug in arrangement, access doors, and provision for expansion in-
cluding detailed descriptive manufacturer's catalogues.
4. Complete technical data on miscellaneous items including indicating lamps,
control and instrument wiring, outgoing and incoming power terminals and
wiring labels, locks grouting, bracing, etc.
D. Equipment Shop Drawings: Shall include but not be limited to:
1. Plans, front, rear and side elevations, with indication of all face-mounted
equipment exact dimensions and weights.
2. Drawings of arrangement of equipment inside the board.
3. One line schematic diagram of circuits.
4. Control circuit diagram, showing all auxiliary contacts remote control, if any,
and remote indication.
5. Indication of arrangement of main incoming feeders and outgoing feeders
(bus-bars or cables).
E. The Contractor shall submit the Main Distribution Boards (MDB) according to the lat-
est requirements of the Egyptian distribution Company (EDC) for approval before
manufacturing.
Any additional requirements shall be considered without any extra cost to the Con-
tract even if these requirements are not clearly mentioned in these specifications.
EDC shall witness the factory testing for the MDB and approved before shipment to
site.

1.4 WARRANTY
A. Contractor shall agree to repair or replace the equipment that does not comply with
the requirements or fails in work.
1. Warranty Period: one year from date of Substantial Completion.
A. Reference Standards
1. The work and equipment of this section shall be designed, manufactured and
design verification in accordance with the International Electro-Technical
Commission (IEC) or other approved equivalent International Standards.
2. International Electro-Technical Commission IEC 61439.
A. Shipments shall be securely packed for delivery and transit, protected against exces-
sive heat and humidity and waterproofed for protection against water damage.
When material must be bundled due to excessive size each bundle shall have a tag,
made of metal, securely tied on with heavy gauge wire. Purchaser's markings shall
be die-stamped on the tag.
B. Equipment, relays, and other components with moving or fragile parts shall be
properly blocked, tied or packed to prevent damage.
C. Any component shipped separately shall be clearly marked with description, use and
installation instructions.
D. All packages shall be marked with equipment tag number for identification when
shipped and when received at site.
E. Sections to be grouped in not more than 3 sections per crate.
F. Each shipping unit shall be equipped with shipping angles or lifting lugs for handling
by crane.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Subject to compliance with requirements, manufacturers offering products that may


2.2 GENERAL
A. Materials and equipment shall be new and completely assembled, wired and tested
at the factory requiring only field installation and connection of power and control
circuits to place the equipment in service, except for multi-unit switchgear which
could be divided into shipping section after being completed and tested at the facto-
ry.
B. All Switchboard to be design verified “Type Tested” according to IEC 61439
C. Manufacturer design and arrangement details of the equipment shall be subject to

the prior approval of the Engineer.
D. Switchgear and auxiliaries shall be designed for continuous operation at 380/220

volt, 3-phase, 5 wire, 50 Hz, solidly grounded neutral power supply. Ambient condi-
tions shall be as specified by Section 260500 "Basic Electrical Materials and Meth-
ods".
E. Index of protection for all Switchboards according to IEC 60529 unless otherwise in-
dicated on the drawings and schedules shall be as follow:
1. IP42 for surface mounted

2. IP54 for outdoor & wet areas
F. Switchgear shall be metal enclosed, form (2b) type as per IEC 61439, complete with
stationary structure, have complete bussing and front access apparatus described
herein.
G. Provide a dead hanged front panel behind the door of a distribution board, to allow
safe operation. This front panel shall carry the required tags of equipment to show
function of each breaker inside or any push-button, etc.
H. The Contractor shall make sure that the space for each switchboard is available in ac-
cordance with the requirements for the installation and operation and maintenance
of the equipment as specified and supplied by the Manufacturer, and as per IEC
60364, 61439. Any inaccuracy in the building shall be corrected as required and di-
rected by the Engineer, and at no extra charge to the Employer.
I. Ratings are shown on the one-line diagrams and the panel details and should be
checked based on the actual loads at no extra cost to the Employer.
J. The switchgear shall contain equipment with ratings as indicated on the one line dia-
gram, panel details, and in this Specification.
K. Approved barriers between adjacent sections of switchboard shall be provided.
L. All ratings shown on the one line diagrams are the required operational equipment
ratings at the ambient temperature. It shall be the Contractor's responsibility to en-
sure that the equipment furnished satisfy the ratings shown without any extra cost
to the Employer.
M. The Contractor shall assume all responsibility for mechanical and electrical coordina-
tion of equipment and devices required by the Drawings and Specifications.

N. Interrupting capacities and short circuit ratings shown on the Drawings are for guid-
ance only; Contractor shall submit calculation for actual levels to the Engineer for
approval.
O. The prospected short circuit current (Isc) value indicated at each bus-bar on drawings
shall represent the maximum 3-phase symmetrical R.M.S. kA, and it is the rating that
all switchboard components (i.g. bus, bars, bolts, circuit breakers, etc. shall with-
stand.
P. Buses shall be 99.9% electrolytic copper of sufficient size to limit temperature rise to
values according to IEC 61439.
Q. Crowded bus-bar arrangement to fit maximum possible number of branch circuit

breakers in a distribution board, shall not be accepted.
R. Stacking of circuit breakers inside the switchboard shall be in accordance to original

Manufacturer design tables in accordance with temperature rise type tests.
S. Forced Ventilation should be used according to design guide of the original equip-
ment manufacturer in order to maintain the internal temperature within the design
limit.
T. The phase arrangement on 3-phases buses shall be R.S.T from front to back, left to
right, or top to bottom from the front of the switchboard.
U. All switchboard components shall be of the same manufacturer and must be tested
according to IEC standards. The assembly must be design verification and fully coor-
dinated.
V. All switchboard doors shall have a key lock and indicating lamp for ON/OFF-READY, in
addition to the necessary equipment for security identification.
W. All indicating lamps used in the switchboards should be semi-conductor LED diodes.
Use of neon or incandescent indicating lamps is not acceptable.
X. All indicating lamps and pushbuttons should be chromatid metallic base and body.
Y. All panel access doors shall be provided with a master key for maintenance and op-
eration.
Z. Main circuit breakers of the MDB shall be provided with smart interface module SIM
for the circuit breakers as indicated on the drawings .
AA. The panel shall be designed to permit continuous operation of all components
mounted therein with panel ambient temperatures of up to 40C for indoor installa-
tion and 45C for outdoor installation.
BB. Digital power meters for Main switch boards shall be provided as indicated in single
line drawings
CC. Digital Power Meter:

1. The digital power meter installed in the MDB shall be embedded with TCP/IP
communication protocol to the BMS system.
2. The DPM shall include but not limited to the following measurements:
a. Volt, Ampere and Power factor.

b. Frequency.
c. Active, reactive and apparent power (KW & KVAR & KVA).
d. Energy metering (KWH & KVARH)
e. Maximum demand.
f. Phase-to-phase, phase-to-neutral and residual voltage.
g. Any other measurements available by the DPM manufacturer.
2.3 CONNECTION TO BUILDING MANAGEMENT SYSTEM (BMS)
A. coordinate with the Building Management System (BMS) supplier and provide all
necessary interface devices using smart panel communication concept as shown in
drawings and BMS schedules.
2.4 COMMUNICATION
A. Smart Interface Module
As Indicating in the drawings, the switchboard shall be equipped with a Smart inter-
face module that makes it possible to:
1. Monitor modular protection, control units and trip units natively and provide
the centralized management system (BMS, supervisor, management software,
etc.) with information on their status and measurements.
2. Transmit orders from the centralized power manager system to the switch-
board control units
3. Transmit real time measurements, status, and trips with Modbus TCP/IP pro-
tocol to a management software database.it shall have embedded Ethernet
port and the data to be ready to be processed and displayed on its embedded
web server.
2.5 SWITCHGEAR
A. Apparatus: All auxiliary equipment, transition sections, bus duct, and other neces-
sary components required for complete installation and proper operation, under TN-
S distribution system, although not specifically listed herein, shall be furnished and
included in the switchgear assembly.
B. All circuit breakers of the same type and rating shall be completely inter-changeable
between compartments and between units at different locations on the site.
C. All doors, panels and cubicles in general, shall be sealed with neoprene or equivalent
gaskets. Enclosure shall be dust and vermin proof. Provide a directory of circuits on
inside cable compartment.
D. Fuses (if applicable) shall be of the same manufacturer, dual elements current limit-

ing type.
E. Overload relays shall be of the anti-single phasing type.
F. Bolted covers on compartments incorporating live connections shall bear a suitable

warning label.
G. All live conductors behind doors should be protected against accidental contact by
use of transparent plexi-glass sheet marked with an electrical shock warning label.
H. Fuses or miniature circuit breakers shall be provided so that relays, controls and in-
struments may be isolated whilst other essential circuits are kept energized. Accord-
ingly the control circuit should be divided into two separate circuits (indicators cir-
cuit) and (circuit breakers control circuit).
I. Supply of any control shall be via a suitably sized control transformer (at least three
times the VA rating of all connected devices). Control circuits which are fed directly
from the busbar will not be accepted. The control transformer shall be protected at
its primary and secondary sides by HRC fuses of suitable size.
J. Main Bus: The main bus shall be made of 99.9% pure copper and shall be continuous
current ratings as indicated on the Drawings or shall be of equal rating to the maxi-
mum setting of the protective device on the incoming side whichever is greater.
K. All bus-bars shall be fully rated and extend with the same size along the entire length
of the switchgear assembly.
L. Short-circuit Duty: Bus bars are to carry at least 125% of the maximum short-circuit
level at point of application for one second, without showing any signs of degrada-
tion.
M. All horizontal bussing shall have provisions for future extension on either end.
N. All main bus connections shall be tight, corrosion-free and with sufficient bolts to
withstand the symmetrical fault currents indicated on the Drawings.
O. The bus-bar supports shall be formed of high strength, low moisture absorbing, high
impact material with ample creepage distance between bus-bars. Bus-bars shall be
braced to withstand the symmetrical fault currents indicated. All busbar bracing ma-
terials should be of a non-magnetic material.
P. All bus-bars and tap connections shall be connected in such a manner that initial con-
tact pressure remains substantially undiminished at bus temperatures ranging from
indicated rated ambient to rated full load temperatures, to maintain minimum con-
tact resistance for the full service life of the equipment.
Q. Vertical Bus: All vertical bus-bars shall be of same material of main bus and shall
have sufficient capacity to supply all installed circuit breakers and each vertical sec-
tion shall have full height and depth, fire stop barriers of approved fire resistant ma-
terial.
R. Vertical bus compartment shall be completely enclosed and isolated from other
components.

S. All vertical bus connections shall be tight, corrosion free and be able to withstand the
symmetrical fault currents indicated.
T. Neutral Bus: Neutral buses shall be sized for the same capacity of the main bus and
shall be of copper.
U. The neutral bus shall be separate and isolated from the ground bus and completely
insulated from ground. A removable bus link shall be provided for grounding the
neutral bus as shown on Drawings.
V. All neutral bus connections shall be tight and corrosion free.
W. Ground Bus: A solid copper ground bus shall extend along the full length of the
switchgear and rigidly bolted to the switchgear lower part compartments, frame and
all sections of structure.
2.6 INCOMING SUPPLY AND OUTGOING CIRCUITS
A. Source: Incoming supply shall be 380 volts, 3-phase, 5 wire, 50 Hz, with symmetrical
fault current level available at the incoming line terminals as indicated on Drawings.
B. The connections from the incoming line terminals to the main bus shall have the
same capacity as the main horizontal bus.
C. Connections to the switchgear shall be by bus-way system, cables in conduit or on

cable trays as indicated on Drawings.
D. If the incoming power supply is shown as cables a removable metallic gland plate
with thickness of not less than 5 mm shall be fixed to the top or bottom or both sides
of the panel depending on the direction of the cables. A non-ferrous material must
be used in case of single core conductors. Pressure lugs shall be provided for the
termination of cables, whose sizes are as shown on the one line diagrams.
E. Outgoing Circuit by Cables: All outgoing feeder sizes shown on Drawings are consid-
ered a minimum and the Contractor shall adjust without any additional cost to con-
form to the IEC 60364 Regulations after final equipment selection, same gland plates
mentioned above will be applicable.
2.7 CIRCUIT BREAKERS
A. Main incoming, bus tie circuit breakers shall be four-pole, single-throw, motorized
circuit breaker with continuous current ratings as shown on the one-line diagram and
wiring schedules.
B. All breakers above or equal to 1600A must be air-type and as indicated in the draw-
ings.
C. As a general rule All breakers above 1600A must be electrically motorized unless
otherwise indicated on drawings
D. Unless otherwise indicated all incoming and coupler breakers must be withdrawable

air type.
E. All automatic source change over (ATS) schemes must have mechanical interlocks in
addition to electrical interlocks.
F. Three (3) phase outgoing circuit breakers shall be Three (3) pole molded case, Three
(3) pole miniature circuit breakers or combined with residual current devices four (4)
pole as shown in the single line diagram or in panel schedules.
G. All four (4) pole circuit breakers must have neutral protection accordingly their trip
units should be able to sense the current on all four (4) poles. The trip unit should al-
low a separate setting for the neutral pole to select one of three settings (neutral
unprotected), (neutral protected at 50% phase current) and (neutral protected at
100% of phase current).
H. Circuit breakers shall be selected in line with this specification at the point of applica-
tion in accordance with the drawings, allocated spaces and the "Regulations" as ap-
plicable and shall be suitably graded for 660 volt line service.
I. Circuit breakers serving as generator incoming must be fitted with a generator class
trip unit capable of achieving low settings suitable to generator applications.
J. Circuit breakers shall be totally enclosed in a molded case construction of approved

manufacturer and shall be provided with a front operated handle mechanism for
manual operation of the main contacts, in addition to the automatic operation under
overload current conditions. Multi-pole breakers shall have a single-handle mecha-
nism for simultaneous operation of all poles. Number of poles and its protection
type shall be suitable for TN-S Grounding System.
K. Each pole of the circuit-breaker shall have an inverse-time delay over current protec-
tion for small overloads and an instantaneous magnetic overcurrent trip element for
operation under short circuit conditions. All poles shall be constructed to open, trip
or close simultaneously.
L. Circuit breakers shall be provided with quick-make, quick break switching mechanism
and positive trip-free operation so that contacts cannot be held closed against excess
currents under manual or automatic operation. Contacts shall be non-welding silver
alloy and shall be adequately protected with effective arc-quenching devices.
M. The service short-circuits breaking capacity of the molded case circuit breaker which
is 100% of ultimate short current shall be in accordance with IEC 60947-2 and shall
be equal to the same value of short circuit level (Isc) indicated on Drawings. Switch-
board and components withstanding rating shall be equal to this short circuit level
also.
N. The miniature circuit breakers shall be rated 10 kA breaking capacity as minimum un-
less otherwise specified, with terminals capacity up to 25 mm2.
O. All miniature circuit breakers should have protection shoulders against accidental
contact with their terminals.
P. When tripped by either the thermal or magnetic elements, the handle shall automat-

ically assume a position midway between ON and OFF positions which clearly indi-
cates a "TRIPPED" position.
Q. All poles shall be constructed so as to open, close or trip simultaneously.
R. Non-interchangeable trip breakers shall have their covers sealed and breakers with
interchangeable trips shall have the trip unit sealed to prevent tampering.
S. All incoming and outgoing circuit breakers in the same switchboard shall be totally
selective at the prospected short circuit level.
T. Molded case circuit breakers shall have trip units that achieve full selective system
for overload, short circuit and instantaneous protection.
U. Circuit breakers of rating 250 Ampere and above shall have electronic trip unit.
V. Thermal overcurrent trips shall be ambient-temperature compensated to allow for

an ambient temperature at the breaker higher than at the protected circuit or de-
vice.
W. Combination of circuit breakers and ground fault circuit interrupters shall be used
wherever specified with a fault indicator lamp. It shall be instantaneous trip with a10
mA, 30 mA and 100 mA sensitivity setting unless otherwise indicated.
X. All circuit breakers shall be derated according to climatic conditions and operating
temperature as per manufacturer standards.
2.8 POWER AIR CIRCUIT BREAKERS (PACBs)
A. Type: Encased in high strength, high temperature resistant, molded plastic insulating
materials, for normal operation at maximum temperature within enclosure at point
of application, tested to approve standards, manually operated for normal functions,
and automatically tripped under over-current conditions. Trip power is to be derived
from main power circuit, with sufficient tripping energy to reliably trip circuit break-
er. Fixed mounted circuit breaker is to be rear connected.
B. Construction: Manually or manually and electrically operated, as shown on the Draw-

ings, with two-step, spring charged, stored energy mechanism, quick-make, quick-
break type, electrically and mechanically trip-free, to prevent maintaining circuit
breaker closed against over-current condition whether under manual or automatic
operation. Electrically operated circuit breakers are to have integrally mounted,
spring charging motor mechanism automatically recharged upon closing. Both man-
ually or manually and electrically operated circuit breakers are to have mechanical
built-in charging lever and are to include open and close direct acting push buttons.
Stored energy provision is to allow open/close/open sequence of operation without
use of external energy. Circuit breaker is to have arc-quenching device on each pole
and replaceable arcing contacts.
C. Control Power: For electrically charged circuit breaker and/or for shunt trip device,
where required, control power is to be obtained from in-built MDB control power
transformer connected and fused on line-side of circuit breaker. Where shunt trip

and/or under voltage release are required, a sufficient capacitor trip device is to be
provided.
D. Rating: 4-pole, unless otherwise shown on the drawings. 750 V rated insulation volt-
age class, with continuous current rating (frame size) as per the approved design and
calculations, ranging between 1600 A and 5000 A (1600, 2000, 2500, 3000, 4000 and
5000 A), fully rated (100%) for service under worst site conditions. Breakers are to be
rated for a symmetrical RMS service short-circuit breaking capacity as per the ap-
proved design and calculations, to IEC 60947-2 sequence II (rated service short-circuit
breaking capacity) at specified voltage and frequency, meeting IEC60947-2, sequence
I, II, III and IV tests (for circuit breakers of utilization category B), tested in an enclo-
sure substantially the same as the enclosure in which they are to be installed.
E. Trip Unit: Totally enclosed, programmable, solid state device, interchangeable for
compatible frame sizes, pluggable into front of circuit breaker, tamper-proof and
with transparent, sealable cover. Trip unit is to measure sinusoidal and non–
sinusoidal current wave forms (fundamental to thirteenth harmonic) by continuously
sampling each phase throughout every cycle. Trip unit is to be direct acting trip de-
vice, current transformer operated, with flux transfer shunt trip that requires no ex-
ternal power. It is to have adjustable current setting (0.5 - 1.0 times trip unit rating)
with adjustable long-time delay, short-time pick-up and short-time delay, earth-fault
pick-up and time delay instantaneous over current pickup. Current setting range is to
be by means of replaceable trip-units within the maximum frame size rating. Once
removed, circuit breaker is to remain in the trip-free position. Short time delay is to
be adjustable in steps, with pre-settable or adjustable time band having maximum
delay of 0.3 to 0.5 seconds. Instantaneous trip is to be adjustable in steps at least 2 –
13 times the trip Unit rating. Over-ride protection is to allow full sensitivity up to in-
terrupting capacity of Circuit Breaker.
F. Trip Unit shall have protective relays including:
1. Over load and short circuit protection.

2. Over-voltage
3. Voltage unbalance.
4. Current unbalance
5. Reverse power.
G. Trip Unit Status Display: Shall indicate in words the status of normal breaker opera-
tion, long time over current pick up, instantaneous time over current trip, short time
over current trip, ground fault trip. Unit shall have integral resettable counter to
count long time, short time, instantaneous and ground fault trips.
H. Position Indicators: Positive with trip indication target. Target indicator is to be me-
chanical and is to give indication even when control power has been lost.
I. Neutral Current Transformer: Provide on the neutral conductor of each main, tie or
outgoing circuit having earth fault protection. Rating and characteristics of the neu-
tral current transformer are to be suitable for proper operation of the earth fault
protection system.

J. Circuit breaker accessories are to include the following:
1. key-locking provisions for all positions (disconnected, test, connected, closing

blocking, open)
2. Overload, short-circuit, and ground fault trip LEDS
3. Trip indicator and reset button
4. Operations counter.
5. On/off pilot lights.
6. Shunt-trip coil and closing solenoid for remote control.
7. Bell alarm for remote over-current trip indication.
8. Under voltage coil.
K. Auxiliary Contacts: Include N.O. and N.C. contacts on switchgear as required for re-
mote monitoring and control, plus 2 N.O. and 2 N.C. spare contacts.
L. Electrical Interlock: If electrical interlock is required between power air circuit break-
ers (as shown on the drawings), the mechanical closing button of the circuit breaker
is to be disabled in the connect position and an additional electrical push button is to
be provided for the closing of the circuit breaker through the breaker’s shunt close
coil. The electrical interlock is to be provided on both shunt trip and close coils of the
circuit breaker in order to perform simultaneous tripping and inhibit closing functions
on the interlocked breaker.
2.9 INSTRUMENTATION AND CONTROLS
A. All instruments, relays and components as contained in the one-line diagrams speci-
fied herein or required by manufacturer’s standard practices, shall be provided.
B. Control switches, if any, shall be the rotary enclosed rear-mounting type with posi-
tive means for maintaining contact position.
C. Ammeters mounted in the main incoming sections shall be moving-iron type having a
measuring range and shall be capable of withstanding twice the rated current for one
second without damage.
D. Voltmeters shall be of the moving-iron type having a 5 VA consumption or less.

Voltmeters shall have measuring range and shall withstand twice the rated full volt-
age for one minute without damage.
E. A voltmeter selector switch shall be mounted in the main incoming panel and shall
be of the rotary type with cam operated contacts. It shall have (7) positions "OFF",
R-S, S-T, T-R, R-N, S-N and T-N.
F. Current transformers (CTS) shall be of accuracy class 0.5 for measurements and shall
comply with IEC Recommendations 60185.
G. Test block with socket and plugs shall be provided for testing all instruments and
CT's.
H. Integrated measuring and instruments of electronic type if shown on Drawings, shall

be panel-type and replace the above mentioned a meter and voltmeter.

I. All remote push buttons, indicating lights and control services, as shown on the
schematic diagrams, shall be furnished and installed by the Contractor. Provisions
for connecting these remote devices to the switchgear shall be made by furnishing
terminal blocks or strips.
J. Circuit protection shall be by circuit breaker of proper rating.
K. Electronic metering is accepted if indicated on the Drawings.
2.10 MCC SPECIAL REQUIREMENTS
A. Frequency Converters: A quite large amount of the installed motors may be driven
by Frequency Converters.
B. If the total amount of Converters has any impact or not on the electrical supply sys-
tem must be considered and investigated. The Converters shall not have impact on
other electrical consumers in the network. It could be that special requirements for
electrical components must be considered. These are components as Circuit Break-
ers and Capacitor Banks.
C. As a rule shall be used on each Converter. Please follow the recommendation given
by the brand.
D. Cables shall be used. The earthing of the screen must be done with special
clamps/terminal made for screened cables. The motor cables shall not be laid to-
gether with instrument cables.
2.11 SURGE PROTECTION DEVICE (SPD)
A. Surge protection device – shall be provided at the incoming supply side of main low
voltage panel, as shown on the drawings. The Contractor should select the proper
type recommended by the supplier and submit to the Engineer for approval support-
ed by calculations.
1. SPD’s test requirements to be compliant with

a. IEC 61643-11 for power systems,
b. IEC 61643-21 for telecommunication and signaling systems.
2. Selection and installation of a coordinated SPD protection to comply with

a. IEC 61643-12 and IEC 60364-5-53 for protection of power systems,
b. IEC 61643-22 for protection of telecommunications and signaling
systems.
2.12 FACTORY TESTING
A. The switchgear shall be factory assembled and tested before shipping. Test reports
shall be furnished by the Contractor.
B. All components shall be thoroughly inspected and tested to ensure alignment and
adequacy of all functions.

PART 3 EXECUTION
3.1 INSPECTION
A. Inspect each switchgear assembly and related accessories for damage, defects, com-
pleteness and correct operation before installing. Inspect previously installed related
work and verify that it is ready for installation of instruments and equipment.
3.2 PREPARATION
A. Ensure that installation areas are clean and that construction operations are com-
pleted prior to installing equipment. Maintain the areas in a broom-clean condition
during installation operations.
3.3 ELECTRICAL WORK
A. The Contractor shall perform all interconnecting wiring and grounding as indicated,
specified and required and shall include cables, conductors, terminals, connectors,
wire markers, conduits, conduit fittings, supports, hardware and all other required
materials.
B. Provide the electrical materials and complete all the required electrical installations
in accordance with the requirements specified in Section 260500 and as required by
Drawings.
3.4 MOUNTING
A. The switchboards and panelboards (both surface and flush types) shall be installed so
that the height of the top edge will not exceed 1.80 m from the finished floor. Direc-
tories shall be typewritten in English and Arabic to indicate load served by each cir-
cuit, and shall be mounted in a holder behind protective coating. Contractor shall
follow manufacturer's installation instructions.
B. For free stand panelboard either steel or concrete base should be made without any
extra cost to Employer.
C. Contractor shall submit to the Engineer for approval, an elevation mounting detail
and plan for each distribution board specially those mounted inside vertical service
ducts, also showing cable risers and racking to a scale of 1:10 or 1:50 before installa-
tion.
3.5 INSTALLATION SUPERVISION
A. Furnish the service of engineer especially trained and experienced in the installation
of the equipment to (1) supervise the installation in accordance with the approved
material and equipment manuals and (2) inspect, check, adjust as necessary in ac-
cordance with the Specifications herein, until the installation and operation are ac-
ceptable. Include all costs for services in the Contract Price.

3.6 FIELD TESTING
A. Contractor shall prepare in full details and submit for approval, post installation, test
procedures attached with test forms for all L.V. panels.
B. Switchgear installations shall be tested in accordance with BS as applicable (or corre-

sponding IEC) for the type of equipment.
C. The tests shall be both electrical and mechanical to demonstrate satisfactory opera-
tion. Where protection relays or adjustable overcurrent trips are incorporated, pri-
mary/secondary injection tests shall be carried out to demonstrate the correct set-
ting of the protection device and its satisfactory operation. Test Certificates shall be
issued by the Contractor when primary injection tests are carried out.
Switchgear and Motor Control Center
D. The whole of the switchgear and control center shall be tested as integral units based
on the completeness of the circuits in the final manufactured form within the Manu-
facturer's works. Witnessed tests shall comprise Routine Tests in accordance with
IEC 61439 with the following:
1. Primary injection tests to ensure correct ratio and polarity of CT's and to
demonstrate the correct operation of current operated protection relays and
direct acting coils over their full range of settings.
2. Operation and through current stability tests on balanced earth fault protec-
tion relays by primary current injection.
3. Correct operation of sequencing and control circuits indications and alarms at
normal operating voltages by operation of local control switches and simula-
tion of operation of remote control circuits and all protection devices.
4. Circuit breakers shall be subject to routine tests together with checking of all
mechanical and electrical interlocks.
5. Type test certificates and performance test data for identical panel types shall
be made available.
6. Measure phase-to-phase and phase-to-ground insulations to meet manufac-
turer's specified minimum resistance.
7. Check electrical continuity of circuits and for short circuits.
8. Coordinate tests with tests of generator and run them concurrently.
9. Demonstrate interlocking and operational functions for at least 3 times.
3.7 SYSTEM VALIDATION
A. Provide the services of trained and field experienced Engineer(s) to validate each
Switchgear System to verify that each system is operational and performing its in-
tended function as specified and detailed in the approved Post-Installation Test Pro-
cedures. Validate each system by simulating inputs.
B. Immediately correct any and all defects and malfunctions disclosed by tests. Use
new parts and materials as required and approved and retest. Provide a report certi-
fying completion of validation of each system.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. PANELBOARDS
CAIRO - EGYPT 262416 – 2874 0

CONTENTS
SECTION 262416
PANELBOARDS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Coordination 3
1.6 Warranty 3
1.7 Factory Acceptance Test 3
1.8 Schedules 4
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 General Requirements 4
2.3 Panelboard Enclosures 5
2.4 Busbars 6
2.5 Molded Case Circuit Breakers (Mccbs) 7
2.6 Miniature Circuit Breakers (Mcbs) 9
2.7 Distribution Panelboards (Dp) 9
2.8 Final Branch Circuit, Power And Sub-Distribution Panelboards -
Generally 10
2.9 Final Branch Circuit, Power And Subdistribution Panelboards - Type
Mccb 10
2.10 Final Branch Panelboards - Type Mcb 11
2.11 Distribution Board For Outdoor Lighting 12
2.12 Lighting Control Panel 12
PART 3 EXECUTION 12
3.1 Installation 12
3.3 Connections 14
Panelboards Section 262416

SECTION 262416 – PANELBOARDS
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including Conditions of Contract

and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This section covers low voltage panel boards as indicated on the drawings and
required by the contract and shall include the following items:
1. Lighting and appliance branch-circuit panel boards.

2. Distribution panel boards.
B. Related sections include the following:
1. Division 26 Section “Grounding and Bonding”.
1.3 SUBMITTALS
A. Equipment Data: Submit data for approval including, but not limited to, the
following:
1. Manufacturers' catalogues indicating specific equipment selected.

2. Types of panel boards and circuit breaker characteristics including duties
and duration at specified ambient conditions and corresponding
temperatures within the enclosures, MCB shall not be derated if the space
where the panels are installed is air-conditioned.
3. Dimensions of panels and specific contents of each panel board.
4. Coordination Study: Submit coordination selectivity and short circuit study
along with setting of protective devices for overload, short-circuit and
earth-fault currents as coordinated with upstream and downstream
systems based on specific coordination curves of protective devices used
and specific calculated prospective short-circuit currents at various points.
B. Tests and Certificates: Submit complete certified manufacturer's Design

Verification test records in accordance with the latest IEC Standards.
C. Point-wise compliance statement to the specifications, duly signed by the

manufacturer /Manufacturer’s authorized representative and the contractor.
D. Shop and Construction Drawings: Submit drawings for approval including, but not
limited to, the following:
1. Exact composition of each panel board, indicating Bus bar rating, frame

and trip ratings of circuit breakers.
2. Typical installation details of panel boards, indicating main feeder and
branch circuit conduit connections, terminal provisions, tags, labels,
mounting methods and materials used.
E. Details of Electrical Closets: Submit details to verify clearances, spaces and

ventilation of the installation of proposed equipment, prior to starting
construction.
F. Panel board Schedules: For installation in panel boards submit final versions after
load balancing.
G. Panel board Schedules: For installation in panel boards. Submit final versions
after load balancing. As-Built (Record) Drawings before energization.
A. Comply with:
1. IEC 61439-1, 2 “Low Voltage Switchgear and Control Gear Assemblies”.

2. IEC60947-1 “Low Voltage switchgear and control Gear- General Rules.
3. IEC 60947-2 “Circuit breakers”.
4. Other components where not specified are to comply with the relevant IEC
standards.
5. NFPA 70
6. NFPA 99
1.5 COORDINATION
A. Coordinate layout and installation of panel boards and components with other
construction that penetrates walls or is supported by them, including electrical
and other types of equipment, raceways, piping, and encumbrances to
workspace clearance requirements.
1.6 WARRANTY
A. Contractor shall agree to repair or replace the equipment that does not comply
with the requirements or fails in work.
1. One-year warranty after the date of Substantial Completion
1.7 FACTORY ACCEPTANCE TEST
A. Contractor shall submit manufacturer's type test certificates and routine test
records in accordance with the IEC 61439.

1.8 SCHEDULES
A. Schedules shall show the designation and required type of panel board using the
following criteria:
1. Type of construction (MCB or MCCB), referring to type of branch circuit

breakers.
2. Voltage, number of phases and wires.
3. Branch circuit breaker trip rating and wire size.
4. Main switch or circuit breaker trip rating and frame size (maximum continuous
rating) for MCCB and MCB.
5. Short-circuit interrupting capacity (IC) in kA.
6. Special arrangement or provisions.
B. These schedules should be used/ filled by the contractor according to load

requirements and following and the Local/ International regulations.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Subject to compliance with requirements, manufacturers offering products That

may be incorporated into the work
2.2 GENERAL REQUIREMENTS
A. Rated insulation voltage is to be in accordance with the respective standards.
B. Panelboards to be Design Verified “type tested” according to IEC 61439
C. Panel boards are to be totally enclosed, dead front type and to be factory
designed and assembled.
D. Unless otherwise indicated in the drawings the degree of protection in

accordance with IEC 60529 to be as follow:
1. IP 31 for surface mounting.

2. IP 42 for free-stand mounting indoor installations.
3. IP 54 for outdoor installations and in Wet Areas.
E. Earthing bar is to be sized as half size of the phase bus bars.
F. Neutral bar is to be sized as the phase bus bars.
G. Protection is to be fully rated throughout the systems.
H. total discrimination (total selectivity): over-current discrimination where, in the

presence of two over-current protective devices in series, the protective device
on the load side effects the protection without causing the other protective
device to operate.
I. All incoming and outgoing circuit breakers in the same Panel board shall be
totally selective at the prospected short circuit level.
J. Molded case circuit breakers shall have trip units that achieve full selective
system for overload, short circuit and instantaneous protection.
K. Circuit breakers are to be non-fused type and all MCCBs, MCSs and MCBs shall be
clearly marked indelibly with manufacturer’s name, ratings, product number and
serial number.
L. Circuit Breaker Arrangement: Panel boards are to have one main incoming circuit
breaker or switch and the required number of branch circuit breakers, including
spare circuit breakers and spaces for future expansion. Three-phase panel boards
are to be designed for sequence phase connection of branch circuit devices.
M. In the event of an insulation fault, the fault current shall be limited to a safe
value and shall not result in a loss of power.
2.3 PANELBOARD ENCLOSURES
A. Type: General purpose type, suitable for relevant ambient conditions, flush or
surface mounted, comprising box, trim, or trim and door to approved
manufacturer's standards and sizes.
B. Construction: Box, trim and doors where required, are to be sheet steel of
gauges in accordance with the standards. Welded joints are to be galvanized
after manufacture. Gutter spaces are to conform to the standards, adequate for
the utilized cables/wires subject to the engineers’ approval and in no case less
than 100 mm on all sides. Enclosure is to have pre-designed angles or threaded
end studs to support and adjust mounting of interior panel board assembly.
C. Trims are to cover and overlap front shield, covering all terminals and bus
compartments, to form a dead front panel. Trims are to be fixed to cabinet/box
by quarter-turn clamps engaging flange of box (use of screws engaging holes in
flange of box is not acceptable). Screws where used are to be oval-head,
countersunk and flush. Trims for flush mounted panel boards are to overlap box
and front shields by at least 20 mm. Trims for surface mounted panel boards are
to be exactly sized to form flush fit to box.
D. Doors are to have concealed hinges integral with trim, and flush combination
cylinder lock and catch. Doors over 1000 mm high are to have vault-type handle
and multiple point latch mechanism. Locks are to be keyed alike.
E. Finish: Inner and outer surfaces of cabinet/boxes, trims, doors etc. Are to be
cleaned, phosphatized, chrome passivated and treated electrostatically with final
thermosetting epoxy powder modified by polyester resins providing high
resistance to mechanical injury, heat, acid and alkali solvents, grease, aging and
corrosion and of standard gray color to the approval of Engineer.
F. Directories under glassine, or an approved alternative durable arrangement, are

to be provided on inside face of doors, or in metal label holders when trim
without doors are specified. Directories are to be typed to identify panel boards
and clearly indicate circuit number and description of load.
G. Outdoor enclosures are to be heavy duty sheet steel cabinets, minimum 2 mm

thick, fully weatherproofed (IP 54), without knockouts, but with removable
sealed/gasket bottom gland plates and gasket doors.
2.4 BUSBARS
A. Type: One piece, 99% pure electrolytic copper, based on total maximum
operating temperature of 90 deg C at any point of the bus, at full continuous
rating. Bolted or clamped contact surfaces are to have maximum current density
not exceeding requirements of the approved standards. Aluminum is not to be
used for bus bars or panel board parts.
B. Design: Bus bars are to be shrouded/insulated and rigidly designed so that

branch circuit devices can be removed without disturbing adjacent units or
changed without additional machining, drilling or tapping. Busing is to be full size
without reduction. Busing and blank plates are to allow installation of future
circuit devices.
C. Rating: Bus bar rating is to be at least equal to main-circuit breaker frame size.
Where no main circuit breaker is required, bus bars are to have main lugs or
disconnect switch, with nominal rating equal to 1.25 times the upstream circuit
breaker trip rating.
D. Short-circuit Duty: Bus bars are to carry at least 125% of the maximum short-
circuit level at point of application for one second, without showing any signs of
degradation.
E. Terminals and connections are to be anti-turn, solder-less screw-pressure type.

Screws and bolts used for making copper/copper connections are to be hard
copper alloy with lock washers (riveted bus connections are not acceptable).
F. Neutral bar is to be solid and fully insulated from cabinet or box. One solder-less
box type set-screw connector is to be provided for neutral wire of each branch
circuit and one bolted clamp-type connector or anti-turn lug with set-screw for
main incoming neutral wire. Neutral is to be fully sized and rated as for phase bus
bars.
G. Earthing bar is to be copper, brazed to panel board cabinet, with bolted pressure
connector for main conductor and one set-screw-type tunnel terminal for each
outgoing conductor, to provide secure and reliable contact with all metal parts
and enclosure.

2.5 MOLDED CASE CIRCUIT BREAKERS (MCCBs)
A. Type: Tested to approved standards, , totally enclosed, molded case, constructed

from high quality, high temperature resistant, tropicalized, molded insulating
materials, for normal operation at maximum temperature within enclosures at
point of application, and provided with front operated single toggle type handle
mechanism for manual operation of main contacts in addition to automatic
operation under over-current conditions. Multi-pole breakers are to have
common integral trip bar for simultaneous operation of all poles. Ampere rating
is to be clearly visible. All terminals are to be box lug or clamp type with set
screws, suitable for copper or aluminum conductors.
B. Circuit Breaker Trip Units: Unless otherwise specified, molded case circuit
breakers of final branch circuit panel boards (LPs), power panel boards (PPs ) and
sub distribution panel boards (SDPs) are to be thermal magnetic type, while
molded case circuit breakers of distribution panel boards (DPs) are to be thermal
magnetic for frame sizes up to 160 amperes and electronic type for higher frame
sizes.
C. Thermal magnetic circuit breaker trip units: are to have bi-metallic inverse time
delay over- current element for small overloads and instantaneous magnetic
over-current trip element for operation under short-circuit conditions on each
pole. Circuit breakers rated 150/160 A are to have adjustable instantaneous trips.
D. Deration: Thermal and Electronic over-current trips are to be ambient

temperature derated at specified ambient conditions and corresponding
temperature within the enclosures. MCCB shall not be derated if the space
where the panels are installed is air-conditioned.
E. Electronic trips units, applicable to circuit breakers 250 A frame size and larger,
are to be solid state with long time delay settings between 0.5 and 1.0 times
maximum trip rating, short time delay range of 3 to 10 times maximum trip
rating with a maximum clearing time of 0.2 seconds, and instantaneous
protection adjustable from 5 to 10 times continuous rating. Solid state trip units
are to be insensitive to changes in ambient temperature between -20 and +55
deg C. Earth fault protection is to be built into trip unit where specified, and is to
be suitable for connection to external current sensor. Push-to-trip button is to be
provided on cover for testing the trip unit. Short time over current protection is
only required for circuit breakers 630A and above.
F. Switching Mechanism: Quick-make, quick-break type, with positive trip-free

operation so that contacts cannot be held closed against excess currents under
manual or automatic operation. Contacts are to be non-welding silver alloy with
approved arc-quenching devices of metallic grid construction.
G. Trip current rating (amps) indicates nominal maximum rating at which overload
element is set to operate.
H. MCCBs for LPs, PPs, SDPs and DPs Type 2: Comply with IEC 60947-2 test
sequences I, II, utilization category A, and are to have rated ultimate short circuit
breaking capacities (sequence III) to meet the electrical requirements at the

panel board location, with preferred ratings.
I. MCCBs for DP Type 1: MCCBs rated 630 A and above are to have utilization
category B (with an intended short time withstand capability), and are to have
rated service short circuit breaking capacities (sequence II) with suitably selected
frame sizes and trip ranges to meet the electrical requirements at the
distribution panel board, with declared ratings as percentage (100%, 75% or 50%)
of the ultimate ratings as quoted by the circuit breaker manufacturer marked on
the circuit breaker rating plate. MCCBs below 630A are to have utilization
category A with rated ultimate short circuit breaking capacity (sequence III) to
meet the electrical requirements at the panel boards locations with preferred
ratings in accordance with the below tables.
J. Frame size is defined as maximum continuous current rating of circuit breaker

which corresponds with its maximum trip range listed below and which is to be
related to minimum acceptable short-circuit interrupting ratings, based on fully
rated interrupting duties: normal duty (N), high break (H), or current limiting (L),
as specified.
K. Interchangeable Trips: Thermal-magnetic trip circuit breakers of 150/160 A frame

size are to have interchangeable trip units.
L. Sealing: Circuit breakers with non-interchangeable trip units are to be sealed.

Circuit breakers with interchangeable trip units are to have trip unit covers
sealed to prevent tampering.
M. Accessories: Circuit breakers are to be designed to accommodate standard

attachments including shunt-trip, under-voltage release, combined auxiliary and
alarm switches, and open / close electrical motor operator to any circuit breaker
of rating (frame size) 100 A and over.
N. Residual current operated earth leakage trip devices (RCDs) are provided as add-
on or built-in earth leakage accessories, where required. Protection against earth
fault current, in addition to over-current and short-circuit protection, is to be in
accordance with the Regulations. Trip current sensitivity on breakers for branch
circuits is to be as per the local Regulations. Circuit breakers are to include
current transformer with tripping coil assembly, test button and trip free
mechanism to ensure circuit breaker cannot be held closed against earth faults.
O. Current Limiting Circuit Breakers: Molded case type without fusible elements.
When operating within current limiting range, the I2t of let-through current is to
be less than 1/2 cycle wave of symmetrical protective short-circuit current as
compatible with breaker construction.
P. Current limiting circuit breakers are to have, on each pole, adjustable inverse
time-delay over-current characteristics for overload protection and
instantaneous trip for short-circuit protection. Operation of main contacts is to
be based on Electro-magnetic repulsion forces between contacts created by fault
current. Ratings are specified at rated voltage for an rms value of prospective
short-circuit current.

2.6 MINIATURE CIRCUIT BREAKERS (MCBS)
A. Type: Thermal magnetic non-adjustable type, tested in accordance with

IEC60947-2.
B. Minimum short-circuit breaking capacities to IEC 60947-2 are to be as follows:
1. 6 - 125A MCB : 10 or 15 kA at 230/240 - 400/415 V A.C
C. Construction: MCBs are to be tropicalized for operation at ambient temperatures

up to 70-degree C within panel board enclosure and humidity up to 95%, and are
to be constructed from high quality, high temperature, molded insulating
materials. Guaranteed duties and characteristics are to be submitted for
temperatures at and above 40 deg C.
D. MCBs and combination devices are to be modular, of unified profile and suitable
for mounting either to a standard din rail, or a plug-in system.
E. Operation: Under overload conditions, thermal tripping is to provide close

protection of insulated conductors. Under short-circuit conditions, magnetic trip
is to operate at 5 – 10 times normal rated current (Curve C). Magnetic operation
is to be in the current limiting region and opening time is not to exceed 5
milliseconds.
F. Ratings: Preferred rated currents are to be 6, 10, 15, 20, 25, 30, 40, 50, 60, 80,
100 and 125 A, calibrated at 40deg.c, available as 1, 2, 3 and 4-pole circuit
breakers. De-rating above 40 deg C is not to exceed 1% per deg C and loading is
not to exceed 70% of circuit breaker rating.
G. Residual current devices for earth leakage protective circuit breakers are to be
add-on devices, or built-in and integral with the standard circuit breaker. Non-
adjustable sensitivities of 30 mA, 100 mA and 300 mA are to be available for all
ratings of 2-pole and 4-pole circuit breakers.
H. Auxiliaries are to include alarm switch, auxiliary switch, shunt trip, under voltage
trip and similar units which are to be modular additions to the circuit breakers.
2.7 DISTRIBUTION PANELBOARDS (DP)
A. DP Type 1: Form 2b to IEC 61439-1, and have a minimum rated insulation voltage
of 750V free standing, with doors, suitable for ratings of main breaker, bus bars
ranging, 3-phase, 4-wire (or 3-wire where specifically indicated), suitably and
orderly arranged for any selected combination of branch MCCBs.
B. Construction: Sheet steel, for cabinet/box; suitable for mechanical impact

resistance of IK 10 to IEC 62262 for enclosures protection degree IP55 and higher
and IK08 to IEC 62262 for enclosures protection degree lower than IP55. Test
certificates for mechanical impact are to be submitted for approval; otherwise
enclosure thickness is not to be less than 2mm. Fronts are to be single or twin
covers to shield circuit breakers, terminals and live ends.

C. Interior of panel board is to be pan assembly consisting of sheet steel chassis
minimum 1.5 mm thick, folded, flanged and reinforced, with bus bars vertically
arranged and mounted on molded insulators.
D. Molded insulators are to have minimum temperature rating of 130 deg C and
insulation grade of 3.5 kV for one minute.
E. Circuit breakers are to be mounted in twin arrangement (except for larger circuit
breakers) and bolted rigidly to copper cross and center bus connectors.
2.8 FINAL BRANCH CIRCUIT, POWER AND SUB-DISTRIBUTION PANELBOARDS -

GENERALLY
A. Arrangement: Comprise set of homogeneous branch circuit breakers with unified

profile and base, and one main circuit breaker or switch. Single and multi-pole
circuit breakers or other devices are to occupy modular spaces. Accommodation
of contactors and split-bus arrangement or other devices is not to change
regularity of standard box width.
B. Indoor Enclosure: Sheet steel, minimum 1 mm thick for box/cabinet and

minimum 2 mm thick for front shield, trim and door. Fixings for flush trim are to
be adjustable to allow for misalignment between box and wall surface. Wiring
spaces (gutters) are to be at least 100 mm wide. Larger gutters are to be
provided where tap-off insulated split connectors are required. Knockouts are to
be provided in top or bottom of enclosures and are to provide a neat and
uniform conduit/cable terminal arrangement.
2.9 FINAL BRANCH CIRCUIT, POWER AND SUBDISTRIBUTION PANELBOARDS - TYPE

MCCB
A. Type: Rated insulation voltage rating 690V as a minimum. Single-phase and

neutral (SPN) or 3-phase and neutral (TPN), with bolted 1, 2, or 3-pole MCCBs on
branch circuits and 2, 3 or 4-pole MCCB on main incoming.
B. Branch circuit breakers are to be 1, 2 or 3-pole, rated 100 A frame size, with trip
ratings between 15 A and 100 A, and compatible ICs, selected from normal (N),
high-break (H) or current-limiting (L) range.
C. Main circuit breaker is to be 2 or 3-pole 100 A, or 2, 3 or 4-pole 160 A, or 225/250

A continuous rating (frame size), with trip ratings and fully rated non-current
limiting ICs of normal (N) or high-break (H) ranges, with or without residual
current device (RCD).
D. Short-circuit Rating: Panel boards may only have integrated equipment (series)
short-circuit ratings in accordance with paragraph F of Article 2.2 "GENERAL
REQUIREMENTS" hereof.
E. Assembly: Busbars are to be rigidly fixed on molded insulators to back pan in

vertical arrangement. Branch circuit breakers are to be bolted in twin
arrangement to rigid copper cross and center bus connectors. Back pan assembly
is to be removable and fixed to four threaded stud’s integral with cabinet.
2.10 FINAL BRANCH PANELBOARDS - TYPE MCB
A. Type: Rated insulation voltage rating of 500V as a minimum.
B. Internal Assembly: Comprise removable back plate or back pan of rigid

construction, attached to enclosure by four captive screws through keyhole
fixings, and provided with DIN rails in horizontal arrangement for SPN panels and
in vertical arrangement for TPN panels. Assembly is to be complete with neutral
terminal block, earthing bar and one piece insulated bolt-on/comb-type phase
bus bar. Bus bars are to be single-phase or 3-phase with spade connectors for
fixing by tightening a single screw on circuit breaker. Insulation is to be high
thermal rating, capable of carrying maximum short-circuit current for one second
without overheating beyond acceptable limits required by the Standards. Panel
boards are to comply with IEC 60439-3.
C. Internal Assembly: Comprise removable back plate or back pan of rigid

construction, attached to enclosure by four captive screws through keyhole
fixings, and provided with bus bars in horizontal arrangement for SPN panels and
in vertical arrangement for TPN panels. Assembly is to be complete with neutral
terminal block, earthing bar and one-piece insulated phase bus bar. Bus bars are
to be single-phase or 3-phase with spade connectors for fixing by tightening a
single screw on circuit breaker. Insulation is to be high thermal rating, capable of
carrying maximum short-circuit current for one second without overheating
beyond acceptable limits required by the Standards.
D. SPN type panel boards are to be suitable for 240 V maximum service voltage,
single-phase and neutral, with MCBs on branch circuits and main incoming.
E. SPN type main circuit breaker is to be double-pole MCB, with or without earth
leakage device (RCD), as shown on the Schedules.
F. Single-pole and double-pole MCBs for 240 V service, are to have trip ratings
between 6A and 125A, with ICs as required in the Schedules.
G. TPN type panel boards are to be suitable for up to 415 V A.C. maximum service
voltage, 3- phase and neutral, with MCBs on branch circuits and 3 or 4-pole MCB
or MCCB main incoming.
H. Triple-pole branch circuit breakers are to have trip ratings between 6A and 125A,
with IC as required in the Schedules.
I. TPN type panel board main circuit breakers are to be MCB or MCCB, 125A
continuous current rating, with trip range from 25 A to 125A, or 250 A MCCB
with trip range 70 A to 250 A, normal (N) or high-break (H) duty with/without
RCD.
J. Short-circuit Rating: TPN panel boards may only have integrated equipment
(series) short-circuit ratings in accordance with clause paragraph F of Article 2.2

"GENERAL REQUIREMENTS" hereof.
2.11 DISTRIBUTION BOARD FOR OUTDOOR LIGHTING
A. When the photoelectric lighting control and timer unit switches on the triple pole
contactor, the outgoing phase lighting circuits shall be energized.
1. Lighting Distribution Board: Shall contain the following:
a. One main circuit breaker

b. One triple pole lighting, AC1 air-type contactor designed to withstand
lamp load inrush current and to carry full rated current on a continuous
basis. It shall be AC operated. A manual override switch shall be also
provided and connected
c. Outgoing Circuit Breakers: The triple pole AC contactor shall be actuated
by means of a photo-electric lighting control unit mounted externally
and a timer module
d. Photo-Electric Lighting Control Units: The distribution/control board
shall be controlled to switch on and off the outdoor lighting as a function
of the ambient daylight intensity by means of a photoelectric lighting
control unit. The unit shall be facing north nearest to
distribution/control board and shall be connected to it by means of
finely stranded copper conductor flexible wires having 2 x 2.5 mm2 cross
sectional area and PVC insulation. Control unit shall be adjusted to
respond between 5 and 1000 lux and its response shall be delayed by 2
minutes to prevent operation on momentary changes in daylight
intensity. An additional programmable timer shall be set to de-energize
and energize the contactor in selected periods of time.
e. Selection switch and push buttons.
2.12 LIGHTING CONTROL PANEL
A. Enclosure: Comply with IEC standards.
B. Provide with bush button and indication lamp only devices as scheduled, matching
the IEC type specified for the enclosure.
C. Interface: Provide interface with the contactor in the panel board.
D. Monitoring: On-off status,
E. Control: On-off operation,
PART 3 EXECUTION
3.1 INSTALLATION
A. Fixing Generally:

1. Align, level and securely fasten panel boards to structure.
2. Fix surface mounted outdoor panel boards at least 25mm from wall
ensuring supporting members do not prevent flow of air.
3. Do not use connecting conduits to support panel boards.
4. Close unused openings in panel board cabinets.
B. Panel board Interiors: Do not install in cabinets until all conduit connections to
cabinet have been completed.
C. Wiring inside Panel boards: Neatly arranged, accessible and strapped to prevent
tension on circuit breaker terminals. Tap-off connections are to be split and
bolted type, fully insulated.
D. Trim: Fix plumb and square prior to painting. Fix trim for flush mounted cabinets
flush with wall surface finish.
E. Protection: Treat concealed surfaces of recessed cabinets with heavy field

application of waterproof compound prior to installation.
F. Mounting Heights: Top of trim 1880 mm above finished floor, unless otherwise
indicated.
G. Mounting: Plumb and rigid without distortion of box. Mount recessed panel
boards with fronts uniformly flush with wall finish.
H. Circuit Directory: Create a directory to indicate installed circuit loads after

balancing panel board loads. Obtain approval before installing. Use a computer
or typewriter to create directory; handwritten directories are not acceptable.
I. Install filler plates in unused spaces.
J. Provision for Future Circuits at Flush Panel boards: as approved by the engineer,
stub four empty conduits from panel board into accessible ceiling space or space
designated to be ceiling space in the future. Stub four empty conduits into raised
floor space or below slab not on grade.
K. Provide panel board key on a stainless steel chain alongside the panel, fixed
securely to the adjoining wall.
L. Operating Instructions: Frame and mount printed, basic operating instructions

for switchboards, including control and key interlocking sequences and
emergency procedures. Fabricate frame of finished wood or metal and cover
instructions with clear acrylic plastic. Mount on the front of switchboards,
drawings, SLD, load schedules etc. to be installed inside rigid folders in drawing
compartment.
3.2 IDENTIFICATION
A. Identify field-installed conductors, interconnecting wiring, and components;

provide warning signs as specified in Division 26 Section "Identification for
Electrical Systems".
B. Panel board Nameplates: Label each panel board with engraved metal or
laminated-plastic nameplate mounted with corrosion-resistant screws.
C. Label designations shall be to User approval.
D. Provide aluminum nameplate identification for electrical cupboard/electrical

room.
3.3 CONNECTIONS
A. Install equipment-grounding connections for panel boards with ground

continuity to main electrical ground bus.
B. Tighten electrical connectors and terminals according to manufacturer's

published torque-tightening values.
C. Multiple connections to one terminal are not acceptable.
D. All terminations shall be provided with tinned copper crimped lugs.
A. Generally: Carry out all tests, required by the governing codes and by the
Engineer, on Panel boards after installation, to verify compliance with the
specifications and standards. Inspect conditions within panel boards and verify
insulation conditions by use of a megger.
B. Inspect conditions within panel boards and verify insulation conditions by use of
a calibrated megger.
C. Installation and testing to be witnessed and certified by original manufacturer.
D. Routine tests on site are to be carried out, in accordance with the Standards, on
all panel boards assembled from standardized components of the manufacturer
outside the works of the manufacturer.
E. Testing: After installing panel boards and after electrical circuitry has been
energized, demonstrate product capability and compliance with requirements.
F. Install layout drawing/SMDB schedules/panel drawings inside laminated rigid

folders in each panel board.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. MOTOR CONTROL CENTERS
CAIRO - EGYPT 262419 – 2874 0

CONTENTS
SECTION 262419
MOTOR CONTROL CENTERS

Page
PART 1 - GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.6 Coordination 3
1.7 Factory Acceptance Test 4
1.8 Coordination 4
PART 2 - PRODUCTS 4
2.1 Approved Manufacturers 4
2.2 Variable Speed Drives (Vsds) 4
2.3 Starters 8
2.4 Combination Starters Switch Disconnectors 10
2.5 Push Buttons 10
2.6 Relays 10
2.7 Motor Control Center 11
2.8 Control Switches 13
PART 3 - EXECUTIONS 14
3.1 Applications 14
3.2 Installation 14
3.4 Control Wiring Installation 15
3.5 Earthing 16
3.6 Connections 16
3.8 Cleaning 17
3.9 Demonstration 17
Motor Control Centers Section 262419

SECTION 262419 - MOTOR CONTROL CENTERS
PART 1 - GENERAL

1.2 SUMMARY
A. This Section includes variable speed drives, motor control centers and panels for use
on AC circuits.
B. Related Sections include the following:
Division 26 Section "Raceways and Boxes for Electrical Systems".

Division 26 Section "Low Voltage Conductors and Cables" for wires and cables.
Division 25 Section “Building Management System”
1.3 SUBMITTALS
A. Technical Data: Include dimensions, ratings and data on features and components &
enclosures. Type test certifications are also to be included as required.
B. Compliance statement: Clause by clause full and compliance statement of

specification shall be submitted, where a clear compliance is indicated as follows:
“Yes” interprets full unconditional compliance.

“No” interprets a deviation (to be clearly indicated as remark or note in the
dedicated column).
“Not Applicable” where the case is.
C. It should be noted that other comments like “noted “ or “partial compliance” are
unacceptable and will be interpreted as a non-compliance.
D. Shop and Installation Drawings: Submit for each motor control center prior to
ordering materials and equipment specified in this Section. Include dimensioned
plans, elevations, and component lists. Show ratings, including short time and short-
circuit ratings, and horizontal and vertical bus ampacities.
1. Complete technical schedule of features, characteristics, ratings, and factory

settings on all motor starters, motor protection relays, sensing units, control
accessories, etc.
2. Instructional details of equipment, particularly motor control centres and
panels.
3. Installation details of motor control centres and panels and of control and
sensing accessories. Maintain adequate clearances and access for
maintenance.
4. Exact routing of power and control cables, wiring and conduits.
5. Feeder termination details at motor control centres, starters, motors, isolating
switches, control and sensing accessories etc.
6. Wiring Diagrams: Interconnecting wiring diagrams (of all power and control
circuits) pertinent to class and type specified for motor control center.
Schematic diagram of each type of controller unit indicated.
7. Wiring Diagrams: Submit for approval detailed control wiring diagrams and a
list of control equipment with descriptive literature.
8. Free hand field wiring diagrams or sketches will not be accepted.
9. Factory certified Routine test certificates to be submitted with each product
delivered on site.
E. Maintenance Data: For products to be included in the Operation & Maintenance

manuals specified in Division 1.
F. Submit certified protection relay coordination settings for review, along with certified
“As- built” connection drawings, before energization of equipment.
G. As-Built (Record) Drawings: At Project close-out, submit certified Record Drawings of

installed electrical motor control centers, in accordance with requirements of the
Specification, Division 1.
A. Source Limitations: Obtain motor control devices, variable speed drives and
enclosures/panels, through one source from a single manufacturer. MCC to be
approved by EDC and manufacturer to be listed in EDC's vender list.
B. Comply with the following standards: IEC 61439
C. All products shall be sourced either directly from the manufacturer or from the
manufacturer’s authorized dealer/agent.
A. Deliver in shipping splits of lengths that can be moved past obstructions in delivery
path as indicated.
B. Store in air-conditioned location so that condensation will not occur on or in VSD

units or motor control centers. Provide temporary heaters as required to prevent
condensation.
C. Handle VSD units and motor control centers according to Standards’

recommendations. Use factory-installed lifting provisions.
1.6 COORDINATION
A. Coordinate features of controllers and accessory devices with pilot devices and
control circuits to which they connect.
B. Coordinate features, accessories, and functions of each motor controller with the
ratings and characteristics of the supply circuit, the motor, the required control
sequence, and the duty cycle of the motor and load.
1.7 FACTORY ACCEPTANCE TEST
A. Contractor shall submit manufacturer's type test certificates and routine test records
in accordance with the IEC 61439-1 & IEC 61439-2
1.8 COORDINATION
A. Coordinate features of controllers and accessory devices with pilot devices and
control circuits to which they connect.
B. Coordinate features, accessories, and functions of each motor controller with the
ratings and characteristics of the supply circuit, the motor, the required control
sequence, and the duty cycle of the motor and load.
PART 2 - PRODUCTS
2.1 APPROVED MANUFACTURERS
A. Available Manufacturers: subject to compliance with requirements. Refer to list of

approved manufacturers /suppliers.
2.2 VARIABLE SPEED DRIVES (VSDs)
A. General:
1. This part of the Specification describes the general requirements for the
variable speed drives, the VSDs. The nominal values, the standard documents
and the drive's minimum performance are defined in this part. The VSD does
not include motors in this specification. The Specification uses the term motor
unit which means a combination of the VSD and the motor.
2. If the Project specific part of the Specification is in contradiction with the other
parts of the document, the Project specific document shall apply.
3. Requirements for the Manufacturer:
a) Country of Origin/Make: The complete VSD as a unit should be

manufactured in its origin as approved by Engineer.
b) Certifications: The frequency converter manufacturer shall have a valid
ISO 9001 certification and an applicable quality assurance system. The
manufacturer shall have the environment certification ISO 14001.
c) Experience: The manufacturer shall have a minimum of 5 years’
experience in frequency converter manufacturing and have adequate
business volume in order to provide credibility in his commitments and a
capability of long term support. The manufacturer shall prove his
experience by quoting references of units in the specified power and
voltage range.

4. Local support:
a) The supplier shall have a permanent representative office with a trained

and skilled support staff, within 160 k.M of the airport, in order to prove
his commitment for local support and to provide a channel for
communication. The local representatives shall be easily accessible and
shall be able to have a technical team at the site within 24 hours' notice,
7 days of the week.
b) The engineers employed by the supplier's regional office shall be
certified by the manufacturer and provide start-up service including
physical inspection of the drive, connected wiring and final adjustments,
to ensure that the VSD meets the required performance.
c) The supplier shall be able to give basic drives training to the Customer's
engineers, preferably on the site but anyway, in the country where the
customer's site is. The training shall, as a minimum, include system
concepts and basic troubleshooting. The supplier shall also be capable of
solving most VSD problems quickly. He shall also have a 24 hour support
from the drives’ factory, to avoid any delays during service or repair
work on the site.
d) The manufacturer shall be able to offer commissioning and certification
of the installation of the drive to be done by the local office.
e) The most common spare parts like fuses, IGBTs as well as main control
and IO boards shall be available in 48 hours from the notification
through a regional service center of the supplier. The more rarely used
spare parts should be available in maximum 5 days on site.
f) Basic requirements for the VSDs
5. General requirements:
a) The VSD shall be of the modern design, yet user friendly and be simple
to install commission and maintain. The VSD shall be able to start and
control the speed of a standard squirrel cage induction AC motor. The
VSDs shall be CE marked. The VSDs have to be built to comply with the
IEC standards.
b) The materials used in the VSD as a complete unit shall be recyclable,
non-toxic and flame retardant.
c) The VSD shall be a digitally controlled drive, using, at least, the pulse
width modulation (PWM) with flux vector control, a direct torque
control (DTC), or equivalent. It shall have IGBT's in the inverter section of
the throughout the power range, and it shall have the following
minimum specifications.
6. Operating conditions:
a) Rated Input Voltage: 380V - 400V, three-phase ±10 percent or - 10

percent, + 5 percent.
b) Rated Input Frequency: 48-63Hz.
c) Fundamental Power Factor: 0.97 or better at nominal load.
d) Efficiency: % 98 percent at nominal load.
e) Output Voltage: 0- UN, 3 phase.
f) Output Frequency Range: 0 to 100% of rated motor speed, adjustable.
g) Output Frequency Resolution: 0.01 Hz.
h) Accel / Decel Time: 0 – 180 s, adjustable.
7. Overload ability (by load type):
a) Constant Torque: 120 percent of nominal current for 1 min in every 5

minutes.
b) Variable Torque (pump & fan): No overload ability required.
c) Ambient Temperature: 45 deg. C.
d) Installation Altitude: 1000 m, for higher altitudes see below.
e) Max. Relative Humidity: 90 percent, non-condensing.
8. Main Protections: Over current, short circuit, input/output phase loss, motor
overload and under load, over/under-voltage, over speed, over temperature,
motor stall, other internal fault.
9. The VSD shall be able to give a 100 percent output current continuously in the
above-specified conditions. In order to ensure that the drive can provide the
required output current in the specified ambient conditions, the manufacturer
shall inform of the required de rating, if the ambient temperature given in the
Project specific Specification is higher than 50 deg. C or if the installation
altitude is more than 1000 m above the sea level. The de rating factor shall be
specified so that neither the lifetime of the VSD nor the unit's performance,
overload ability included, nor the reliability of the VSD shall suffer.
10. Storage conditions (in the protective package):
a) Ambient Temperature: - 40 to + 60 deg. C (40 to 158 deg. F)

b) Corrosion Level of the Cooling Air Chemical Gases : IEC 60721-3-3, class
1C2. Solid Particles: IEC 60721-3-3, class 1S3.
c) Max. Vibration Level (IEC 60068-2-6) 2 to 9 Hz: 1.5 mm. 9 to 200 Hz: 5
m/s².
d) Shock (IEC 60068-2-29): Max. 100 m/s², 11 ms.
e) Free fall: 250mm for weight under 100kg. 100 mm for weight over 100
kg.
11. Panel Design Specs:
a) Standards: IEC 61439-1, VDE 66O Part 500.

b) Protection Class: IP 54 for outdoor and IP 42 for indoor installations.
c) Cabinet access: From front.
d) Cable entry and exit: Bottom entry as standard. Both bottom and top
entry have to be possible.
e) Color: Grey RAL 7032 with White RAL 9003 inside the panel/s.
f) User interface: For user interface refer to control specification
12. Software features:
a) Power loss ride-through: The drive shall have a power loss ride-through
capability. This means that the drive controls should stay alive during a
power loss by means of the energy stored in the load. The ride through
time shall be the longer the higher the kinetic energy of the load is. The
motor shall be magnetized as long as there is kinetic energy in the
system.
b) Flux Optimization: The VSD shall have a built-in automatic flux
optimization function. The flux optimization function minimizes the sum
of the magnetizing current and the load current so that the drive can still
follow the given reference. This feature reduces energy consumption
and motor noise when driving at less than the nominal load.
c) Critical speed jump-over: The VSD shall have programmable skip speeds
to jump over critical resonance speeds. If the speed reference is in the
critical speed area, it is ignored and the latest speed reference is
maintained. 3 programmable critical speeds at least shall be available.
d) Current/speed limiting: In case the acceleration or deceleration ramps
are too fast for the drive capacity, the drive shall be able to
automatically reduce the ramp to prevent tripping. Also, in case of
transient overloads the drive shall automatically reduce speed to
prevent an over current trip, if the drive capacity is not sufficient to
handle the load.
e) PID-controller the drive shall have a built-in PID-controller for control of
the customer process.
f) Restart in the event of a fault trip due to over voltage, over current or
loss of analog signal, the VSD shall be programmable to attempt an
automatic restart. For safety reasons, the maximum number of attempts
shall be five (selectable) within a short time. If the fault does not clear
after the attempts, the drive shall lock out.
13. Environmental effects:
a) EMC Regulations and Compatibility/C-Tick: The supplied VSDs shall carry

the CE mark (or C-Tick in Australia) indicating that they comply with the
essential requirements of the relevant EU directives (or C-Tick
requirements in Australia). The VSDs shall meet the requirements set in
EN 61800-3 for Industrial Low-Voltage Networks. If the project- specific
specification states that the requirements for Public Low-Voltage
Networks stated in EN 61800-3 must be met, the supplier shall be able
to provide such units in earthed networks. If separate EMC filters are
required, they shall be of built-in type.
b) A detailed description and other directions to maintain the EMC
Compatibility during the installation of the VSD and associated field
cables and connections, shall be given by the Supplier in conformance
with the EMC Directives or C-Tick. The Contractor shall follow the
directions during installation, in order to achieve attenuation of the RFI.
c) Audible Noise: The full load audible noise of the frequency converter as
measured at a distance of 1000mm, shall not exceed 70 dB(A) in 200 kW
applications and below. Above 200 kW, the full load audible noise shall
not exceed 78 dB(A). If the frequency converter is installed in a cabinet
and requires a separate cooling fan, these limits also include the noise of
the additional cooling fan. This requirement is made to keep the
electrical room quiet so that it is not necessary to use hearing
protection. The audible noise of the motor should also be minimized. For
that purpose, the switching frequency of the frequency converter shall
be at least 2 kHz throughout the power range.
d) Efficiency: The full load efficiency of the VSD shall be at least 98 percent
including all the additional equipment, which is needed to meet the
Specification.
14. Documents:
a) Documents to be delivered with the quotation: The following documents

have to be delivered with the quotation:
b) Technical: Guaranteed technical particulars
c) Drawings: Dimension drawings, control connection diagram for a
standard unit. If order specific engineering is required, the engineered
drawings have to be sent for approval before the delivery.
d) Quality Assurance: Quality Plan including test procedures.
e) Documents to be delivered with the supply of equipment: The following
documents have to be delivered with the supply of the equipment:
f) Manuals: These must contain instructions on how to install and start-up
the VSD, how to program the VSD, instructions for maintenance and for
troubleshooting. The VSD manufacturer must also present proper
recycling instructions for the VSDs.
g) Drawings: Dimension drawings, control connection diagram.
h) Quality Assurance: Certified routine Test reports from the factory.
i) The VSD manufacturer must also present proper recycling instructions
for the VSDs.
2.3 STARTERS
A. Starters for 3 phase motors to be magnetic or electronic type to automatically

disconnect motor from power supply in case of supply failure, phase failure,
excessive voltage drop and over voltage, phase rotation, over current and lack of
balance in phases. Overload trips to be provided for 3 phases. All starters should be
supplied by one manufacturer.
B. Motor Data: Obtain from equipment supplier before ordering any motor starter, or
check motor nameplate for full load current rating and allowable temperature rise in
order to select proper overload thermal element for motor starter.
C. Short circuit protection device fitted to starter to be independent of controller and

overload protection.
D. Control voltage for starters and control circuits is not to exceed 110 V.
E. Step Down Control Circuit Transformers: 2 winding isolating type.
F. Control Circuit Protection: Use high rupturing capacity fuses or circuit breakers.
G. Auxiliary supply for controls other than from main power circuit, to be effectively
isolated by auxiliary contacts on main isolator.
H. Control devices on starters to be as follows unless otherwise indicated or required by

driven equipment: start, stop, push buttons, one red pilot light for "running", one
group pilot light for "stopped" and one reset push button. All indicating lights to be
LED type.
I. Starter type A for single phase motors not exceeding ½ HP to be surface or flush
mounted, manual 2 pole toggle type, for non-reversing across the line starting, fitted
with 1 overload element.
J. Starter type B for 3 phase motors not exceeding 10 HP to be Direct-On-Line, non-

reversing, magnetic type, with manual reset, 3 pole overload relay and low voltage
protection, unless otherwise required by local regulations.

K. Starter type C for 3 phase motors ratings higher than 10 HP and not exceeding 50 HP
to be star-delta or electronic “soft” starter type as applicable and shown on the
drawings, with 3 pole overload relay and low voltage protection, unless otherwise
required by local regulations. Harmonics produced by such starters shall be certified
to be within the relevant IEC limits
L. Starter type D for 3 phase motors over 50 HP to be soft starter or variable frequency
drive as applicable, with 3 pole overload relay and low voltage protection, unless
otherwise required by local regulations. Harmonics produced by such starters shall
be certified to be within the relevant IEC limits.
M. Individually mounted starters to be totally enclosed in galvanized sheet steel

enclosure with baked enamel finish. Design is to suit location and application. It
shall be impossible to open enclosure door unless isolator is in open position, door
interlock shall be defeat able by means of a tool.
N. Nameplates: Starters and controls to have engraved nameplates identifying system

and defining its function. The identification plate shall clearly state the Nomenclature
of the drive and the ratings. The identification shall be engraved stainless steel in
locations directly affected by the outdoor climate and engraved white trifoliate at
indoor locations. Sizing shall be to client approval. Refer to Division 26 “Identification
for Electrical Systems”
O. Contactors: Comply with IEC 60947-4, utilization category AC3 or AC4 as applicable,
and be 3 phase, 4 pole, magnetic type, 600 V rating, capable of interrupting at least
ten times rated current inductive or non-inductive loads under normal service
conditions and are to have replaceable main arcing contacts and arc quenching
devices. Contactors are to withstand, without welding or burning of contacts, an
inrush current of 20 times normal rating for 4 seconds upon closing and are to be
capable of closing on the heaviest short circuit of the system and withstand the short
circuit for period required by upstream short circuit protective device to operate. 3
N.O. (normally open) and 3 N.C. (normally closed) spare contacts are to be provided
on each contactor.
P. Contactors shall be of robust design and shall comply with BS EN 60947: Part 4-1.
They shall operate without undue noise or vibration. Where 2 or more contactors are
contained in the same cubicle, they shall be separated by barriers. All secondary
wiring shall be so arranged and protected as to prevent its being damaged by arcing.
Q. Starter Coordination: Motor starter devices shall be of type 2 coordination to IEC

60947-4-1.
R. Adjustable acceleration rate control utilizing voltage or current ramp, and adjustable
starting torque control with up to 500 percent current limitation for 20 seconds.
S. Surge suppressor in solid-state power circuits providing 3-phase protection against

damage from supply voltage surges 10 percent or more above nominal line voltage.
T. LED indicators showing motor and control status, including the following conditions:
1. Control power available.

2. Controller on.
3. Overload trip.
4. Loss of phase.
5. Shorted silicon-controlled rectifier.
U. Automatic voltage-reduction controls to reduce voltage when motor is running at

light load.
V. Motor running contactor operating automatically when full voltage is applied to

motor.
2.4 COMBINATION STARTERS SWITCH DISCONNECTORS
A. Components to comprise magnetic starter switch disconnectors and short circuit

protection devices required by the IEC Standards, in approved galvanized sheet metal
enclosure with approved paint finish and IP rating to suit application. Starters are to
be installed in accordance with Clauses in 2.3 of this Section. All starters should be
supplied by one manufacturer.
B. Switch Disconnectors Operating Mechanism: Quick make, quick break, with external
operating handle mechanically interlocked with enclosure cover necessitating
disconnecting switch to be in OFF position for access to inside of enclosure. Means
are to be provided for by-passing interlocks. Position of isolating switch to be clearly
indicated on cover.
C. Short circuit protection gear to be HRC fused cartridges or molded case circuit
breakers of appropriate current rupturing capacity. Switch disconnectors are not
required if circuit breakers are used for the short circuit protection. In this case the
circuit breaker will perform the disconnection function.
D. Operation of circuit breaker to be possible from outside of enclosure. Position of

breaker ON/OFF/TRIPPED to be clearly indicated by position of handle.
2.5 PUSH BUTTONS
A. Push buttons to be one-unit momentary contact START/STOP with normally open or

normally closed contacts as required by wiring diagrams and with lockout
attachments. Heads to be color-coded as per IEC and STOP button to be protected.
Push buttons controlling each piece of equipment to be housed in separate
enclosure with clear identification labels.
B. Lock keys shall be suitably attached within easy access on a stainless steel chain fixed
to immovable surface with anchor-bolts.
C. All push buttons shall be of the non-retaining type with body of stainless steel and
button made of non-hygroscopic materials, non-swelling and fitted to avoid any
possibility of sticking.
2.6 RELAYS
A. Relays to be multi-pole with normally open or normally closed contacts, electrically

operated at 110 V maximum, and magnetically held. Contacts to be double break
silvered type, interchangeable from normally open to normally closed without
additional parts. Relays are to be rated at 10 A, 600 V.
B. Relays installed on relay bases shall have retaining clips.
C. All relays shall be certified for a minimum of 100,000 operations.
2.7 MOTOR CONTROL CENTER
A. Type: Totally enclosed, IP 42 for free standing-indoor installation, and IP 54 for

outdoor installation and in wet areas (e.g. pump rooms), free-standing, form 2b
according to IEC 61439, Fixed type.
B. Construction: 2 mm thick, sheet steel, adequately reinforced and braced for

maximum rigidity, sand blasted, rust inhibited after fabrication and sprayed
electrostatically internally and externally.
C. Outdoor MCC: Electro galvanized sheet steel with metal parts of the housing are to
be cleaned, primed with rust inhibiting and waterproofing primer and finished with
corrosion and weather-resistant enamel and final coat of air drying enamel.
Alternative finish may be used subject to approval of the Employer/Engineer before
manufacturing.
1. The outdoor MCC should be installed under a shade to be protected from

direct exposure to sunlight
D. Components: Motor control center to include the following:
1. Main incomer of MCC shall be as shown on the Drawings, for terminating

incoming supply cables and isolating the bus bar system. Main incomer shall be
with electronic trip release unit and with software connection to BMS for low
voltage MCC.
2. MCC shall have meters connected to the BMS and as indicated in the drawings
and BMS Schedules.
3. Main horizontal full-length bus bars, fully isolated tinned copper, rated as main
incoming circuit breaker or as shown on the Drawings. Bus bars shall be
designed to withstand main breaker frame size and three phase symmetrical
short circuit for 1 seconds; ASTA or KEMA certificate shall be provided for
approval.
4. Branch vertical full height bus bars, PVC sleeved tinned copper, of adequate
capacity to distribute power to each circuit breaker and starter served.
5. Neutral bus bar, Copper, rated at full capacity of main bus bar and distributed
throughout whole motor control center.
6. Earth bus bars, copper, minimum half capacity of the phase busbar extending
full length of motor control center.
7. All copper used for the bus bars shall be electrolytic type of minimum 99 %
purity and all bus bars shall be 4-pole type.
8. Starters, circuit breakers, push buttons, indicating high intensity/colored LED
type lights with guaranteed life of 7 years minimum, switches, relays,
contactors and accessories as shown on the Drawings.
9. MCCBs protecting outgoing sections shall be provided with electronic trip
release unit with shunt trip and connections to remote BMS/Fire Alarm
tripping. MCCBs shall be to IEC 60947-2. All MCCBs shall be provided with two
N.O. and two N.C. auxiliary contacts wired to terminal blocks.
10. Interconnecting and interlock wiring with stranded copper conductors having
heat resistant color-coded insulation, neatly wired in place with holders and
“spiral binds” as necessary.
11. Each MCC section shall be equipped with anti-condensation heater with
related accessories.
12. Each MCC section shall be provided with its own control transformer,
manufactured to relevant IEC regulations, located in an independent
compartment to facilitate easy maintenance.
E. All internal painting shall be white RAL9003.
F. Door interlock shall be defeat able by means of a tool.
G. Wiring: Motor control center wiring to be coordination type 2 to IEC standard.
H. Bus bars to be adequately isolated and braced to sustain maximum possible short
circuit current which may be encountered at the proposed location. Type test
certification required by ASTA or KEMA.
I. Compartment doors to be interlocked so that isolators or breakers must be in OFF

position before door can be opened.
J. Spare Positions: Fully equipped cells, ready for connection to motors, are to be
provided in adequate number.
K. Space Positions: if required to be fully equipped cells ready to receive control unit are
to be provided in adequate number.
L. Starters, switches, other components and electrical devices to be clearly labeled in

English and Arabic as to number and function, with incised black letters on white
laminated Bakelite/ Trifoliate. Labels to be permanently fixed under each
component.
M. Incoming line connections to be made with solder less terminal 4 bolt type clamps.
N. Mounting plates for the draw-out feeders shall be painted galvanized sheet steel and
of minimum 2m thickness, with necessary “lock-in-place” fixtures made of metal.
Draw-out shall imply no requirement of any cable disconnection requirements for
either power or control.
O. Control wiring and BMS wiring shall not be routed through power areas within the
BMS.
P. All terminal blocks for control and BMS wiring shall be of 500V insulation class, DIN
rail mounted and manufactured from non-toxic, color coded non-inflammable, self-
extinguishing material and shall contain nickel plated electrolytic copper terminals.
The terminal contacts shall be suitable to meet the “pull-out” forces as per IEC
60947-7-1. All terminals shall be clearly identified in respect of service usage,
designation and number.
Q. All internal wiring and cabling shall be terminated with tinned copper lugs.
R. Current transformers provided in the MCC shall conform to IEC 60185, class H
insulation, 0.2 accuracy class as per IEC and secondary 5A, of suitable VA rating. The
Current transformers shall have type test certification from an internationally
accredited testing laboratory and shall be subject to 100 % routine tests as per the
IEC.
S. Certified and stamped Schematic and wiring diagrams to be firmly fixed within motor
control center, showing each component and cross- referenced with component
labels.
T. Submit for approval electrical schematic diagram of whole installation suggested

layout of motor control center, interior wiring details and complete technical
literature on all proposed components, prior to fabrication or purchase.
2.8 CONTROL SWITCHES
A. Float Switch: Level operated, stainless steel, heavy duty, bracket mounted type,
suitable for application in open tanks, complete with 178 mm spun copper float,
brass rod, two stops, floor mounting stand, lever and counterweight. Switch to have
oil tight and dust tight enclosure and 2 pole double throw silver contacts that open
on liquid rise.
B. Pressure Switch: Industrial, heavy-duty bellows actuated type, suitable for water
service, with contacts to close on falling pressure. Range to be 0.1 to 8 kg/cm².
Switch to be good for 1720 kPa operating pressure and to have 6 mm pipe tap
bottom connection. It is to have oil tight and dust tight enclosure, single pole double
throw contacts and setting adjustment.
C. Low Suction Pressure Switch: Industrial, sensitive, low range, diaphragm actuated
type, suitable for water service, with range of 2 to 20 kPa of falling pressure, preset
at factory to 3 kPa. Switch to be good for 690 kPa operating pressure and to have 6
mm pipe tap bottom connection. It is to have oil tight and dust tight enclosure,
single pole double throw contacts, range adjustment knob, sealing cap and range
locking nut.
D. Control Switches shall be operated by shrouded push buttons or have handles of the
spade type. Control, reversing, selector and test switches shall be mounted,
constructed and wired so as to facilitate the maintenance of contacts without the
necessity for disconnecting wiring. Control switches shall carry KEMA or ASTA or UL
certification.
E. Where necessary, control switches shall be capable of being locked in appropriate

positions but control switches for circuit breakers and for motor operated setting
devices, etc., shall be of the non-locking type with spring return to the "neutral"
position. Such switches shall be controlled by independent springs, the use of
contact springs alone for restoring not being acceptable.
F. Control switches for use in direct control schemes shall be rated for the substation
battery voltage.
G. All control switches shall be provided with identification labels, including labels to
give clear indication to the direction of each operation, for example, "open", "close",
"raise", "lower", etc.
PART 3 - EXECUTIONS
3.1 APPLICATIONS
A. Select features of each motor controller to coordinate with ratings and

characteristics of supply circuit and motor; required control sequence; duty cycle of
motor, drive, and load; and configuration of pilot device and control circuit affecting
controller functions.
B. Select horsepower rating of controllers to suit the motor controlled.
C. Push-Button Stations: In covers of magnetic controllers for manually started motors

where indicated, start contact connected in parallel with sealing auxiliary contact for
low-voltage protection.
D. Emergency disconnect switches or push buttons (as applicable) for all motors, within
3 meters of the equipment that it is meant to protect, located at a logically
convenient position where it is clearly identifiable.
E. Hand-Off-Automatic Selector Switches: In covers of manual and magnetic controllers

of motors started and stopped by automatic controls or interlocks with other
equipment.
3.2 INSTALLATION
A. Install motor control centers according to manufacturer's written instructions with

minimum 1100 mm clearance on all sides where walls are present and min 2000 mm
away from any other board in front or back. MCC may be located adjoining to
another panel
B. Anchor each motor control center assembly to steel-channel sills 100 mm high,
arranged and sized according to manufacturer's written instructions. Attach by tack
welding or bolting. Level and grout sills flush with motor control center mounting
surface.
C. Fuses: Install correctly rated and clearly labeled fuses in each fusible switch as
indicated.
D. Power and Control Wiring: Run in separate conduits unless otherwise specified.
E. Rigid conduits are not to terminate in nor be fastened to a motor frame or base.
F. Flexible conduits to be used at motor connections. Allow sufficient slack to permit

motor to slide over adjustable length of motor base. Flexible conduit in external
areas to be metallic corrosion resistant type with outer finish suitable for U.V
radiation.
G. Flexible Conduits: Length and radius to be sufficient to permit bending of feeder

cables without damage to conductor or its insulation.
H. Flexible Conduits: Do not use in place of rigid conduits except at motor connections,
unless otherwise specified.
I. Support conduit with conduit supports in an adequate approved manner.
J. Conduits are not to cross pipe or vent shafts, ducts or openings. They are to be run a
minimum 100 mm away from pipes of non-electrical services.
K. Conduits: Install so that moisture can drain to lowest point. Provide screw plug at all
low points for draining.
L. Keys for MCCs and other panels to be provided on stainless steel chain alongside the
panel, fixed securely to immovable surface with anchor bolt.
M. All installations shall particularly comply with requirements of IEC 60204- “Safety of
machinery-Electrical equipment of machines”. Contractor is required to submit
specific certification to this effect before power energization.
3.3 IDENTIFICATION
A. Identify all field-installed wiring, equipment and components with nomenclature

labels and provide warning signs according to DIVISION 26 Section "Basic Electrical
Requirements" and “Identification for Electrical Systems”.
B. Operating Instructions: Frame printed certified operating instructions for motor

control centers, including control sequences, and emergency procedures. Fabricate
frame of metal and cover instructions with clear acrylic plastic. Mount on front of
motor control centers or on nearby wall to enable clear and easy viewing.
C. Starters: Fix certified, detailed wiring diagram inside enclosure cover to clearly
indicate circuits.
D. Starters: Identify control and power wires either by distinctive colored insulation,
engraved tags or other approved method.
E. All equipment located outdoors or in external areas subject to atmospheric and

climatic influences, shall be clearly identified with stainless steel engraved labels with
the equipment function name and nomenclature and “fed from “indication. Labels
shall be fixed with s/s screws.
3.4 CONTROL WIRING INSTALLATION
A. Bundle, train, and support wiring in enclosures.
B. Protect circuits with high rupturing capacity fuses or circuit breakers. Auxiliary supply
for controls other than from main power circuit, to be effectively isolated by auxiliary
contacts on main isolator.
C. Provide bus bar mounted fuses where direct control connections are required.
D. Connect hand-off-automatic switch and other automatic control devices according to

an indicated wiring diagram or one that is manufacturer approved, where available.
E. Connect selector switches to bypass only the manual and automatic control devices
that have no safety functions when switch is in the hand position.
F. Connect selector switches with motor control circuit in both hand and automatic
positions for safety-type control devices such as low- and high-pressure cutouts,
high-temperature cutouts, and motor-overload protectors.
3.5 EARTHING
A. Earth motors by connecting green insulated conductor from earthing bushing in

starter to motor frame. Run earth conductor together with circuit wiring and
terminate in motor terminal box, provided earth terminal in box is connected to
motor frame. If this is not feasible, extend earth conductor through insulated
bushed opening in terminal box and connect to motor base.
B. Earth equipment by connecting non-current carrying metal parts of system to earth

source. Non-currents carrying metal parts include conduits, cable trays, outlet boxes,
cabinets, enclosures, doors, grilles, and barriers protecting or shielding electrical
equipment from direct access.
C. All MCCs shall be provided with a second earthing connection through the local
common earth bar located in the respective electrical/mechanical room.
3.6 CONNECTIONS
A. Tighten motor control center bus joint, electrical connector, and terminal bolts with a
torque-wrench, according to manufacturer's published torque-tightening values.
B. Ensure all covers and doors are in proper alignment and all equipment handles
functioning properly.
A. Installation and testing to be witnessed and certified by manufacturer/authorized

representative.
B. Energization to be accorded only after approved protection calculations have been

accepted and BMS connections set. Pre-testing of the MCCS shall be carried out by
the contractor’s own construction power supply.
C. Testing: After installing motor control center and after electrical circuitry has been
energized, demonstrate product capability and compliance with requirements, as per
approved method statement.
D. Procedures: Perform recommended visual and mechanical inspection and electrical

test as listed in NETA. Certify compliance with test parameters. Test method and test
result recording formats shall be to engineer’s approval.
E. Remove and replace malfunctioning units with new units, and retest.
F. Submit settings along with justification to support them both at overload and short
circuit.
G. Circuit Breakers: Coordinate earth fault detection and interruption with those of
main incoming breaker on main distribution panel, and submit settings.
H. Pressure Switches: Test after installation to ensure dependable operation and correct
setting.
I. Low Suction Pressure Switches: Test after installation to ensure dependable

operation and correct setting.
3.8 CLEANING
A. Inspect interior and exterior of motor control centers before energization and
vacuum clean all dust and debris. Remove paint splatters and other spots, dirt, and
debris. Touch up scratches and mars of finish to match original finish. Clean devices
internally, using methods and materials recommended by manufacturer.
3.9 DEMONSTRATION
A. Training: Engage a factory-authorized service representative to demonstrate solid-

state soft starter and variable-speed controllers and motor control centers, and train
the Employer's maintenance personnel.
B. Conduct a minimum of 4 hours of training in operation and maintenance as specified

in Division 1. Include training relating to equipment operation and maintenance
procedures.
C. Schedule training with at least 7 days' advance notice.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. ENCLOSED BUS ASSEMBLIES
CAIRO - EGYPT 262500 - 2874 0

CONTENTS
SECTION 262500
ENCLOSED BUS ASSEMBLIES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.7 Warranty 3
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 Enclosed Bus Assemblies 4
2.3 Supports And Accessories 6
2.4 Fire Stopping 7
PART 3 EXECUTION 7
3.1 Inspection 7
3.2 Installation 7
3.3 Field quality control 8
Enclosed Bus Assemblies Section 262500

SECTION 262500 - ENCLOSED BUS ASSEMBLIES
PART 1 GENERAL
A Drawings and General provisions of the Contract, including General Conditions,

Conditions of Particular Application, and Division 1 Specification Sections, apply to
work of this Section.
1.2 SUMMARY
A This Section includes enclosed bus assemblies and fittings.
B Extent of busway work is shown on Drawings.
C Related Sections
D The following sections contain requirements that relate to this section:
1. Division 07 Section 078413 “Fire Stopping”

2. Division 26 Section "Identification for electrical system"
3. Division 26 Section "Grounding and bonding"
4. Division 26 Section "Low Voltage Switchboards"
5. Division 26 Section "Distribution Transformer"
1.3 SUBMITTALS
A General: Submit the following according to the Conditions of the Contract and
Division 1 Specification Sections.
B Product data for each component. Include electrical ratings, dimensions, mounting
position, mounting method, vertical supports, materials, fire stops, and weather
stops.
C Shop drawings detailing fabrication and installation of enclosed bus assemblies,

include plans, elevations, sections, details of components, and attachments to other
construction elements. Detail connections to switchgear, switchboards,
transformers, and panel boards, as well as detail of supports and connections to
building are also included.
D Coordination drawings include floor plans and sections drawn to accurate scale.
Submit shop drawings. Show bus assemblies layout and relationships between
components and adjacent structural and mechanical elements. Show support
locations, type of support, and weight on each support. Indicate and certify field
measurements.

E Qualification data for firms and persons specified in the "Quality Assurance" Article
to demonstrate their capabilities and experience. Include a list of completed
projects with project names, addresses, names of Architects and Owners, and other
information specified.
F Field test reports indicate and interpreting test results relative to compliance with
specified requirements.
A Testing Agency's Field Supervision: in addition to local code requirements the

busway system shall comply with the latest edition of NFPA 70 "National Electrical
Code" for components and installation or IEC 61439-6
B Reference standard:
1. IEC 60529 Degree of protection provided by enclosure (IP code)

2. IEC 61439-1 LV switchgear and controlgear Part1: General rules
3. IEC 61439-6 Part6: Busbar trunking system
4. IEC 61557-12 Electrical safety in LV distribution system
5. NFPA 70 National Electrical code
6. NECA 408 Standard for installing and maintaining busway
C Manufacturer qualification: company specializing in manufacturing the products

specified in this section with minimum fife years’ experience in the local market.
D Single-Source Responsibility: All busway components shall be the product of a single

manufacturer.
A Delivery, storage, and handling refer to Section 16050 “BASIC ELECTRICAL

MATERIALS AND METHODS”.
A Field Measurements: Don’t take measures from electrical drawings. Verify existing
dimensions by field measurements. Verify clearances and locate obstructions within
manufacturing and installation tolerances of busway.
1.7 WARRANTY
A The Maintenance Period for the equipment and appurtenances shall begin when the
B Warranty: One year from date of substantial completion.

PART 2 PRODUCTS
2.1 MANUFACTURERS

2.2 ENCLOSED BUS ASSEMBLIES
A General: Provide totally enclosed, sandwiched insulated, non-ventilated bus

assemblies for use as feeder bus way as indicated in the drawings.
B Bus-way is to include bus bars, electrical insulators, enclosures, switchboard flange,

elbows, terminal cover, offsets, cable tap boxes, transformer flange connections with
flexible copper braid link, generator flange connection with flexible copper braid link
and vibration as indicated in the drawings.
C The ratings, numbers of busbars, lengths of trucking and equipment shall be as

indicated in the drawings.
D Feeder type Bus way: shall be indoor type for non-tapped straight runs and direct
connections between equipment, as applicable, complete with manufacturer's
recommended fittings and accessories where indicated and as required for a
complete, functioning and safe installation. The busway must comply with IEC
standards.
E The Feeder type bus-way shall be designed and constructed for a rated voltage of
1000 V three-phase, 50 Hz, with four conductors where the size of the neutral
conductor is 100% of the phase conductor as follow [L1, L2, L3 + 100%N] +50%
integrated housing ground, with earthed neutral (i.e. TN-S system grounding) and
having a source fault level for 1.0 second at operating voltage 380V as indicated in
the drawings.
F Temperature Rise: 55C above 40C ambient maximum.
G The busbar insulation and insulating supporting supports will be made from
insulation possessing flame retardant and self-extinguishing, die-electric and non-
hygroscopic properties.
H The bus shall carry its rated current continuously, without exceeding the
temperature rise of 55°C over an outside ambient of 40°C.
I The joints shall be designed to provide optimum electrical contact and mechanical
strength.
J Busbars: Busbars shall be generally comply with IEC 61439-1 and IEC 61439-6.

K The bus-way conductor material shall be Bi-metal (copper clad aluminum conductor)
bus way tin plated and insulated over entire length with flame retardant 130°C class
(B).
L The temperature rise values for Bus Duct shall not exceed the limit as per IEC 61439-
6 and as specified.
M Hot Spot Temperature Rise not in excess of 55 deg C above an ambient temperature
of 40 deg C at any point in the bus bar when bus bar is operated at continuously
rated load current and system frequency.
N Each busbar except the earth shall be totally enclosed in insulating material.
Insulated and anti-tracking supports for the busbar shall be provided at regular
spaced intervals of 300/600 mm. The supports shall be suitable for use of the busbar
trunking in any position. In vertical positions the supports shall be capable of holding
the vertical thrust of the busbars.
O Bus bar is to be specially built and assembled to provide low reactance and very low
voltage drop.
P Where straight length of busbar trunking are installed in excess of 40 meters thermal
expansion joints shall be fitted in the busbar run, in accordance with the
Manufacturer’s recommendations.
Q Phase busbars will be completely enclosed with molded or extruded insulation,

except where provisions will be made for splicing adjacent sections together.
R Jointing of the busbars shall be in accordance with the recommendations of the

manufacturer and tested according to IEC 61439-6.
S The joints for splicing adjacent sections together will be tin plated and enclosed by
either insulation bolts or approved taped insulation paint film.
T The joints shall provide optimum electrical contact and mechanical strength. Not
require special tools or bus connectors to join busway sections and shall not require
maintenance after installation.
U Joints shall be properly clean and free from contamination before joint.
V Joints in busbars shall not cause any loss in mechanical strength, electrical
continuity, current carrying capacity and short circuit capacity of the busbars
compared with an un-joined part.
W Joints shall be properly aligned before the final tightening of all joint bolts.
Bolts shall not be over or loosely tightened. Bolt tightening shall be done as specified
by the manufacturer or in accordance with the manufacturer’s special procedure.
X The metal housing surfaces will be chemically cleaned and treated to provide a bond
between the primer light gray paint and the metal surface paint film.

Y The exterior surfaces will be cleaned and sprayed with a finishing coat of paint
before assembly of the equipment. The color of metal enclosed bus is according to
the manufacturer’s Standards.
Z After assembly, all conductor joints shall be accessible by the removal of covers in
the enclosure. Such covers shall be weather-proof by neoprene gaskets or other
suitable means.
AA The preliminary layout will be furnished as a part of the material requisition. The
complete installation shall coordinate throughout and shall consist of standard
sections and special section and fittings provided to suit the installation. All material
and installation shall comply with the applicable standard.
BB Enclosure: The bus assemblies casing shall be manufactured and enclosed in 2.5 mm
thickness extruded aluminum with a sandwich configuration to prevent air
circulation inside the casing and to allow excellent heat dissipation performance and
provide minimum hysteresis and eddy current losses. The casing shall be totally
enclosed, non-ventilated and to be bonderized inside and outside and finished with
gray baked electrostatic paint. Joints between sections are to have special insulation,
flanged and pressure bolted, easily dismantled and giving equally strong mechanical
connection to bus bar sections. Any one section of the bus way is to be removable
without disturbing adjacent sections.
CC The enclosure shall be mechanically and electrically continuous and provide a degree
of protection not less than IP 54 as per IEC standards.
DD All non-current-carrying metal associated with enclosure for use in enclosed

buildings shall be finished in accordance with IEC or DIN/VDE and all additional fixing
and fitting shall be corrosion resistant.
EE The busbar enclosure shall be designed and constructed suitable for mounting in
horizontal flat or edgewise position and in the vertical plane. Fixing points shall be at
any position in the run, with the supported spans recommended by the
manufacturer.
2.3 SUPPORTS AND ACCESSORIES
A. Spring Mounted Vertical Riser Supports: adjustable for leveling and spring tension
and arranged to permit relative movement between floor and bus bar.
B. Rigid Floor Supports: adjustable for leveling.
C. Expansion Section: capacity and conductor provisions same as adjacent bus bar
section. Arranged to absorb expansion and contraction of bus bars and housing.
D. Fasteners to connect busbar supports to the building structure as follows:
1. Expansion Anchors: carbon steel wedge or sleeve type.

2. Toggle Bolts: all steel spring head type.
3. Powder. Driven Threaded Studs: heat. Treated steel, designed specifically for

the intended service.
2.4 FIRE STOPPING
A. Materials approved for fire ratings consistent with penetrated barriers.
B. Wall and Floor Flanges: sheet steel, 2 mm (12-gage) minimum thickness close fitting
to bus bar arranged to close the wall or floor opening at the bus bar penetration.
C. Fire Barrier: Where busbar trunking passes through wall or slab a proper fire barrier
made of non-hygroscopic material having a fire-resistance period of not less than
that of the corresponding wall or slab shall be provided.
D. Fire resisting barriers shall be fitted in enclosure where it passes through fire
compartment walls and floors. In vertical runs of enclosure, irrespective of fire
resisting barriers at floor levels, where the floor to ceiling height exceeds 3 meters,
an additional barrier shall be fitted in the trunking mid-way between floor and
ceiling.
PART 3 EXECUTION
3.1 INSPECTION
A Examine conditions under which busbar trunking are to be installed. Notify Engineer
in writing of conditions detrimental to proper completion of the work. Do not
proceed with the work until unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A The bus assemblies shall be installed so that the maximum unsupported span does
not exceed 3 meters. Any fixings used shall be of mild steel angle or channel finished
to the same standard as the trunking and shall not cause any long term corrosion or
electrolytic action.
B Where any cutting or damage is caused during erection, the burrs and rough edges
shall be removed, and the finish made good. Any corrosion, which has occurred,
shall be removed and the area treated with a rust-proof agent. The finish shall then
be made good by the application of either a zinc rich epoxy primer or equal
alternative, and for Class 2 finishes shall be followed by coat of color matching paint.
C Runs of enclosure shall not be used to support other equipment or services nor shall
any cables be installed in the enclosure unless the trunking is specially designed for
these purposes.
D Where bus assemblies enclosure passes through fire barriers, walls, floors and
ceilings, fire resting barriers shall be fitted in the trunking and the hole surrounding
the trunking shall be made good to the full thickness with resisting material to

provide fire resistance equal to that of the structure through which the trunking
passes.
E In vertical runs of assemblies thrust supports shall be fitted either at each floor level
or at 3 meters spacing whichever is of lesser dimensions.
F Incoming cables and all outline shall be supported to avoid appreciable mechanical
loads being imposed on the busbar trunking.
A Prior to installing, test for electrical continuity of bonding, and earthing connections
is to demonstrate compliance with grounding requirements.
B Electrically energize bus assemblies systems and demonstrate functioning in

accordance with requirements. Where necessary, correct malfunctioning units, and
then retest to demonstrate compliance. Replace equipment which cannot be
satisfactorily corrected.


ISSUED FOR
PURCHASE
CONSTRUCTION
X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. WIRING DEVICES AND
CAIRO - EGYPT DISCONNECTORS 262726 – 2874 0

CONTENTS
SECTION 262726
WIRING DEVICES AND DISCONNECTORS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittal 2
PART 2 PRODUCTS 3
2.1 Manufacturers 3
2.2 Wiring Devices 3
2.3 Motor Circuit Protectors And Switches 6
2.4 Touch-Up Paint 7
PART 3 EXECUTION 8
3.1 Installation 8
3.2 Grounding 8
Wiring Devices and Disconnectors Section 262726

SECTION 262726 - WIRING DEVICES AND DISCONNECTORS
PART 1 GENERAL
A. Drawings and General Provisions of the Contract, including General Conditions,

Conditions of Particular Application and Division-1 Specification Sections, apply to work of
this Section.
1.2 SUMMARY
A. This Section shall cover various types of receptacles, connectors, switches and finish
plates.
B. Related Sections
1. The following sections contain requirements that relate to this Section:
a. Division 26 Section “Raceways, boxes and cabinets “

b. Division 26 Section “Lighting “
1.3 SUBMITTAL
A. Submit the following according to the Conditions of the Contract and Division 1
Specification Sections:
B. Product Data: Data shall be submitted for each product specified in this section, with
catalog clippings and manufacturer’s technical specifications.
C. Samples: Provide three (3) samples for each device, which shall be used, and for all
relevant accessories (cover, plates). Color selection and technical features shall be
complied with the requirements of codes, interior decoration and Owner’s representative
acceptance.
D. Operation and Maintenance Data: Provide operation and maintenance data for materials
and products specified in this section.
E. Field Quality Control: Submit for Engineer’s approval quality control plan.
A. Manufacturer shall be regularly engaged in manufacturing electrical devices, sizes, and

ratings. These products have been in satisfactory use and in service for not less than 5
years. Products shall comply with requirements of local codes and IEC Standards.

B. Applicable Standards referred to in this Section:
1. IEC 60669-1: Switches for Domestic and Similar Purpose (for Fixed or Portable
Mounting).
2. IEC 60947-3: switches, disconnectors and fuse combination unit.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Subject to compliance with requirements, manufacturers offering products that may be

incorporated into the Work.
2.2 WIRING DEVICES
A. General: Wiring devices shall comply fully with the relevant Local, and International
Standards.
1. All types shall be of the same manufacturer to provide consistent appearance

and finish, colors, openings may distinguish the functional use of similar
fittings or units.
2. Rated voltage and ampere should be indicated on all wiring devices. Fixed
screen shall be installed to separate live parts in case of multi-phase existing in
one box.
3. Wiring devices in classified areas (as required) shall be EEXe IIA T3 type.
B. All wiring devices must be suitable for 3-wire systems for single phase and 5-wire
systems for three phase i.e. earthing terminal must be provided in sockets plugs, lighting
switches, power socket, etc.
C. Boxes and Fittings: Boxes shall be provided with means to terminate conduits securely.
1. For heavy-molded rigid PVC boxes shall be provided with brass insert threads
and fixed lugs to receive cover screws or galvanized steel with suitable marked
earth terminal for exposed and outdoor use.
2. For more details on boxes and fittings, refer to Section 260533.
D. Plates: Plates shall be of square or rectangular shape to adequately cover corresponding

outlet boxes and be designed to fit the electrical devices.
E. Various samples shall be submitted for approval and/or selection by the Engineer.
1. Fixing screws shall be chromium plated, polished. Screw head shall suit the
plates.
2. Combination (multi-gang) plates shall be provided for grouped outlets and
devices as detailed on the Architectural or Electrical Drawings. Color shall be
selected by the Engineer for different typical areas without any cost
implication to the Contract.

3. Unless otherwise stated or specified in Volume 5 "Interior and Furnishing
Works", heavy-molded, break-resistant material, White-Ivory color, flush-
mounted plates shall be used for individually installed switches and wall socket
outlets.
4. Plates for socket outlets shall match switch plates telephone and data outlets
in each particular area.
F. Convenience Socket Outlets: The Contractor shall supply a unified standard type socket
outlet for the whole project.
1. Socket outlets shall be rated 16 Amp and 250 Volts with two rounded poles
plus side earth and 20 mm spacing. The earth terminal of each socket shall be
effectively connected with the earth continuity conductor, phase and neutral
conductors to the respective terminals.
2. Socket outlets shall have a molded plastic or porcelain base and be designed
to fit the appropriate plate as required or as approved, before execution, by
the Engineer.
3. Contacts shall be self-adjusted and have a non-expanding size limiting entry, to
prevent permanent distortion.
4. Where duplex socket outlets are shown on Drawings, two of this type of
socket shall be mounted under one common plate.
5. Weatherproof socket outlets shall be mounted in the box specified with a
gasketed, weatherproof cast-metal cover plate, with individual cap over each
socket outlet opening and stainless steel mounting screws. Caps shall be
tightly closed with stainless steel springs when the socket outlet is not in use.
6. Where indicated on Drawings, receptacles shall be served by ground fault
circuit interrupters for personnel protection.
7. Application: Outlets for internal use shall generally be of the insulated pattern
ivory finish, or as specified in Volume 5 interior and furniture works. Color is
to be selected by Engineer. In utility and workshop areas metal clad enclosures
and finishes shall be used.
8. Outlets for exterior use shall be weatherproof pattern enclosed in Glass-fibre
Reinforced Plastic (GRP) or galvanized metal boxes.
9. Terminals for 250 V outlets shall each be capable of receiving and satisfactorily
connecting two (2) conductors (solid or stranded), each of 4 mm2 minimum.
10. Contact pressure with conductors shall preferably be by clamp plate rather
than by pinch screw.
11. Socket outlets for flush fitting shall be mounted in appropriate recessed box.
12. Socket outlets and their enclosures shall be complete with necessary terminals
for the connection of circuit protective conductors as required by the IEE
Regulations and IEC latest edition.
13. Boxes providing enclosure and/or mounting for socket outlets shall be PVC if
concealed, or galvanized steel if exposed complete with conduit entries.
G. Industrial Power Outlets: Industrial pattern socket outlets shall comply with IEC 60309-2.
Unless specifically detailed, single phase or 3 phase with neutral and earth 250 or 415 V
sockets shall be fitted flush or surface mounted. Rating of power socket and number of
poles shall be according to the drawings and/or data sheets.

1. Power sockets shall be IP 55, made of high tech polymer material, water
resistant and supplied with its compatible plug. Earth pole shall be 6 h for all
kinds of power sockets.
2. Matching plugs shall be provided with the socket.
H. Lighting Switches
1. Internal Lighting Switches: Internal lighting switches shall comply with IEC
60669 and shall be complete with box, cover plate and fixing screws. At multi-
switch positions, the switches shall be contained in multi-gang boxes.
2. Wall mounted switches shall be suitable for use at a system voltage of 220 V
and continuously rated at 10 A. Each switch terminals shall be capable of
terminating two (2) conductors (solid or stranded), each of 3 mm2 minimum.
3. Generally where a number of switches are mounted adjacent to each other,
they shall be grouped in one box and share a common switch plate, except
those fed from different supply panels or different phases.
4. Switches shall not disconnect the grounded conductor of a circuit. A switch in
a wet location or outside of a building shall be enclosed in a weatherproof
enclosure.
5. Switches for internal use shall generally be of the insulated, ivory finish
pattern unless otherwise specified. In utility and workshop areas, metal clad
enclosures and finish shall be used. Lighting switches shall be mounted in a
galvanized metal or PVC box with conduit entry facilities suitable for flush or
surface mountings as appropriate. In all cases, a sample shall be approved by
the Engineer.
6. Lighting switches for external use and wet areas shall be weatherproof and
shall be enclosed in Plastic Glass-fibre Reinforced (GRP) or galvanized metal
boxes.
7. Lighting switches shall be provided with all necessary terminals to allow
connection of circuit protective conductors as required by the 16th edition of
the IEE Regulations or IEC latest edition.
8. Multi Pole Switches: Multi pole switches shall conform to the requirements of
IEC 60669 Standard where used for the connection of fixed appliances.
9. Switches shall be installed as shown on Drawings, and for height refer to
general notes.
10. All units shall be of similar style and finish to those specified for lighting
switches and socket outlets.
11. Primary connection terminals shall be capable of receiving and satisfactorily
connecting the following stranded conductors:
Switch Rating Min. Conductor Size
10 A 3(1 x 3) mm2
20 A 3(1 x 4) mm2
25 A 3(1 x 6) mm2
12. Contact pressure with conductors shall be by clamp plate.

13. Push Button Switches: The push button shall be in general (unless otherwise
indicated on drawings) used to make momentary contact switch for lighting
contactor control. The switches shall be suitable for inductive load, and shall
comply with the standards.
14. The rated of the switches shall be 10A, 250V (unless otherwise indicated on
drawings).
I. Load Break Switches (LBS) Disconnector:
1. Load break switches or disconnector shall be provided and installed as shown

on Drawings and on wiring schedules.
2. Electrical characteristics of load break switches such as Ampere rating and
number of poles shall be as indicated on Drawings, wiring schedules and/or as
herein specified. Ratings have to be re-adjusted by the Contractor and
approved by the Engineer before ordering if the served load is different than
that shown in design documents.
3. The LBS shall be a non-fusible for three phases and single phase, single-throw,
as indicated on Drawing.
4. Switches shall effectively interrupt the power supply for all line conductors
where it exists, and simultaneously disconnect the supply for control circuits.
5. The operating mechanism shall be quick-make, quick-break with the external
operating handle mechanically interlocked with the enclosure cover.
6. Interlocks shall make it necessary for the switch to be in the "OFF" position for
normal access to the inside of the enclosure. Switch shall have means of by-
passing the interlocks.
7. All motors loads shall be provided with a switch, category AC23, non-fused,
single throw, with arc quenching devices on each pole.
8. Any LBS shall be so placed that gravity shall not tend to close when approved
for use in the inverted position. It shall be provided with a locking device that
will ensure that the blades remain in the open position when so set.
9. Indication to the position of the switch shall be positive and clearly indicated
on the cover.
10. Enclosure: All types of Enclosures such as Polycarbonate, Painted sheet Metal
and stainless steel or any other material shall be used as per manufactures
recommendation and as suitable for the Environment take into consideration
corrosion, chemicals and mechanical impact subject to Engineer approval on
site.
11. Enclosure shall have provisions for locking the operating handle in the "OPEN"
and "CLOSED" positions.
2.3 MOTOR CIRCUIT PROTECTORS AND SWITCHES
A. Motor Circuit Protector: Molded case, magnetic break type with adjustable instantaneous
setting suitable for motor protection.
B. Motor Circuit Protectors are to be in compliance with IEC 60947-2, utilization category A,
sequence II (service capacity) for motor control centers and sequence III (ultimate
capacity) for motor control panels and combination starters unless otherwise indicated on
the Drawings.

C. Main incoming switches to be equipped to provide earth fault under voltage and phase
sequence protection through shunt trip coil. Earth fault detection and interruption to be
time coordinated with those of main incoming breaker on main distribution board.
D. All motors shall be provided with a safety disconnect switch, 1000 V insulation class,
category AC23, non-fused, single throw, safety type, housed in separate metallic
enclosure IP 55 with arc quenching devices on each pole, and provided with padlock.
E. When located outdoors, the switch disconnector enclosures shall be provided with U.V
resistant paint finish.
F. Switch disconnector handle and indicator markings shall be Red/yellow and is to have
provision for bypassing interlock by authorized and trained technicians. Position of handle
is to be positive and clearly indicated on cover. Locking of operating handle is to be
possible in open and closed positions. Where safety disconnect switch ratings are required
to be in excess of 250 Amps, provide “Emergency” push button stations wired directly for
trip.
G. Switch disconnectors shall comply with IEC 60664 and IEC 60947 and shall carry KEMA or
ASTA or UL certification. They shall be manufactured to environmentally friendly and
recyclable materials.
H. Switch disconnectors shall be provided with non-inflammable, non-toxic terminal shrouds

and one set of N.O and N.C auxiliary contacts.
I. Control switches for electrically operated circuit breakers and motor operated
disconnectors shall be discrepancy type and arranged to operate clockwise when closing
the devices and anti-clockwise when opening them. There should be marking for
discrepancy indications. They shall be designed to prevent accidental operation, which
shall be effected by 2 independent movements.
J. The contacts of all switches and push buttons shall be strong and to have a positive wiping
action when operated.
K. All safety switches and emergency push buttons shall be clearly labeled as per
specification 260553
2.4 TOUCH-UP PAINT
A. The surface of all wiring devices shall be of the manufacturer's finish according to location
and the Engineer’s approval.

PART 3 EXECUTION
3.1 INSTALLATION
A. General: Flush-mounted boxes shall be cast in concrete walls and grouted into brick
walls. Metal boxes threaded to raceways in exposed installations shall be separately
supported.
B. Boxes installed in concealed conduits or raceway systems shall be set flush with the
finished surfaces. The location of all boxes shall be easily accessible and any interference
with mechanical equipment or structural features shall be relocated as directed by the
Engineer without any additional cost.
C. Receptacles: The receptacles shall be located and installed as shown on the Drawings.
The location shall be easily accessible. Receptacles shall be so installed that the neutral
pin is always on the left side when viewed facing the installation.
D. Switches: Local wall switches near doors, shall be located at free side of doors as finally
hung, whether so indicated on Drawings or not.
E. A junction box shall be placed in the back of each wall mounted switch or socket outlet.
F. If thickness of wall does not permit such an installation, adjacent position shall be
accepted.
G. The switches shall be installed as shown on the approved Drawings. Where more than
one switch is shown for one indoor outlet box, the switches shall be installed under one
plate. Toggle switches for lighting, except for 2-way and 3-way switches shall be installed
so that the contacts are closed when the handle is in the up position.
H. Switches shall be mounted with the longer dimension vertical and operating handle in an
upward position when in the "ON" position.
I. Single pole switches shall switch the (phase) wire circuit. Neutral wire shall not run
through switches.
J. No switches shall be located inside toilets or shower places.
K. Device Plates: Device plates shall be installed with all four edges in continuous contact
with finished wall surfaces without the use of mats or similar devices. Device plates shall
be installed vertically with an alignment tolerance of 0.16 mm (1/16 inches).
L. Mounting Height: The mounting height of wall-mounted outlet and switch boxes shall be
as specified and approved by the Engineer and measured between the bottom of the box
and the finished floor.
3.2 GROUNDING
A. Grounding system shall be installed as required by Drawings, and as specified herein.

Neutral conductors of the wiring system shall be grounded at the transformer

secondaries and at the panelboards, the grounding connections shall be made as
indicated on Drawings, and as required by the IEC Code.
B. Devices grounding connections shall be made by means of screw-type pressure

connectors to the box's frame and receptacle ground pin in accordance with the IEC
Code.
A. Provide checking, adjusting and testing operations on the wiring devices installation
including the following:
1. All wire terminals shall be checked to assure tight connections, electrical

continuity and for short circuit
2. Operate each device at least 6 times. All wiring services shall be clean before
energizing
3. Adjust wiring devices to operate in the indicated and required sequence
4. The tests shall be performed to detect wrong connections, short circuits,
continuity
5. Test wiring devised for proper polarity and ground continuity
6. Check output voltage at each output for voltage drop
7. Check phase balancing at switchboard terminal
8. Replace damage or defective components


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. ENGINE GENERATORS
CAIRO - EGYPT 263213 – 2874 0

CONTENTS
SECTION 263213
ENGINE GENERATORS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Coordination 4
1.8 Spare Parts 5
1.9 Instructions And Training On Operation & Maintenance 5
1.11 Coordination 6
1.12 Warranty 6
1.13 Maintenance Service 6
PART 2 PRODUCTS 6
2.1 Engine-Generator Set 6
2.2 Engine 8
2.3 Fuel Oil Storage 11
2.4 Control And Monitoring 11
2.5 Generator Overcurrent And Fault Protection 12
2.6 Generator, Exciter, And Voltage Regulator 13
2.7 Vibration Isolation Devices 13
2.8 Finishes 14
PART 3 EXECUTION 14
3.1 Examination 14
3.2 Installation 15
3.4 Grounding 15
3.5 Connections 15
Engine Generators Section 263213

SECTION 263213 - ENGINE GENERATORS
PART 1 GENERAL
1.2 SUMMARY
A. This section covers the equipment, installation and testing of diesel engine and driv-
en electric generator units. The engine generator unit/s shall be installed as indicated
on the drawings.
1. The engine-generator unit shall be a skid-mounted, indoor type unit consisting

of an engine, an alternator, auxiliary systems, controls, and accessories as
specified and as required for a complete operating system.
2. Equipment furnished under this section shall be assembled, erected, and
placed in proper operating condition in full conformity to the specifications of
the equipment manufacturer unless exceptions are noted by the Engineer.
The engine-generator unit shall be a standard product of the manufacturer and
shall be a packaged type unit, fully shop assembled, wired, and tested, requir-
ing no field assembly of critical moving parts.
B. Related sections include the following:
1. Section 231113 “Facility Fuel Oil Piping”

2. Section 262413 “Switchboard”
3. Section 250000 “BMS”
1.3 SUBMITTALS
A. Drawings and Data: Complete descriptive and engineering data shall be submitted.
These data shall consist of drawings and photographs in sufficient detail that the con-
struction of the equipment is indicated, together with details, specifications, perfor-
mance curves, installation drawings, schematics, and wiring diagrams; and founda-
tion drawing showing location detail and size of anchor bolts. Data submitted shall
include the following:
1. Engine Data.
a. Manufacturer.
b. Model.
c. Number of cylinders.
d. RPM.
e. Bore x stroke.
f. Rated capacity kW.
g. BMEP at rated kW (including any parasitic loads and Gen. efficiency).

h. Make and model of governor.
2. Generator Data.
a. Manufacturer.
b. Model.
c. Rated kVA.
d. Rated kW at 0.8 PF.
e. Voltage.
f. Temperature rise above 50 C ambient for Stator and Field.
g. Class of insulation.
3. Generator Efficiency Including Excitation Losses and at 80 Percent PF.
a. Full load.
b. 3/4 load.
c. 1/2 load.
d. 1/4 load.
4. Guaranteed Fuel Consumption Rate.
a. Full load liters/hour.

b. 3/4 load liters/hour.
c. 1/2 load liters/hour.
d. 1/4 load liters/hour.
5. Engine-generator Unit and Accessories.
a. Weight of base-mounted unit.

b. Overall length.
c. Overall width.
d. Overall height.
e. Exhaust pipe connection size and location.
f. Airflow required for combustion and ventilation, m3/min.
g. Heat rejected to room by engine and generator, Btu/hour.
h. Heat rejected to jacket water and lubricating oil, Btu/hour.
B. Test Reports: Copies of the manufacturer’s certified shop test record of the complete
engine driven generator. The engine-generator log test sheets and a performance re-
view report shall be signed by the engine tester and certified by the manufacturer.
The report shall include brief outlines of all test procedures and shall compare actual
test results to the requirements of these specifications by means of calculations,
graphs, or charts.
C. Submit name and address of nearest factory authorized service and parts facility.
D. Operations and Maintenance Manuals/Charts and Spare Parts Data: Complete opera-
tions and maintenance manuals/Charts including spare parts data and wiring dia-
grams of all equipment furnished under this section.
E. Exhaust Pipe calculations to ensure the back pressure limits is within the manufac-
turer limit.

A. References Standards.
1. Governing Standards: Except as modified or supplemented herein, all equip-

ment and materials required in this section including their installation shall
conform to local code and the applicable requirements of the following stand-
ards. Standards current at the time of tender shall be used.
2. Institute of Electrical and Electronics Engineers Inc.
(IEEE) No. 115
3. Test Procedures for Synchronous Machines.
4. American National Standards Institute.
ANSI No. B16.5
5. Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24-157
6. National Electrical Manufacturers Association.
NEMA MG 1& NEMA 250
7. MG1 Motors and Generators.
8. National Fire Protection Association.
9. NFPA No. 70.72 & 110.
10. Occupational Safety and Health Act (OSHA).
11. BS 5514 reciprocating internal combustion engines performances.
12. International Commission (IEC) Standard – IEC 60034.1
13. British Standards (BS 4999/5000 & BS 5514).
14. ISO Standard (8528 , 3046-1, 3744)
1.5 COORDINATION
A. All equipment specified in this section shall be furnished through a single manufac-
turer who shall be responsible for the design, manufacture coordination, and proper
installation and operation of the entire system and as mentioned in section division
26 Section “Basic Electric materials & methods “.
A. Power Supply: The power supply for the engine-generator accessories will be
380Y/220 Volts AC, 50 Hz, three-phase, 5-wire or as may be required by manufactur-
ers standard.
A. Manufacturer Date: The required manufacturing date of the package engine genera-
tor (s) shall be 6 – 8 months before the delivering date.
B. Storage: Contractor shall acknowledge storage conditions at the time of submitting

his Tender. If the equipment will not be operational within 90 days after manufac-
ture, the manufacturer shall crate and prepare the equipment for export transporta-
tion and long-term storage. Precautionary measures for prolonged storage shall be
provided by the manufacturer at the factory. The Contractor shall be responsible for

storage and maintenance of the protective measures as recommended and instruct-
ed by the manufacturer while stored at the storage site. The manufacturer's warran-
ty on units held in prolonged storage exceeding three months shall be covered by
special agreement reflecting the storage conditions.
C. Packaging: In addition to the protection specified for prolonged storage, the packag-
ing of spare units and spare parts shall be similar to export packing and shall be suit-
able for long-term storage in a damp location. Each spare item shall be packed sepa-
rately and shall be completely identified on the outside of the container.
D. Instructions for the servicing of equipment while in long-term or prolonged storage

shall accompany each item of equipment. Advisement of enclosed instructions with
each package shall be noted on the exterior of the package in both Arabic and Eng-
lish.
1.8 SPARE PARTS
A. A list of all spare parts recommend by the manufacturer for 1000 operating hours
and required for adjustment, operation, and maintenance of the equipment shall be
submitted in accordance with the requirements set forth at the Conditions of Con-
tract.
B. In addition, all special tools required for adjustment, operation, and maintenance of
the equipment. plus the following spare parts shall be furnished with each unit:
1. Five sets of air filter elements.

2. Five sets of lube oil filter elements.
3. Five sets of fuel oil filter elements.
4. One thermostat.
1.9 INSTRUCTIONS AND TRAINING ON OPERATION & MAINTENANCE
A. Contractor shall provide instructions and training for the staff to be assigned in the
and instructions shall be in accordance with the requirements set forth at the Condi-
tions of Contract.
A. Interruption of Existing Electrical Service: Do not interrupt electrical service to facili-

ties occupied by Owner or others unless permitted under the following conditions
and then only after arranging to provide temporary electrical service according to re-
quirements:
1. Notify Construction Manager no fewer than two days in advance of proposed

interruption of electrical service.
2. Do not proceed with interruption of electrical service without Construction
Manager's written permission.

B. Environmental Conditions: Engine-generator system shall withstand the following
environmental conditions without mechanical or electrical damage or degradation of
performance capability:
1. Ambient Temperature: 5 to 45 deg C.

2. Relative Humidity: 0 to 95 percent.
3. Altitude: Sea level.
1.11 COORDINATION
A. Coordinate size and location of concrete bases for package engine generators. Cast
anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements
are specified in Division 03.
1.12 WARRANTY
A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to re-

pair or replace components of packaged engine generators and associated auxiliary
components that fail in materials or workmanship within specified warranty period.
1. Warranty Period: Two years from date of Substantial Completion.
1.13 MAINTENANCE SERVICE
A. Initial Maintenance Service: Beginning at Substantial Completion, provide 24 months'

full maintenance by skilled employees of manufacturer's designated service organiza-
tion. Include quarterly exercising to check for proper starting, load transfer, and run-
ning under load. Include routine preventive maintenance as recommended by manu-
facturer and adjusting as required for proper operation. Provide parts and supplies
same as those used in the manufacture and installation of original equipment.
PART 2 PRODUCTS
2.1 ENGINE-GENERATOR SET
A. Factory-assembled and -tested, engine-generator set.
B. Mounting Frame: Maintain alignment of mounted components without depending

on concrete foundation; and have lifting attachments.
C. Capacities and Characteristics:
1. Power Output Ratings: Nominal ratings as required, with capacity as re-

quired to operate as a unit as evidenced by records of prototype testing.
2. Output Connections: Three-phase, four wires.
3. Nameplates: For each major system component to identify manufacturer's
name and address, and model and serial number of component.

D. Generator-Set Performance: The diesel generator set should have performance class
G2 according to ISO 8528.
E. Steady state voltage, Steady state frequency, Voltage recover time, frequency recov-
er time, Maximum voltage Dip, Maximum frequency Dip shall comply with ISO 8528-
5 for performance class G2.
F. Start Time: Comply with NFPA 110, Type 10.
G. Noise reduction is to be achieved by silencer, sound attenuators for air inlet and out-
lets and sound absorbing wall lining. Achieve an overall Noise Rating of 85 dBA at 1 m
outside the room in any direction in accordance with ISO standards. Coordinate with
the Architectural works for the needed provisions and installations.
H. Generator-Set Performance for Sensitive Loads:
1. Over sizing generator compared with the rated power output of the engine
is permissible to meet specified performance.
a. Nameplate Data for Oversized Generator: Show ratings required ra-

ther than ratings that would normally be applied to generator size in-
stalled.
2. Steady-State Voltage Operational Bandwidth: 1 percent of rated output

voltage from no load to full load.
3. Transient Voltage Performance: Not more than 10 percent variation for 50
percent step-load increase or decrease. Voltage shall recover and remain
within the steady-state operating band within 0.5 second.
4. Steady-State Frequency Operational Bandwidth: Plus or minus 0.25 per-
cent of rated frequency from no load to full load.
5. Steady-State Frequency Stability: When system is operating at any con-
stant load within the rated load, there shall be no random speed variations
outside the steady-state operational band and no hunting or surging of speed.
6. Transient Frequency Performance: Less than 2-Hz variation for 50 percent
step-load increase or decrease. Frequency shall recover and remain within the
steady-state operating band within three seconds.
7. Output Waveform: At no load, harmonic content measured line to neutral
shall not exceed 2 percent total with no slot ripple. Telephone influence factor,
determined according to NEMA MG 1, shall not exceed 50 percent.
8. Sustained Short-Circuit Current: For a 3-phase, bolted short circuit at system
output terminals, system shall supply a minimum of 300 percent of rated full-
load current for not less than 10 seconds and then clear the fault automatical-
ly, without damage to winding insulation or other generator system compo-
nents.
9. Excitation System: Performance shall be unaffected by voltage distortion
caused by nonlinear load.
a. Provide permanent magnet excitation for power source to voltage

regulator.
10. Start Time: Comply with NFPA 110, Type 10, system requirements.

2.2 ENGINE
A. Fuel: Fuel oil, Grade DF-2.
B. Rated Engine Speed: 1500 rpm.
C. Maximum Piston Speed for Four-Cycle Engines: 2250 fpm (11.4 m/s).
D. Lubrication System: The following items are mounted on engine or skid:
1. Filter and Strainer: Rated to remove 90 percent of particles 5 micrometers

and smaller while passing full flow.
2. Thermostatic Control Valve: Control flow in system to maintain optimum
oil temperature. Unit shall be capable of full flow and is designed to be fail-
safe.
3. Crankcase Drain: Arranged for complete gravity drainage to an easily remova-
ble container with no disassembly and without use of pumps, siphons, special
tools, or appliances.
E. Engine Fuel System:
1. Main Fuel Pump: Mounted on engine. Pump ensures adequate primary fuel
flow under starting and load conditions.
2. Relief-Bypass Valve: Automatically regulates pressure in fuel line and returns
excess fuel to source.
F. Coolant Jacket Heater: Electric-immersion type, factory installed in coolant jacket

system.
G. Comply with NFPA 110 requirements for Level 1 equipment for heater capacity.
H. Governor: Adjustable isochronous electronic type class G2 according to ISO 8528-

5, with speed sensing for sensitive loads.
I. Cooling System: Closed loop, liquid cooled, with radiator factory mounted on en-
gine-generator-set mounting frame and integral engine-driven coolant pump.
1. Coolant: Solution of 50 percent ethylene-glycol-based antifreeze and 50

percent water, with anticorrosion additives as recommended by engine
manufacturer.
2. Expansion Tank: Constructed of welded steel plate and rated to withstand
maximum closed-loop coolant system pressure for engine used. Equip with
gage glass and petcock.
3. Temperature Control: Self-contained, thermostatic-control valve modu-
lates coolant flow automatically to maintain optimum constant coolant
temperature as recommended by engine manufacturer.
4. Coolant Hose: Flexible assembly with inside surface of nonporous rubber
and outer covering of aging-, ultraviolet-, and abrasion-resistant fabric.
a. Rating: 50-psig (345-kPa) maximum working pressure with coolant at

180 deg F (82 deg C), and non-collapsible under vacuum.
b. End Fittings: Flanges or steel pipe nipples with clamps to suit piping

and equipment connections.
J. Muffler/Silencer: Critical type, sized as recommended by engine manufacturer

and selected with exhaust piping system to not exceed engine manufacturer's
engine backpressure requirements.
1. Minimum sound attenuation of 25 dB at 500 Hz.

2. Sound level measured at a distance of 1 m from the center of the Gen-set after
installation is complete shall be 85 dBa.
K. Exhaust System: The engine-generator installation shall include a critical exhaust silencer,
exhaust piping, expansion joints, stainless steel rain cap, hangers, and accessories as re-
quired for a complete operating system. Exhaust piping and insulation shall be terminat-
ed with a single pipe flange connection.
1. Hangs and supports shall be provided for the silencer and exhaust piping
such that essentially no load is transmitted to the engine exhaust connec-
tion.
2. The exhaust silencer shall be a chamber type, attenuated for low noise
emission, all welded steel construction, with suitable bracket supports for
vertical or horizontal mounting. The silencer shall be reinforced to be able
to withstand a horizontal force of not less than 2224 N at the inlet connec-
tion. The silencer size shall be such that the silencer produces half the
maximum allowable back pressure at future operating conditions with inlet
and outlet flanged connections. The silencer shall be suitable for critical
type silencing.
3. Noise level required is 85 dB (A) at one meter from air intake and outlet
louvers or as required in the drawings and bill of quantities.
4. Expansion joints shall be furnished in the engine exhaust piping as indicat-

ed on the construction drawings. The expansion joint in the horizontal ex-
haust piping shall be the double bellows type fabricated of stainless steel
one-piece construction with welded ends. The expansion joint shall be de-
signed for 50 mm lateral offset, 38 mm axial compression.
5. The expansion joint in the vertical riser immediately above the engine ex-
haust connection shall be bellows type, fabricated of all stainless steel with
a flange on one end and a butt weld connection on the other end and shall
be designed for 6 mm lateral offset, and vibration isolation.
6. A stainless steel rain cap shall be furnished and installed on the exhaust
stack to prevent the entry of dust and rain.
7. Insulation: for exhaust silencer and all interior exhaust piping is to be 100
mm thick Calcium silicate molded block type of rigid hydrous calcium sili-
cate with thermal conductivity of 0.060 W/M-K. Outer covering shall be
aluminum jacket, 0.4 mm inches thick, and type 3003 or 5005 alloys with 4
mm corrugations. Jacket shall have a factory applied vapor barrier on the
inside with aluminum straps over transverse joints. Adjacent section cor-
rugations shall overlap.

L. Air-Intake Filter: Heavy-duty, engine-mounted air cleaner with replaceable dry-
filter element and "blocked filter" indicator.
M. Starting System: 24-V electric, with negative ground.
1. Components: Sized so they will not be damaged during a full engine-

cranking cycle with ambient temperature at maximum specified in Part 1
"Project Conditions" Article.
2. Cranking Motor: Heavy-duty unit that automatically engages and releases
from engine flywheel without binding.
3. Cranking Cycle: As required by NFPA 110 for system level specified.
4. Battery: Adequate capacity within ambient temperature range specified in
Part 1 "Project Conditions" Article to provide specified cranking cycle at
least twice without recharging.
5. Battery Cable: Size as recommended by engine manufacturer for cable
length required. Include required interconnecting conductors and connec-
tion accessories.
6. Battery Compartment: Factory fabricated of metal with acid-resistant finish
and thermal insulation. Thermostatically controlled heater shall be arranged to
maintain battery above 10 deg C regardless of external ambient temperature
within range specified in Part 1 "Project Conditions" Article. Include accesso-
ries required to support and fasten batteries in place.
7. Battery-Charging Alternator: Factory mounted on engine with solid-state
voltage regulation and 35-A minimum continuous rating.
8. Battery Charger: Current-limiting, automatic-equalizing and float-charging
type. Unit shall comply with UL 1236 and include the following features:
a. Operation: Equalizing-charging rate of 10 A shall be initiated auto-

matically after battery has lost charge until an adjustable equalizing
voltage is achieved at battery terminals. Unit shall then be automati-
cally switched to a lower float-charging mode and shall continue to
operate in that mode until battery is discharged again.
b. Automatic Temperature Compensation: Adjust float and equalize
voltages for variations in ambient temperature from minus 40 deg C
to plus 60 deg C to prevent overcharging at high temperatures and
undercharging at low temperatures.
c. Automatic Voltage Regulation: Maintain constant output voltage re-
gardless of input voltage variations up to plus or minus 10 percent.
d. Ammeter and Voltmeter: Flush mounted in door. Meters shall indi-
cate charging rates.
e. Safety Functions: Sense abnormally low battery voltage and close
contacts providing low battery voltage indication on control and
monitoring panel. Sense high battery voltage and loss of ac input or
dc output of battery charger. Either condition shall close contacts
that provide a battery-charger malfunction indication at system con-
trol and monitoring panel.
f. Enclosure and Mounting: NEMA 250, Type 1, wall-mounted cabinet.

2.3 FUEL OIL STORAGE
A. Comply with NFPA 30.
B. Day Tank: Comply with UL 142, freestanding, factory-fabricated fuel tank assem-
bly, with integral, float-controlled transfer pump and the following features:
1. Containment: Integral rupture basin with a capacity of 150 percent of nominal

capacity of day tank.
a. Leak Detector: Locate in rupture basin and connect to provide audi-

ble and visual alarm in the event of day-tank leak.
2. Tank Capacity: As recommended by engine manufacturer for an uninterrupted

period of 8 hours' operation at 100 percent of rated power output of engine-
generator system without being refilled.
3. Pump Capacity: Exceeds maximum flow of fuel drawn by engine-mounted fuel
supply pump at 110 percent of rated capacity, including fuel returned from en-
gine.
4. Low-Level Alarm Sensor: Liquid-level device operates alarm contacts at 25 per-
cent of normal fuel level.
5. High-Level Alarm Sensor: Liquid-level device operates alarm and redundant
fuel shutoff contacts at midpoint between overflow level and 100 percent of
normal fuel level.
6. Piping Connections: Factory-installed fuel supply and return lines from tank to
engine; local fuel fill, vent line, overflow line; and tank drain line with shutoff
valve.
7. Redundant High-Level Fuel Shutoff: Actuated by high-level alarm sensor in day
tank to operate a separate motor device that disconnects day-tank pump mo-
tor. Sensor shall signal solenoid valve, located in fuel suction line between fuel
storage tank and day tank, to close. Both actions shall remain in shutoff state
until manually reset. Shutoff action shall initiate an alarm signal to control
panel but shall not shut down engine-generator set.
2.4 CONTROL AND MONITORING
A. Automatic Starting System Sequence of Operation: When mode-selector switch

on the control and monitoring panel is in the automatic position, remote-control
contacts in one or more separate automatic transfer switches initiate starting
and stopping of generator set. When mode-selector switch is switched to the on
position, generator set starts. The off position of same switch initiates generator-
set shutdown. When generator set is running, specified system or equipment
failures or derangements automatically shut down generator set and initiate
alarms. Operation of a remote emergency-stop switch also shuts down generator
set.
B. Configuration: Operating and safety indications, protective devices, basic system

controls, and engine gages shall be grouped in a common control and monitoring
panel mounted on the generator set. Mounting method shall isolate the control
panel from generator-set vibration.

C. Indicating and Protective Devices and Controls: As required by NFPA 1 10 for
Level 1 or 2 system as required, and the following:
1. AC voltmeter.
2. AC ammeter.
3. AC frequency meter.
4. DC voltmeter (alternator battery charging).
5. Engine-coolant temperature gage.
6. Engine lubricating-oil pressure gage.
7. Running-time meter.
8. Ammeter-voltmeter, phase-selector switch (es).
9. Generator-voltage adjusting rheostat.
10. Fuel tank derangement alarm.
11. Fuel tank high-level shutdown of fuel supply alarm.
D. Supporting Items: Include sensors, transducers, terminals, relays, and other de-
vices and include wiring required to support specified items. Locate sensors and
other supporting items on engine or generator, unless otherwise required.
E. Include necessary contacts and terminals in control and monitoring panel.
1. Over crank shutdown.

2. Coolant low-temperature alarm.
3. Control switch not in auto position.
4. Battery-charger malfunction alarm.
5. Battery low-voltage alarm.
F. Remote Emergency-Stop Switch: Flush; wall mounted, unless otherwise required;

and labeled.
G. Push button shall be protected from accidental operation.
2.5 GENERATOR OVERCURRENT AND FAULT PROTECTION
A. Generator Circuit Breaker: Molded-case, electronic-trip type; 100 percent rated.

Circuit Breakers 800A and above shall be Power Air circuit breakers (ACB).
1. Tripping Characteristics: Adjustable long-time and short-time delay and in-

stantaneous.
2. Trip Settings: Selected to coordinate with generator thermal damage curve.
3. Shunt Trip: Connected to trip breaker when generator set is shut down by
other protective devices.
4. Mounting: Adjacent to or integrated with control and monitoring panel.
B. Ground-Fault Indication: Comply with NFPA 70, "Emergency System" signals for
ground- fault. Integrate ground-fault alarm indication with other generator-set
alarm indications.

2.6 GENERATOR, EXCITER, AND VOLTAGE REGULATOR
A. Comply with NEMA MG 1.
B. Drive: Generator shaft shall be directly connected to engine shaft. Exciter shall be
rotated integrally with generator rotor.
C. Electrical Insulation: Insulation class H for stator and rotor and temperature rise
class H.
D. Stator-Winding Leads: Brought out to terminal box to permit future reconnection

for other voltages if required.
E. Construction shall prevent mechanical, electrical, and thermal damage due to vi-
bration, over speed up to 125 percent of rating, and heat during operation at 110
percent of rated capacity.
F. Enclosure: Drip proof.
G. Voltage Regulator: Solid-state type, separate from exciter, providing perfor-

mance as specified.
1. Adjusting rheostat on control and monitoring panel shall provide plus or

minus 5 percent adjustment of output-voltage operating band.
H. Strip Heater: Thermostatically controlled unit arranged to maintain stator wind-

ings above dew point.
I. Windings: Two-thirds pitch stator winding and fully linked amortisseur winding.
J. Sub transient Reactance: 12 percent, maximum.
2.7 VIBRATION ISOLATION DEVICES
A. Elastomeric Isolator Pads: Oil- and water-resistant elastomer or natural rubber,

arranged in single or multiple layers, molded with a nonslip pattern and galva-
nized-steel base plates of sufficient stiffness for uniform loading over pad area,
and factory cut to sizes that match requirements of supported equipment.
1. Material: Bridge-bearing neoprene, complying with AASHTO M 25 1.

2. Durometer Rating: 65.
3. Number of Layers: Three.
B. Restrained Spring Isolators: Freestanding, steel, open-spring isolators
1. Housing: Steel with resilient vertical-limit stops to prevent spring extension

due to wind loads or if weight is removed; factory-drilled base plate bond-
ed to 1/4-inch- (6-mm-) thick, elastomeric isolator pad attached to base
plate underside; and adjustable equipment mounting and leveling bolt that
acts as blocking during installation.
2. Outside Spring Diameter: Not less than 80 percent of compressed height of

the spring at rated load.
3. Minimum Additional Travel: 50 percent of required deflection at rated
load.
4. Lateral Stiffness: More than 80 percent of rated vertical stiffness.
5. Overload Capacity: Support 200 percent of rated load, fully compressed,
without deformation or failure.
2.8 FINISHES
A. Indoor Enclosures and Components: Manufacturer's standard finish over corro-

sion-resistant pretreatment and compatible primer.
A. Prototype Testing: Factory test engine-generator set using same engine model,
constructed of identical or equivalent components and equipped with identical
or equivalent accessories.
1. Tests: Comply with NFPA 110, Level 1 Energy Converters and with IEEE 115.
B. Project-Specific Equipment Tests: Before shipment, factory test engine-generator

set and other system components and accessories manufactured specifically for
this Project. Perform tests at rated load and power factor. Include the following
tests:
1. Test components and accessories furnished with installed unit that are not
identical to those on tested prototype to demonstrate compatibility and
reliability.
2. Full load run.
3. Maximum power.
4. Voltage regulation.
5. Transient and steady-state governing.
6. Single-step load pickup.
7. Safety shutdown.
8. Provide 14 days' advance notice of tests and opportunity for observation of
tests by Owner's representative.
9. Report factory test results within 10 days of completion of test.
PART 3 EXECUTION
3.1 EXAMINATION
A. Examine areas, equipment bases, and conditions, with Installer present, for com-
pliance with requirements for installation and other conditions affecting pack-
aged engine-generator performance.
B. Examine roughing-in of piping systems and electrical connections. Verify actual

locations of connections before packaged engine-generator installation.

C. Proceed with installation only after unsatisfactory conditions have been correct-
ed.
3.2 INSTALLATION
A. Equipment and accessories installed under this section shall be assembled,

erected, and placed in proper operating condition in full conformity with specifi-
cations, engineering data, instructions, and recommendations of the equipment
manufacturer unless exceptions are noted by the Engineer.
B. The complete engine-generator unit shall be grouted in place on a level concrete

pad. Anchor bolts shall be supplied by the generator unit manufacturer.
A. Field Supervision and Tests: The Contractor shall include a minimum of three 8
hour working days allowance for the services of a competent manufacturer's
technical representative to check the installation, make all necessary adjust-
ments and, in the presence of the Engineer, perform acceptance tests on the en-
gine-generator unit to determine whether the equipment conforms to specified
requirements for load capacity and starting duty.
B. As part of the field test, each of the automatic shutdown devices shall be made
to be operated and the respective values recorded at which the devices actually
stopped the engine. Any adjustments required shall be made in the devices to
make the operating values correspond to those recommended by the engine
manufacturer.
C. Before running the field test, submit a copy of the proposed log sheet on which
shall be recorded the load and all corresponding temperatures and pressures as
well as the total quantity of fuel consumed during the test. The test shall consist
of operations under a load bank at the specified power rating for four continuous
hours.
D. Readings shall be taken and recorded at 15-minute intervals over the four-hour
test period.
E. The Contractor shall furnish the fuel, lubricants, load bank, instruments and all
other devices necessary for the tests.
3.4 GROUNDING
A. Provide equipment grounding connections for diesel engine – as shown on the

drawing details of grounding refer to section 260526
3.5 CONNECTIONS
A. Piping installation requirements are specified in Division 23 Sections.

B. Connect fuel, cooling-system, and exhaust-system piping adjacent to packaged
engine generator to allow service and maintenance.
C. Connect cooling-system water piping to engine-generator set and heat exchanger

with flexible connectors.
D. Connect engine exhaust pipe to engine with flexible connector.
E. Connect fuel piping to engines with a gate valve and union and flexible connect-
or.
1. Diesel storage tanks, tank accessories, piping, valves, and specialties for
fuel systems are specified in Division 23 Section “Facility Fuel-Oil Piping”.
F. Ground equipment according to Division 26 Section “Grounding and Bonding for

Electrical Systems”.
G. Connect wiring according to Division 26 Section “Low-Voltage Electrical Power

Conductors and Cables”.
3.6 IDENTIFICATION
A. Identify system components according to Division 23 Section “Identification for

HVAC Piping and Equipment” and Division 26 Section “Identification for Electrical
Systems”.
3.7 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance

personnel to adjust, operate, and maintain packaged engine generators. Refer to
Division 01 Section “Demonstration and Training”.
1. Coordinate this training with that for transfer switches.

2. Train the Owner's maintenance personnel on procedures and schedules for
starting and stopping, troubleshooting, servicing, and maintaining equip-
ment.
3. Review data in maintenance manuals. Refer to Division 1 Section “Opera-
tion and Maintenance Data”.
4. Schedule training of a minimum of 2 days with the Owner’s technical per-
sonnel, through the Engineer, with at least 7 days' advance notice.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. STATIC UNINTERRUPTIBLE POWER
CAIRO - EGYPT SUPPLY 263353 – 2874 0

CONTENTS
SECTION 263353
STATIC UNINTERRUPTIBLE POWER SUPPLY

Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Definitions 2
1.4 Submittals 3
1.7 Warranty 5
1.8 Extra Materials 5
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 Description 5
2.3 System Operation 6
2.4 System Characteristics 8
2.5 Ups Systems 11
2.6 Rectifier Charger 12
2.7 Inverter 12
2.8 Automatic Static Bybass Transfer Switch 13
2.9 Maintenance By-Pass Switching 13
2.10 Battery 13
2.11 Controls And Indicators 14
2.12 Rack Mounted U.P.S 16
PART 3 EXECUTION 16
3.1 Examination 16
3.2 Installation 17
3.3 Grounding 17
3.5 Battery Equalization 17
PART 4 SCHEDULES 18
Static Uninterruptible Power Supply Section 263353

SECTION 263353 - STATIC UNINTERRUPTIBLE POWER SUPPLY
PART 1 GENERAL

1. Division 26, Section "Grounding and Bonding".

2. Division 26, Section "Conductors and Cables".
1.2 SUMMARY
A. This Section includes, on-line, static-type, continuous duty, solid state, double
conversion uninterruptible power supply (UPS) system installation and static transfer
switch, comprising the following:
1. Complete rectifier/charger-battery-inverter system with 100% rated for

continuous automatic static switch and maintenance by-pass circuit
2. Input harmonic filter.
3. Isolation transformer.
4. Power conditioner
5. Interplant power and control cabling
6. Connection of normal A.C. power from assigned terminals/switch/circuit
breaker, as shown on the Drawings
7. Earthing system.
8. Connection to BMS system for full monitoring, including interface elements
such as relays, transducers, etc. as detailed in BMS schedules and /or shown
on the Drawings.
1.3 DEFINITIONS
A. EMI: Electromagnetic interference.
B. LCD: Liquid-crystal display.
C. LED: Light-emitting diode.
D. UPS: Uninterruptible power supply.
E. THD: Total harmonic distortion.
F. PC: Personal computer.

1.4 SUBMITTALS
A. Product Data: Submit full technical data of equipment for approval including:
1. Manufacturers’ catalogue cuts and / or data sheets describing the proposed

equipment to be submitted, compliance sheet with the Specification listing all
deviations, operating performance characteristics, protective and control
provisions, heat losses, ambient conditions.
B. Shop and Construction Drawings: Submit drawings for approval including:
1. Plans, front and side elevations, physical data (dimensions and weights),
installation and arrangement details for the UPS and batteries, power wiring
diagram, control / signal wiring diagram, ratings of each piece of equipment,
cabling, grounding etc.
C. Manufacturer Certificates: Signed by manufacturers certifying that they comply with

requirements.
D. Qualification Data: For firms and persons specified in "Quality Assurance" Article.
E. Test Certificates: Submit type test and routine test certificates.
F. System is to undergo a functional and load test program approved by the Engineer,
and is to undergo a minimum 24 hours 'burn-in' test.
G. Final test procedures for each equipment shall include a check of performance
specification before and after the 24 hours 'burn-in' test.
H. Field Test Reports: Indicate test results compared with specified performance
requirements, and check the controls and indicators after installation.
I. Maintenance Data: For UPS units to include in maintenance manuals including

detailed operating instructions covering operation under both normal and
emergency conditions.
A. Manufacture’s Certification: The manufacturer is to be specialized in manufacturing

of UPS modules specified in this document.
1. The manufacturer shall be one of the listed manufactures in this section.
B. Factory Testing: Prior to shipment the manufacturer is to complete a documented

test procedure to test all functions of the UPS modules, Tests are to comply to IEC
62040-3 and include but not necessarily limited to the following:
1. Light load test.

2. AC input failure test.
3. AC input return test.
4. Transfer test.

5. Full load test.
6. UPS efficiency test.
7. Unbalanced load test.
8. Balanced load test.
9. Short-circuit test.
10. Harmonic components test.
11. Certificate for battery tests should be provided by the battery manufacture.
C. Materials and Assemblies:
1. All materials and parts comprising the UPS shall match the project
specifications and local codes.
2. All components shall be stored, installed, sealed and dust covered in a proper
way matches the manufacture recommendations ensuring maximum
reliability. The manufacturer is to conduct inspection on incoming parts,
modular assemblies, and final products.
3. The manufacture or his representatives (agent) is responsible for installation,
regular and emergency maintenance and providing spare parts of all units and
components.
4. Failure to satisfy Engineer may disqualify a manufacturer.
D. Standards: Installation is to comply with the following standards:
IEC 62040-1,2,3 Uninterruptible Power Systems.

IEC 61000-3-2 Limits for harmonic current emissions (equipment input
current ≤16 A per phase.
IEC 61000-3-3 Limits - Limitation of voltage changes, voltage fluctuations
and flicker in public low-voltage supply systems, for
equipment with rated current ≤16 A per phase and not
subject to conditional connection”.
IEC 61000-3-4 Limitation of emission of harmonic currents in low-voltage
power supply systems for equipment with rated current
greater than 16 A.
IEC 61000-4 Testing and Measurement Techniques
IEC 61000-6-2 Generic standards - Immunity for industrial environments
IEC 61000-6-3 Generic standards - Emission standard for residential,
commercial and light-industrial environments
IEC 62040-1 Part 1: Safety Requirements
IEC 62040-2 Part 2: Electromagnetic compatibility (EMC) requirements
IEC 62040-3 Part 3: Method of specifying the performance and test
requirements
IEC 62310 Static Transfer Systems
IEEE 485 IEEE Recommended Practice for Sizing Lead-Acid Batteries for
Stationary Applications”

E. Delivery, storage, and handling
1. Delivery, shipping and storage shall be carried out according to the

manufacture recommendations, damage test procedures, and temperature
and humidity tolerance.
2. Certificate for the batteries production date are to be submitted to the
engineer, powering of batteries during the storage time should follow the
manufacture recommendations approved by the engineer prior to shipping.
3. Equipment with modules longer than 1650 mm shall be spitted during
shipping to sections not more than 1650 mm length each.
A. Temperature limits within which equipment is to be designed to operate are zero to

+40 deg. C at 100% rated output. UPS Shall be installed in room with Air
conditioning operate 24 hours/ 7days per week.
1.7 WARRANTY
A. Manufacturer’s Warranty: Submit a written warranty signed by the manufacturer

agreeing to 24 hours / 7 days per week, and remedial coverage inclusive of all parts,
labor, transportation and living costs during the warranty period.
1. Warranty Period: 1 year from date of substantial completion.
1.8 EXTRA MATERIALS
A. Provide list of manufacturer's spare parts for five years’ operation together with
current prices.
PART 2 PRODUCTS
2.1 MANUFACTURERS

2.2 DESCRIPTION
A. System: UPS system is to be online, continuous duty, double conversion and class
VFI-SS-111 according to IEC 62040-3.
B. System is to be of the programmable type, microprocessor based with CPU and

memory capabilities for storage of alarms, faults, status change, etc. The UPS shall
permit setting parameters for the environment and type of usage to be specified by
the Engineer. UPS is to be of the self-diagnostic type, equipped with a self-test

function to verify correct system operation. The self-test shall identify the parts of
the UPS requiring repair in case of a fault. The system is to be provided with multi-
password levels to limit access to software and data.
C. General: System is to be interposed between normal A.C. power supply and critical
load, to secure a minimum period of continuity of no-break battery back-up for the
durations shown on drawings, in case of failure of normal A.C. supply and maintain
output voltage, frequency and phase deviation within specified tolerances.
D. System is to be 100% fully rated, for number and capacity as shown on drawings;
which implies complete UPS unit(s). UPS is to be maintained (continuously supplying
load through the inverter), with automatic no-break transfer to or retransfer from
alternate source (bypass) in case of failure or overload on rectifier- battery-inverter
system. System is to employ decentralized bypass technique so that each UPS unit is
to be provided with its own static bypass transfer switch. Each UPS unit is to be
provided with its own master controller. Master and slave configuration is not
acceptable.
E. Normal A.C. power supply will be available from one protected source fed from
either normal A.C. network or from A.C. Characteristics of output of generator set
(when provided) and UPS system are to be coordinated for best results. Study and
advice on special requirements of generator characteristic output and stability.
F. UPS Bypass and Output Neutral shall be designed to continuously carry twice the full
load phase current.
G. System overall efficiency is not to be less than [94] % at full load and [95] % at half
load.
H. Noise level of complete assembly is not to exceed [65] dB(A) at 1.0 m distance
anywhere within UPS room.
I. Surge suppression: Protect internal UPS components from surge that enter at each
AC power input connection
2.3 SYSTEM OPERATION
A. Automatic Operation Includes the Following:
1. Normal Conditions:
B. Load is supplied with power flowing from the normal power input terminals, through
the rectifier-charger and inverter, with the battery connected in parallel with the
rectifier-charger output. Upon loss of normal a.c. supply, battery is to continue
supply of no-break power to inverters, which then free-run on self- generated UPS
frequency reference.
1. Abnormal Supply Conditions:
a. If normal supply completely failed or deviates from specified and

adjustable voltage, voltage waveform, or frequency limits, the battery

supplies energy to maintain constant, regulated inverter power output
to the load without switching or disturbance.
2. Return to Normal Conditions:
a. When power is restored at the normal supply terminals of the system,

controls automatically synchronize the inverter with the external source
before transferring the load. The rectifier-charger then supplies power
to the load through the inverter and simultaneously recharges the
battery.
b. If the battery becomes discharged and normal supply is available, the
rectifier-charger charges the battery. On reaching full charge, the
rectifier-charger automatically shifts to float-charge mode.
3. Transfer to Bypass AC Power Source:
a. Automatic Transfer To Bypass: Static transfer switch is to automatically

transfer critical (100%) load from inverter to by-pass source (which is
normal A.C. supply) if:
1. Inverter output voltage characteristics fall outside specified limits.
2. If a fault occurs in the system supplied by the UPS, and current

flows in excess of the overload rating of the UPS system, the static
bypass transfer switch operates to bypass the fault current to the
normal ac supply circuit for fault clearing. When the fault has
cleared, the static bypass transfer switch returns the load to the
UPS system.
3. Over-temperature is sensed.
4. If any element of the UPS system fails and power is available at

the normal supply terminals of the system, the static bypass
transfer switch switches the load to the normal ac supply circuit
without disturbance or interruption.
5. Transfer to by-pass mode is to be inhibited, and an alarm initiated

if voltage, frequency and/or phase shift of bypass power is
outside acceptable tolerances.
4. Retransfer to Inverter:
a. The static bypass switch shall be capable of automatically retransferring

the load back to the inverter after the inverter has returned to normal
conditions.
b. In case of many retransfer operations failed during 10 minutes, transfer
shall not be occurred as the two sources are not synchronized (Lock out
Feature).
c. Downgrade:
5. If the battery is taken out of service for maintenance, it shall be

disconnected from the rectifier/charger and inverter by the

battery circuit breaker. The UPS shall continue to function and
meet the performance criteria specified herein except for the
battery reserve time.
C. Manual Operation Includes The Following:
1. Turning the inverter off causes the static bypass transfer switch to transfer the
load directly to the normal ac supply circuit without disturbance or
interruption.
2. Turning the inverter on causes the static bypass transfer switch to transfer the
load to the inverter.
D. Maintenance Bypass/Isolation Switch Operation:
1. Switch is interlocked so it cannot be operated unless the static bypass transfer

switch is in the bypass mode. Device provides manual selection among the
three conditions in subparagraphs below without interrupting supply to the
load during switching:
E. Full Isolation: Load is supplied, bypassing the UPS. Normal UPS ac input circuit,
static bypass transfer switch, and UPS load terminals are completely disconnected
from external circuits.
F. Maintenance Bypass: Load is supplied, bypassing the UPS. UPS ac supply terminals
are energized to permit operational checking, but system load terminals are isolated
from the load.
G. Normal: Normal UPS ac supply terminals are energized and the load is supplied
through either the static bypass transfer switch and the UPS rectifier-charger and
inverter, or the battery and the inverter.
H. Environmental Conditions:
1. The UPS shall be capable of operating continuously in the following

environmental conditions without mechanical or electrical damage or
degradation of operating capability, except battery performance.
2. Ambient Temperature for Electronic Components: (0 to 40 deg.C).
3. If the battery must operate within the temperature range specified in first
subparagraph below rather than in the environment specified in the special
battery warranty, special battery selection requirements may apply. Consult
battery manufacturers.
4. Ambient Temperature for Battery: (5 to 35 deg.C).
5. Relative Humidity: 0 to 95 percent, non-condensing.
6. Altitude: Sea level to (1000 m).
2.4 SYSTEM CHARACTERISTICS
A. Rectifier/Charger Input:
Voltage: 380V, three phase, 4 Wire or 220V, single phase, 2

Wire as indicated on the drawings 50 Hz

Voltage Range: +10% to -15% without discharging the battery
Frequency: 50 Hz ± 5 Hz
Current Walk-In: From 25% to 100% full Load rating at 15 seconds.
Input Current Limit: 125% of nominal full load current
Power Factor: 0.95 lagging at nominal input voltage with filter
Current Harmonics:  3% THD at nominal conditions and at full UPS load
for ratings greater than 20 KVA and < 7% for ratings
less than 20 KVA
B. UPS Module Output:
1. Nominal net system power output rating in kVA: as shown on drawings with
load power factor 0.9 lag.
Output voltage regulation For Balanced load: ± 1% of nominal

For Unbalanced load (3-phase output only): ± 5% of
nominal
Voltage: 380V, three phase 4 Wire or 220V, single phase, 2
Wire as indicated on the drawings 50Hz, adjustable
+/-3% of nominal.
Frequency: 50 HZ ± 0.5 HZ
Power Rating: As Shown on the drawings
Voltage Regulation: ±3% of nominal @ unbalanced loads &
±1% of nominal @ balanced loads for any of the
combined effects:
a. No load to full load.
b. 1.0 to 0.9 lagging power factor.
c. Minimum to maximum AC input voltage.
d. Minimum to maximum DC input voltage.
e. 0 to 40° C ambient temperature.
Dynamic Regulations: +5% from nominal for 100% step load
+2% from nominal for 50% step load
+1% from nominal for re transfer to Inverter from
bypass.
Recovering to be within ±1% in less than 20
milliseconds
Voltage Adjustability: Maximum to +3%
Phase Separation: +3 Degrees with balanced and unbalanced loads.
Linear Load Voltage 1% Phase to Phase
Distortion: the maximum 2% Phase to Neutral
output voltage distortion
shall be as follow:
Non-linear Load Voltage 2% Phase to Phase
Distortion: When driving 3% Phase to Neutral
100% non-linear load

consisting of typical three
phase rectifier loads with
individual harmonics of 30%
fifth and 10% seventh or
balanced single phase loads
(PC power supplies) with
30% third, 20% fifth and
10% seventh, the maximum
output voltage distortion
shall be as follow:
Current distortion (THD):  3% (linear load)
 6% (Non-linear load)
Crest Factor: 3:1 maximum
Frequency Stability: 0.1% free-running
Frequency Slew Rate: 0.25 Hz to 2 Hz/second, selectable in 0.25 Hz
increments
Overload (Inverter) a. 125% for 10 minutes
b. 150% for 1 minute
c. 105% for continuous running
Fault Clearing (Static 1000% for 6 cycle
Bypass):
C. Reliability: The UPS shall have a minimum of 200,000 hours Mean-Time-Between-

Failure (MTBF), including bypass.
D. Battery
1. Voltage: As required by the inverter

2. Protection: Total fault isolation
3. Type: 10 years long life sealed lead acid maintenance free batteries
4. Minimum Discharge Voltage: 1.8 volts per cell
E. Automatic Static Bypass Transfer Switch:
1. Transfer Time: 150 microsecond (overlapping) maximum.

2. Total Sensing and Transfer/Retransfer Time: 2 milliseconds, maximum.
3. Retransfer Mode: automatic/inhibit (selectable).
4. Retransfer Delay: 2 - 32 secs. In auto mode (selectable).
5. Transfer Point: ±10% of nominal output voltage (adjustable).
6. Retransfer Point: ±5% of nominal output voltage (adjustable).
7. Transfer Inhibit Point: ±20% of nominal output voltage (adjustable).
8. Bypass circuit is to be provided with back feed protection to IEC 60240-1.

2.5 UPS SYSTEMS
A. Materials and Parts: Electronic devices are to be solid state, hermetically sealed.
Indicator lights are to be twin LED type, those denoting blown fuse conditions are to
be seen by operator without removing panels or opening cabinet doors.
B. Cables are to be fire resistant high temperature grade.
C. Monitoring by Remote Computer
D. Coordinate this article with "Basic Battery Monitoring" Article if battery monitoring is
included. Coordinate with Division 26 Section "Electrical Power Monitoring and
Control."
E. Communication module in unit control panel provides capability for remote

monitoring of status, parameters, and alarms specified in "Controls and Indications"
Article. The remote computer and the connecting signal wiring are not included in
this Section. Include the following features:
1. Connectors and network interface units or modems for data transmission via
RS-232 link or USB
2. BMS Port: Each unit shall be equipped with an RS 485 serial port
communication board capable of implementing the lon, backnet, Modbus,
OPC as specified in BMS System.
3. Data Port: Each unit shall be equipped with an SNMP communication board
for connection to an Ethernet network.
4. Software designed for control and monitoring of UPS functions and to provide
on-screen explanations, interpretations, diagnosis, action guidance, and
instructions for use of monitoring indications and development of meaningful
reports. Permit storage and analysis of power-line transient records. Designs
for Windows applications, software, and computer are not included in this
Section.
5. Software and Hardware: Compatible with that specified in Division 26 Section
"Electrical Power Monitoring and Control."
F. Housing: Equipment is to be housed in a free-standing, floor mounted, galvanized

sheet steel construction treated against corrosion with front accessible lockable
hinged doors.
G. Suitable casters and leveling pads shall be included to suite installing the equipment
directly on floor.
H. Enclosures are to be suitable for such environment, protection IP according to IEC

60529.
I. Ventilation: units shall be provided with forced-air, cooling system in each UPS
module to ensure components operate within environmental ratings suitable for
best performance. Air is to enter from air inlets near to the bottom of cabinet
through input filters, and discharge from outlets near to the top. Redundant fans or
blowers are to be provided for ventilating each enclosure to keep on the same
performance in case of one fan failure. Inlet air temperature shall be monitored and
displayed to initiate alarm if maximum working temperature is exceeded.

2.6 RECTIFIER CHARGER
A. Rectifier/charger unit is to be Insulated Gate Bipolar Transistor (IGBT) type for UPS
ratings 200 kVA and below; and IGBT or 12 pulse type with filter (to reduce feedback
current harmonics to specified values) for ratings above 200 kVA.
B. The unit is to have mainline circuit breaker, EMI transient suppressor network, I/O
filters , control circuitry providing constant V/I electronic current limiters and is to
be automatic with soft start-up (walk-in) feature over a period of approximately 15
seconds.
C. Input Filter to be automatically disconnected in case of utility power supply failure

while the UPS is operating at light loads (less than 25%).
D. Rectifier charger shall be provided with built-in or inherent electronic current-

limiting protection against permanent self damage effective down to short-circuits.
Fast acting, current limiting devices are to protect against failure of any solid state
component.
E. Rectifier charger shall be automatically turned off without opening the circuit
breaker in case of sensing high DC voltage, AC over/ under voltage of (10%), loss of
phase in input and loss of normal AC input.
F. Using IGBT with vector control design to suit power output requirements and
protect against primary power surges, lightning transients, under-voltage and over-
voltage conditions. Output is to be passed through LC filters to D.C. bus.
G. Rectifier/charger unit is to be capable of supplying full load power to inverter, and to

charge the battery from a discharge condition to 80% charge within ten times
discharge period, and maintain full charge at floating voltage until next operation.
H. The rectifier/battery charger is to employ input AC current limiting as well as battery

charge current limiting for battery protection. Charger current is to be voltage
regulated and current limited.
2.7 INVERTER
A. Inverter is to employ IGBT technology in three leg, vector control or high frequency
switching and real time control technique, and complete with filters. Inverter start-
up is to be automatic, to reach full voltage within milliseconds and deliver power to
the load during less than one (1) seconds. Inverter is to start at any load including
short-circuit.
B. Inverter oscillator is to operate and maintain output frequency of inverter within

specified tolerances, and be capable of synchronization and phase-locking to
normal/generator power supply characteristics to optimize the system compatibility.
C. Inverter shall be provided with built-in or inherent electronic current-limiting

protection against permanent self-damage effective down to short-circuits. Fast
acting, current limiting devices are to protect against failure of any solid state
component

D. Inverter shall be turned off in case of over temperature, or overloads over specified
limits or high / low DC voltage or over / under AC voltage (10%).
E. Inverter shall shut down if the battery reaches the low DC shut down level, and shall
be automatically restarts and returns to normal when AC power return.
2.8 AUTOMATIC STATIC BYBASS TRANSFER SWITCH
A. Static bypass switch continuously rated at (125% FL), hybrid type (make-before-
break), consists of one pair of silicon controlled rectifiers (SCR’s) per phase, each pair
connected in parallel with logic thyristor assembly isolatable or completely
removable for maintenance.
B. When signal to close switch is initiated, thyristors are to instantaneously conduct

power to prevent deviations and breaks in load voltage outside specified tolerances.
2.9 MAINTENANCE BY-PASS SWITCHING
A. Manual (make-before- break) by-pass switch is to allow load to be transferred to by-

pass source without interruption of output, and provide isolation of UPS and static
switch during maintenance.
B. Test position is to permit testing of static switch while load is being fed from bypass
power circuit.
2.10 BATTERY
A. High rate discharge, valve-regulated, premium, maintenance free, sealed lead- acid
(gas recombination) type cells; with automatically re-closing explosion proof safety
vents.
B. Ampere-hour rating is to be sufficient for emergency period specified with all

inverters operating at full rated output, to a discharge limit of not less than 1.8 V per
cell. Cells are to be normally maintained at 2.25 V per cell.
C. Battery life time is not to be less than 10 years.
D. Batteries to be factory assembled from UPS manufacturer, in an isolated

compartment or in a separate matching cabinet, complete with battery circuit
breaker.
E. Enclosures of welded construction and formed from heavy gauge steel with added
supports to retain cabinet square-ness and integrity during harsh shipping and
handling conditions.
F. Adjustable battery rails or trays are to be provided to allow for multiple battery
configurations and facilitate battery upgrades in the future, Cabling is to be routed
down the sides of the cabinet, away from the front of the batteries allowing full
access for easy maintenance, series wiring is to be routed efficiently and neatly with

tier to tier jumpers located at front batteries allowing for safe and easy
maintenance.
G. A load rated circuit breaker for over current protection and isolating the battery
from the UPS module for maintenance purposes shall be furnished; fused switches
shall not be acceptable. The battery circuit breaker shall be installed inside the
battery enclosure when the matching cabinet is provided. Remote tripping and
position indicating shall be included as required by the UPS module.
H. Battery calculations are to be carried out by UPS supplier and submitted for
approval, based on the following:
1. Nominal active power factor of not less than 0.8 Lag

2. Temperature factor for operation at 25 Deg C.
3. Aging factor of 1.15
4. Design margin factor of 1.10
5. Recharge time not exceeding 10 autonomy time
2.11 CONTROLS AND INDICATORS
A. Mimic Panel: UPS assembly is to include a mimic diagram with digital and LED
displays, indicating instruments and control devices, in true relative positions.
B. Minimum displays, indicating devices, and controls include those in lists below.
Provide sensors, transducers, terminals, relays, and wiring required to support listed
items. Alarms include audible signals and visual displays.
1. Quantitative indications shall include the following:
a. Input voltage, each phase, line to line.

b. Input current, each phase, line to line.
c. Bypass input voltage, each phase, line to line.
d. Bypass input frequency.
e. System output voltage, each phase, line to line.
f. System output current, each phase.
g. System output frequency.
h. DC bus voltage.
i. Battery current and direction (charge/discharge).
j. Elapsed time discharging battery.
2. Basic status condition indications shall include the following:
a. Normal operation.
b. Load-on bypass.
c. Load-on battery.
d. Inverter off.
e. Alarm condition.
3. Local Alarm indications shall include the following:
a. Bypass ac input over voltage or under voltage.

b. Bypass ac input over frequency or under frequency.
c. Bypass ac input and inverter out of synchronization.
d. Bypass ac input wrong-phase rotation.
e. Bypass ac input single-phase condition.
f. Bypass ac input filter fuse blown.
g. Internal frequency standard in use.
h. Battery system alarm.
i. Control power failure.
j. Fan failure.
k. UPS overload.
l. Battery-charging control faulty.
m. Input overvoltage or under voltage.
n. Input circuit breaker tripped.
o. Input wrong-phase rotation.
p. Input single-phase condition.
q. Approaching end of battery operation.
r. Battery under voltage shutdown.
s. Maximum battery voltage.
t. Inverter fuse blown.
u. Inverter over temperature.
v. Static bypass transfer switch over temperature.
w. Inverter power supply fault.
x. Inverter transistors out of saturation.
y. Identification of faulty inverter section/leg.
z. Inverter output overvoltage or under voltage.
aa. UPS overload shutdown.
bb. Inverter current sensor fault.
cc. Inverter output contactor open.
dd. Inverter current limit.
4. Remote panel control and indicators are to include at least the following:
a. Audible alarm to sound for any alarm condition.

b. LED indicators for mains power available.
c. By-pass source available.
d. Inverter a.c. output available.
e. Inverter synchronized and phase locked.
f. Critical load connected to inverter.
g. Critical load connected to by-pass source.
h. Hybrid transfer switch inhibited.
i. High/low d.c. voltage.
j. Over-temperature.
k. Inverter output overload.
l. Alarm-indicator switch.
m. Emergency system shutdown push-button.
n. Silence/test/reset switch.
5. Controls shall include the following:
a. Inverter on-off.
b. UPS start.

c. Battery test.
d. Alarm silence/reset.
e. Output-voltage adjustment.
C. Dry-form "C" contacts shall be available for remote indication of the following
conditions:
1. UPS on battery.
2. UPS on-line.
3. UPS load-on bypass.
4. UPS in alarm condition.
5. UPS off (maintenance bypass closed).
D. Emergency Power off Switch: Capable of local operation and operation by means of
activation by external dry contacts.
E. Input active harmonic filter: is to be available to limit input current harmonic

distortion to less than 7% THD at all load currents from 0 to 100% of full load and
improve power factor to not less than 0.9.The input filter shall be mounted inside
the UPS cabinet or in a separate enclosure.
2.12 RACK MOUNTED U.P.S
A. A compact, line-interactive UPS system is designed especially for IT applications such

as network closets and small data centers. It provides reliable power protection for
servers, critical nodes, network workstations, large network peripherals, network
routers, bridges, hubs and other electronic equipment. Matching battery cabinets
shall be available to extend the on-battery operating time.
B. This unit shall allow manual transfer of connected equipment to utility power via a
maintenance bypass switch, permitting scheduled maintenance or UPS replacement
without disrupting data center power.
C. The UPS shall include data line surge protection, transient voltage surge protection,
and optional communications for shutdown and reporting. The UPS with minimum 8
output receptacles. A rack mounting rail kit is included as standard.
D. Optional telescoping rack rails mount to the sides of the UPS for easy installation
into a rack enclosure. A standard tower support base ships with the UPS.
E. The rack mounted UPS shall be provided with LAN interface.
PART 3 EXECUTION
3.1 EXAMINATION
A. Installation conditions which may affect the UPS performance shall be examined by
engineer before installation, Proceed with installation only after unsatisfactory
conditions have been corrected.

3.2 INSTALLATION
A. Equipment Bases: Ensure that concrete bases and foundations provided for
installation of equipment are constructed in accordance with approved shop and
construction drawings and equipment manufacturers' drawings and that holes for
fixing bolts and provisions for passage of cables etc. are provided as required.
B. For supported equipment, install epoxy-coated anchor bolts that extend through
concrete base and anchor into structural concrete floor.
C. Tools: Use only tools recommended by equipment manufacturers for installations,

particularly in making connections and adjustments.
3.3 GROUNDING
A. Provide direct interference free grounding circuit in accordance with Division 26

Section "Grounding and Bonding" of the Specification.
3.4 IDENTIFICATION
A. Identify components and wiring according to Division 26 Section "Basic Electrical

Materials and Methods."
3.5 BATTERY EQUALIZATION
A. Equalize charging of battery cells according to manufacturer's written instructions.

Record individual-cell voltages.
A. Electrical Tests and Inspections: Perform tests and inspections according to

manufacturer's written instructions and as listed below to demonstrate condition
and performance of each component of the UPS:
1. Inspect interiors of enclosures, including the following:
a. Integrity of mechanical and electrical connections.

b. Component type and labeling verification.
c. Ratings of installed components.
2. Test manual and automatic operational features and system protective and
alarm functions.
3. Test communication of status and alarms to remote monitoring equipment.
B. Power Supply Output Disturbance: Provide microprocessor based instrument, and

monitor and record power supply output disturbance of voltage and frequency.
Instrument details are to be submitted for approval.

C. Tests are to include loads at various power factors from low-load to overload
condition, and measurements of temperature, heat losses, output voltage, wave
shape, and harmonic content and frequency stability.
D. The UPS system will be considered defective if it does not pass tests and inspections.
E. Record of Tests and Inspections: Maintain and submit documentation of tests and
inspections, including references to manufacturers' written instructions and other
test and inspection criteria. Include results of tests, inspections, and retests.
3.7 DEMONSTRATION
A. Train Employer's maintenance personnel to adjust, operate, and maintain the

system installation.
PART 4 SCHEDULES
A. Provide UPS rated as shown on the drawings and each for minutes shown on the
drawings. Quantities as shown on the drawings and Bill of quantities.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. LOW VOLTAGE POWER FACTOR
CAIRO - EGYPT CORRECTION EQUIPMENT 263533- 2874 0

CONTENTS
SECTION 263533
LOW VOLTAGE POWER FACTOR CORRECTION EQUIPMENT

Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Standard Products 3
1.6 Extra Materials 3
1.7 Substitution of Materials And Methods 3
1.8 Safety Signs 3
1.9 Warranty and Product Quality 3
PART 2 PRODUCTS 3
2.1 Manufacturers 3
2.2 General Description 3
2.3 System Configuration 4
2.4 Fault Current Considerations 5
2.5 Performance Requirements 6
2.6 Withstanding Transients 6
PART 3 EXECUTION 6
3.1 Inspection 6
3.2 Installation 6
3.4 Maintenance 7
Low Voltage Power Factor Correction Equipment Section 263533

SECTION 263533 - LOW VOLTAGE POWER FACTOR CORRECTION EQUIPMENT
PART 1 GENERAL
A. Drawings and general provisions of Contract including General Conditions, Conditions of

Particular Application and Division-1 Specification Section, apply to this section.
1.2 SUMMARY
A. This section specifies capacitor-type power factor correction equipment for use in
electrical power systems rated 600 Volts and less.
1.3 SUBMITTALS
A. Product Data: For products specified, include data on features, components, ratings and
performance.
B. Drawings: Include dimensioned plan, elevation views of enclosure and details of control
panels.
1. Show access and working space requirements.
C. Special Studies: For the effect of the following systems (actual selected sizes of the
project) on the capacitors:
1. Motors.
2. Generators.
D. Three (3) complete original sets of operation and maintenance manuals. Each set shall
include:
1. Lists of spare parts for 3 years.

2. Detailed Operating instruction covering operation under both normal and abnormal
conditions.
3. Detailed installation construction manuals
A. Reference Standards: The design, Manufacture, installation practice of plant equipment

as a part of main low tension panel shall be in accordance with one or more of relevant
publications of the following standards:
1. International Electro-Technical Commission (IEC).

2. Institute of Electrical Engineers (IEE).
3. National Electrical Manufacturing Association (NEMA).
4. Egyptian Standards (ES).

1.5 STANDARD PRODUCTS
A. Material and equipment to be provided by the manufacturer shall be essentially the

standard cataloged products.
B. Standard catalogue items and IEC (or NEMA) sizes, ratings, capacities and voltages shall
be given preference.
C. Products and Manufacturer shall be nationally “listed”, “labeled” and “approved” from
local concerned authority.
1.6 EXTRA MATERIALS
A. Furnish extra materials suitable for interconnection, commissioning and operation

matching all products installed and identified with labels describing contents.
1.7 SUBSTITUTION OF MATERIALS AND METHODS
A. In case of any proposed deviation or alternatives, provide sufficient data to allow

evaluation of proposed offer.
1.8 SAFETY SIGNS
A. All access panels to the electrical equipment shall have appropriate warning labels.
1.9 WARRANTY AND PRODUCT QUALITY
A. One year warranty after the date of Substantial Completion, for the power factor
correction equipment shall be provided, for the materials and manufacturing quality
control.
B. Contractor shall agree to repair or replace the equipment that does not comply with the
requirements or fails in work.
PART 2 PRODUCTS
2.1 MANUFACTURERS

incorporated into the Work include, but are not limited to, the ones mentioned on the
attached list of manufacturers Section 012950.
2.2 GENERAL DESCRIPTION
A. The system shall consist of a power factor correction unit(s) installed in its own enclosure
to achieve at least 0.93 power factor correction, IP 42 , for indoor installation, and shall be
an integral part of low voltage panel board. System includes a separately mounted
current transformer sensing current in the power circuit being corrected and providing
input to the system controls. Capacitor shall be of the dry type and shall be capable of
withstanding twice its rated voltage for 10 seconds at rated frequency between terminals
and container. Capacitor shall also withstand 3 kV for 10 seconds, capacitor losses shall be
less than 0.5 W/KVAR.
2.3 SYSTEM CONFIGURATION
A. The basic types of power factor correction equipment used to incorporate the capacitor
cells may include:
1. Automatic Systems: System includes integrally mounted, factory wired major

components incorporating:
a. Individual capacitors (440-470V. rated) shall be self-healing utilizing dry

polypropylene films as a dielectric with vacuum deposited conductors
on the polypropylene as electrode.
b. Each three (3) phase capacitor shall be furnished with an approved
pressure sensitive interrupter. The interrupter shall disconnect all three
(3) phases at the same time to maintain a balanced circuit.
c. Dielectric material shall be low loss, less than 0.5 Watts per KVAR.
d. Dry cells encapsulation medium shall be a thermoplastic material which
allows out gassing to engage the pressure interrupter.
e. Terminal bushings shall withstand 10 KVAC to ground and be rated
30 kV or greater.
f. Nominal design life of individual capacitor cells shall be 10 years.
g. Individual capacitor cells shall be covered by a five (5) year warranty.
h. All capacitor cells shall have threaded terminals for wire connection.
i. To reduce line transients on system no stage shall switch more than 120
KVAR and no capacitor cell shall exceed 50 KVAR.
j. Multiple fused capacitor banks dry metallized dielectric, self-healing
type.
k. Multiple contactors that connect capacitor banks selectively to the
output circuit. Contactors should be 660 V rated category “AC–6b” with
damping resistors, for the repetitive high-inrush-switching duty
presented by the capacitor loading, and should be of the fast opening
and closing type. Contactors used shall help reducing the transient
starting current from 200 to 100 times (maximum) the nominal current.
l. Solid-state microprocessor-based controls (power factor regulator) that
switch the banks on and off (on flexible steps basis) to suit the amount
of power factor correction needed as load conditions change in the
distribution system served, and shall be suitable to harmonic
applications.
m. Discharge resistors to discharge safely and automatically the stored
energy in the capacitors. Discharge shall be within 1 minute after
disconnection from the supply. Resistor shall be chosen to ensure 20
years minimum life.
n. Potential transformer needed for the under-voltage relay.
o. Under-voltage relay that interrupts capacitor switching for power supply
interruption longer than 15 ms.

p. “Advance” and “Retard” pushbuttons on the control panel shall permit
manual sequencing of capacitor switching.
q. On-off switch.
r. Knobs to adjust the target power factor range from 0.75 to 1.0 P.F
inductive, and to adjust or select the step combination as well as the
delay between steps.
s. Current transformer shall measure the overall current of loads and
capacitors mounted on the incoming of the main switchgear and
interconnected to the control switching.
t. Air-core Type inductors coil mechanically braced to withstand short-
circuit current (S.C.C.) and installed in capacitor circuit may be used to
limit switching surges within Contactor ratings.
u. Indicating lights LEDs to designate energized capacitor banks.
v. Power factor meter.
w. Blown fuse indicators, three (3) “push-to-test” blown fuse pilot lights,
one per phase, door mounted to indicate a blown fuse condition.
x. Circuit breakers magnetic characteristics shall be Curve “D” and as per
IEC recommendations for switching and protecting capacitors by circuit
breakers.
y. HRC Fuses to provide for major, fault protection, line fuses shall be
provided on all three (3) phases of each switched stage and fixed bank.
z. Line fuses shall be current limiting, recognized Class T type or
equivalent, minimum interrupting ratings shall be 200 000 Amps. for
fuses of 30 Amps. and above.
aa. Fuses shall be designed for capacitor applications and shall be rated not
less than 200% capacitor current rating.
bb. Alarms for:
Low power factor

Over load
Over current
Under voltage
Over voltage
Over/temperature
2.4 FAULT CURRENT CONSIDERATIONS
A. Air-Core Type inductors and power bus-work in the power factor correction units shall
withstand the mechanical forces that occur when the prospected short circuit currents
flow.
B. These currents shall be limited by the appropriate protective means, and the bracing of
these components shall withstand the peak asymmetrical symmetrical short-circuit
current (S.C.C.) of the system.
C. The switching device should be over sized (as mentioned below) to exceed the capacitor
nominal current as follows:
1. Molded Case Breakers 150%
D. The wire sizes shall match the switching devices rating.

2.5 PERFORMANCE REQUIREMENTS
A. The controls shall continuously sense the power factor on the circuit being corrected and
when it differs from the target settings for more than 10 seconds, system shall bring the
corrected circuit power factor closer to the target setting.
B. The supply cables and the control and protection devices of selected capacitor bank
ratings shall be oversized to at least (1.3 x 1.15 = 1.5) times their current rating (other
than installation derating requirements)
C. Only one capacitor bank shall be switched at a time.
2.6 WITHSTANDING TRANSIENTS
A. The construction of the system should give excellent withstanding capability to current
transients resulting from frequent switching of the stages of a multi stage capacitor bank.
PART 3 EXECUTION
3.1 INSPECTION
A. Examine conditions under which centralized automatic power factor capacitor assemblies
are to be installed. Notify Engineer in writing of conditions detrimental to proper
completion of the work. Do not proceed with work until unsatisfactory conditions have
been corrected.
3.2 INSTALLATION
A. Install centralized automatic power factor capacitor assemblies as indicated in accordance

with manufacturer’s written instruction, requirements of applicable standards and with
recognized industry practices to ensure that installation complies with requirements and
serves intended function.
B. Coordinate as necessary to interface installation of centralized automatic power factor

capacitor assemblies with other work.
C. Mount the switchboard assembly on flush steel aligning channels elevated above floor
level by a concrete pad and as noted on Drawings. Provide aligning shims to achieve level
installation where channels cannot be provided.
D. Ensure that centralized automatic power factor capacitor assemblies are shipped in
sections which can be fitted through the available structures and openings available.
E. Bond together the centralized automatic power factor capacitor assemblies structure,
sections and all conduits terminating at the same with a 120 mm2 bare copper earth
(ground) cable, and connect to the switchboard earth (ground) bus and to the earthing
(grounding) grid as required. Provide conduits terminating at centralized automatic
power factor capacitor assemblies with earthing (grounding) Wedges of the required size.

F. Tighten electrical connectors and terminals, including screws and bolts, in accordance
with equipment manufacturer have published torque tightening values for equipment
connectors.
G. Provide 6.35 mm minimum thick x 60 cm wide insulation material (on ground) in front of
centralized automatic power factor capacitor assemblies and rear of freestanding
equipment and extend 30 cm beyond ends.
H. Provide protective covering during construction.
I. Touch-up marred or scratched surfaces to match original finish.
J. Provide control fuses, with five spare fuses for each rating.
K. Adjust operating mechanism for free mechanical movement.
A. Upon completion of installation of equipment and after circuitry has been energized, test
equipment to demonstrate compliance with requirements. When possible, field-correct
malfunctioning units, then retest to demonstrate compliance.
B. Prior to energization of switchboards and centralized automatic power factor capacitor

assemblies:
1. Perform insulating resistance test on each pole, phase-to-phase and phase-to- earth
for one (1) minute. Minimum test voltage to be 1000 Volts D.C. with a minimum
resistance of 100 mega ohms.
2. Check centralized automatic power factor capacitor assemblies for continuity and for
short circuits.
3. Notify Engineer of any abnormalities.
C. After assemblies are energized, demonstrate functioning in accordance with

manufacturers requirements.
3.4 MAINTENANCE
A. All maintenance and inspection on the capacitor assembly shall be done with the system
disconnect device in the open position.
B. Maintenance and inspections (before handing over of the installation) should be limited
to 15 minutes or less so not to affect utility billing.
C. An annual inspection of the capacitor cell (before the handing over of the installation)
shall be done to identify failing capacitor cells (a bulged cover is the symptom to watch
for).


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. AUTOMATIC TRANSFER SWITCHES
CAIRO - EGYPT 263600 - 2874 0

CONTENTS
SECTION 263600
AUTOMATIC TRANSFER SWITCHES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Warranty 3
1.7 Instructions And Training On Operation And Maintenance 4
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 Change Over Switch 4
2.3 Enclosure 6
2.4 Testing 6
PART 3 EXECUTION 7
3.1 Installation 7
3.2 Operational Testing 7
Automatic Transfer Switches Section 263600

SECTION 263600 - AUTOMATIC TRANSFER SWITCHES
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including General Conditions, Conditions
of Particular Application and Division-1 Specification Sections, apply to this Section.
B. Section 23 “Fire Pumps”
1.2 SUMMARY
A. This section covers the furnishing, the installing, and the placing in operation of the
Automatic Transfer Switch.
1.3 SUBMITTALS
A. Drawings and Data: One line diagram of transfer switch (change over switch) assembly
and elementary or schematic and wiring diagram of the unit in plastic lamination
permanently secured to the inside of the front enclosure door. An interface equipment
connection diagram showing all conduits and wiring between the transfer switch all other
related equipment. The one-line diagram shall show interlocking provisions and
cautionary notes, if any.
1. It shall also general arrangement and complete dimensional layout of the equipment.
2. Above drawings shall show components description, technical ratings of equipment
and materials.
3. Single Line Diagram: Show connections between transfer switch, power sources
B. Certificates: Test certificates shall be executed and submitted prior to final inspection and
acceptance in accordance with the requirements of IEC standards. The certified tests
reports shall show date, time and duration of the overload, endurance and temperature
tests, and that the unit under test was not de-energized during the test sequence. Three
certified copies of each test certificate shall be submitted to the Owner’s Representative.
C. Test Plan: Test plan and test procedures for the acceptance tests. The test plan and test
procedures shall explain in detail, step-by-step actions and expected results to
demonstrate compliance with the requirements specified. The procedure shall also
explain methods for simulating the necessary conditions of operation to demonstrate
system performance.
D. Acceptance Tests: Test reports in booklet form showing all field tests are performed to
adjust each component and to prove compliance with the specified performance criteria,
upon completion and testing of the installed system. The reports shall include the
manufacturer, model number, and serial number of test equipment used in each test.
Each report shall indicate the final position of controls and operating mode of the system.

E. Operations and Maintenance Manuals/Charts and Spare Parts Data: Complete
operations and maintenance manuals/charts including spare parts data and wiring
diagrams of all equipment furnished under this section.
A. Reference Standards: Except as modified or supplemented herein, all equipment and

materials required in this section including their installation shall conform to the
applicable requirements of the following standards. Standards current at the time of
tender shall be used.
International Electrotechnical committee
IEC 60947-6-1 Low-voltage Switchgear and Control gear.
IEC 61439 Low-voltage switchgear and control gear assemblies.
IEC 60947-2 circuit breakers
National Fire Protection Association (NFPA)
70 National Electrical Code

99 Standards for Health Care Facilities
110 Emergency and Standby Power Systems
B. Source Limitations: Obtain transfer switch and related control panels through one source
from a single manufacturer.
C. Installer’s Qualifications: Contractor shall submit data showing that he has successfully
installed systems of the same type and design as specified herein, or that the Contractor
has a firm contractual agreement with a subcontractor having not less than ten years
experience in the design and installations of such system. Data shall include names and
location of at least two installation he or his referenced subcontractors has installed such
systems. The references shall indicate type and design of each system and certification
that each systems has performed satisfactorily in the manner intended for not less than
three years.
D. Owner’s Acceptance and Contractor’s Responsibility: Owner’s acceptance of the

Contractor’s working drawings shall not relieve the Contractor from responsibility for
errors, omissions, or deficiencies in the work. The Contractor shall verify actual
conditions in the field and shall take all measurements necessary for proper installation of
this work.
1.5 WARRANTY
A. Contractor shall agree to repair or replace the equipment that does not comply with
the requirements or fails in work.
1. Warranty Period: one year from date of Substantial Completion.

A. Storage: Supplementing the storage requirements described in Section 01605, General

Equipment Stipulations the manufacturer shall acknowledge storage conditions at the
time of submitting his Tender. The equipment may not be operational within 90 days
after manufacture, and the manufacturer shall crate and prepare the equipment for
export transportation and long-term storage. Precautionary measures for prolonged
storage shall be provided by the manufacturer at the factory. The Contractor shall be
responsible for storage and maintenance of the protective measures as recommended
and instructed by the manufacturer while stored at the storage site.
B. In addition to the protection specified for prolonged storage, the packaging of spare parts
(If Any) shall be prepared for export packing and shall be suitable for long-term storage in
a damp location. Each spare item shall be packed separately and shall be completely
identified on the outside of the container.
C. Instructions for the servicing of equipment while in long-term or prolonged storage shall
accompany each item of equipment. An enclosed instruction with each package shall be
noted on the exterior of the package and shall be in the Arabic and English languages.
D. Verification of Dimensions: The Contractor shall become familiar with the details of the
work and working conditions, shall verify dimensions in the field, and shall advise the
Owner’s Representative of any discrepancies before performing the work.
E. Spare Parts: All lists of all spare parts required for adjustment, operation, and
maintenance of the equipment for a period of three years from the date of the certificate
of completion shall be provided in accordance with the requirements of Section 01605,
General Equipment Stipulations.
1.7 INSTRUCTIONS AND TRAINING ON OPERATION AND MAINTENANCE
A. Contractor shall provide instructions and training for the staff to be assigned in the
operation and maintenance of the equipment specified under this section. Training and
instructions shall be in accordance with the requirements set forth at the Conditions of
Contract.
PART 2 PRODUCTS
2.1 MANUFACTURERS

incorporated into the Work. include, but are not limited to, the ones mentioned on
the attached list of manufacturers Section 01295
2.2 CHANGE OVER SWITCH
A. Shall be electrically operated, mechanically held, fully protected, complete with voltage

sensing relay.
B. Shall be suitable for use in emergency or standby systems described in NFPA 70. Transfer
switch shall comply with IEC Standard. Test certificate and test reports are shall be
provided.
C. Transfer Switch shall have a continuous phase or main current rating equal to or exceed
the rating shown but, in no case, less than 125 percent of the full load rating of the
emergency power source, 380 Volts, 4P, 50 Hz and symmetrical interrupting capacity as
per final short circuit calculation approved by the engineer.
D. Override Time Delay: Time delay to override monitored source deviation shall be
adjustable from 0.5 to 6 seconds and factory set at 1 second. The device shall detect and
respond to a sustained voltage drop of 30 percent of nominal voltage between any two
of the normal supply conductors, and initiate transfer action to the emergency source
and start the engine-driven generator set after the set time period. The pickup voltage
shall be adjustable between 90 to 100 percent of nominal and factory set 90 percent. The
dropout voltage shall be adjustable from 65 to 70 percent of the pickup value, and factory
set at 70 percent of nominal voltage.
E. Transfer Time Delay: Time delay before transfer to the emergency power source shall be
adjustable from 0.2 to 120 seconds and factory set at 10 seconds. The device shall
monitor the frequency and voltage of the emergency power source and transfer when
frequency and voltage is stabilized at or above 90 percent of rated values. The pickup
voltage shall be adjustable from 85 to 100 percent of nominal, and factory set at 90
percent. The pickup frequency shall be adjustable from 90 to 100 percent of nominal and
factory set at 90 percent.
F. Return Time Delay: Time delay before return transfer to the normal power source shall
be adjustable from 2 to 30 minutes and factory set at 30 minutes. The time delay shall be
automatically defeated upon loss or sustained under voltage of the emergency power
source, provided that the normal supply has been restored.
G. Auxiliary Contacts: Two normally opened and two normally closed auxiliary switches shall
operate when the transfer switch is connected with the normal power source, and two
normally opened and two normally closed switches shall operate when the transfer
switch is connected with the emergency power source.
H. Control Panel: The transfer switch shall be equipped with a microprocessor based control
panel. This panel will perform the operational and display functions of the transfer switch.
The panel digital display shall be accessible without opening the door of enclosure.
I. Supplemental Features: The transfer switch shall also be furnished with the following:
1. Engine start contact

2. Pilot lights to indicate switch positions
3. Alternate source monitor
4. Test switch
5. Close differential protection
6. Three-position selector switch “STOP”, “TEST”, “Automatic”

J. Override Switch: The override switch shall by-pass automatic transfer controls so the
transfer switch will transfer and remain connected with the emergency power source,
regardless of the conditions of the normal power source. If the emergency source fails
and the normal source is available, the transfer switch shall automatically retransfer to
the normal source.
K. Green Indicating Lights: A green indicating light shall supervise the normal power source
and shall have a nameplate engraved NORMAL.
L. Red Indicating Lights: A red indicating light shall supervise the emergency power source
and shall have a nameplate engraved EMERGENCY.
2.3 ENCLOSURE
A. Transfer Switch and accessories shall be in a wall mounted, free-standing or floor-

mounted IP 42 smooth sheet metal enclosure constructed in accordance to IEC 60521
shall be not less than 2 mm. Doors shall have suitable hinges, locking handle latch, and
gasketed jambs
B. Wiring shall be color coded or the wires shall be permanently tagged near the terminal
at each end with the wire number shown on approved detail drawings.
C. Construction: Enclosure shall be constructed for convenient removal and replacement of

contacts, coils, springs and control devices from the front without the disconnection of
external power conductors or the removal or disassembly of major components.
Enclosure housing of the transfer switch shall be constructed to protect personnel from
energized components.
D. Finishing: Painting required for surfaces not otherwise specified and finish painting of
items only primed at the factory shall be as Manufacturer’s recommendations.
2.4 TESTING
A. Laboratory Testing: Testing shall be completed on the transfer switch to be supplied

under these specifications as per IEV 61439 design verification. The test sequence shall
include but not limited to the following:
1. Strength of material and parts.

2. Verification of degree of protection.
3. Clearances and creepage distances.
4. Assembling devices and equipment.
5. Effectiveness of the protective circuit.
6. Incorporation of connection devices and components.
7. Internal electrical circuits and connections.
8. Terminals for external conductors.
9. Dielectric properties.
10. Temperature rise Limits.
11. Short - circuit withstand strength.
12. Electromagnetic compatibility.

13. Verification of the mechanical operation.
14. Over voltage.
15. Under voltage.
16. Temperature rise.
17. Contact Opening.
B. Factory Testing: In addition to other factory tests, each completely assembled transfer
switch unit shall be subjected to dielectric and operational tests, and withstand tests.
C. Withstand Test requirements: .
D. Dielectric Tests: Tests shall be performed in accordance with NEMA ICS 1. Wiring of each
control panel shall be subjected to voltage surge tests as stipulated in IEEE C37.90.1.
Impulse withstand rating tests shall be performed in accordance with the requirements of
NEMA ICS 1.
E. Operational Tests: Tests shall be performed and shall demonstrate that the operational
sequence of each transfer switch unit conforms to the requirements of the specifications
with regard to operating transfer time, voltage, frequency, and timing intervals.
PART 3 EXECUTION
3.1 INSTALLATION
A. The transfer switch shall be installed as indicated and in accordance with approved
Manufacturer's instructions.
3.2 OPERATIONAL TESTING
A. Following completion of the installation of each of the transfer switch, the Contractor
shall perform operational tests in accordance with the written instructions of the
manufacturer after having made proper adjustments and settings to demonstrate that
each of the transfer switch functions satisfactorily and as specified. The Contractor shall
advise the Owner’s Representative not less than 5 work days prior to the scheduled date
or dates for operational testing, and shall provide certified field test reports to the
Owner’s Representative within 2 calendar weeks following successful completion of the
operational tests. The test reports shall describe all adjustments and settings made and
all operational tests performed.
B. INSTRUCTIONS AND TRAINING ON OPERATION AND MAINTENANCE
1. Contractor shall provide instructions and training for the staff to be assigned in the
and instructions shall be in accordance with the requirements set forth at the


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. LIGHTNING PROTECTION FOR
CAIRO - EGYPT STRUCTURES 264113 – 2874 0

CONTENTS
SECTION 264113
LIGHTNING PROTECTION FOR STRUCTURES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.5 Coordination 3
PART 2 - PRODUCTS 3
2.1 Lightning Protection System Components 3
2.2 Design Criteria 4
3.1 Installation 6
3.2 Corrosion Protection 7
3.4 Testing 8
3.5 Personnel Training 8
Lightning Protection for Structures Section 264113

SECTION 264113 - LIGHTNING PROTECTION FOR STRUCTURES
PART 1 GENERAL

Section.
B. Division 26 section “Grounding and Bonding for Electrical Systems”
1.2 SUMMARY
A. This Section includes lightning protection for buildings and building site components
.including but not limited to
1. Air Termination Network.

2. Down Conductors or Connections to reinforcing bars of structures.
3. Earth Termination Network.
4. Bonding.
5. Surge Protection Device (SPD).
6. Accessories.
B. The words "earth" and "earthing" as used herein are synonymous with the words
"ground" and "grounding" and may be used interchangeably within this specification.
1.3 SUBMITTALS
A. Product Data: During the time of the contract and as required by the Contract
program, submit to the Engineer three (3) copies of descriptive literature, technical
data, and maintenance recommendations (from the equipment Manufacturer),
catalogues etc for air terminals, fasteners, test links, connectors, wall inserts , bolts ,
earth point , rods and any accessories forming part of the lightning protection
system.
B. Shop Drawings: Submit detail lightning protection system, including air-terminal

locations, conductor routing and connections, and bonding and grounding provisions.
Include indications for use of raceway, data on how concealment requirements will
be met, and calculations required by British Standard (BS) for bonding of grounded
and isolated metal bodies.
C. Qualification data for firms and persons specified in "Quality Assurance" Article to
demonstrate their capabilities and experience. Include lists of completed projects
with project names and its locations, Engineer/Consultant and Owner. The firm
should have at least two years of success full installation experience.
D. Retain first paragraph below for air terminals mounted on single-ply membrane

roofing.
E. Certification, signed by Contractor, that roof adhesive for air terminals is approved
by manufacturers of both the terminal assembly and the single-ply membrane
roofing material.
F. Installation Instructions: Submit to the Engineer/Consultant complete manufacturers

installation instructions of all the products used.
G. Field inspection reports indicating compliance with specified requirements.
H. As-Built Drawings: Indicate nature of soil, special earthing arrangements, date and
particulars of additives to soil or in bore-holes if used, test conditions and results
obtained.
A. Installer Qualifications: Engage an experienced installer who has specialized in

installing lightning protection systems similar in material, design and extent to those
indicated for this project and whose work has resulted in installations with a record
of successful in service performance.
B. Standards:. Design, manufacture, testing and method of installation of all apparatus

and materials furnished under requirements of these specifications shall conform to
latest publications or standard rules of the following:
1. Local Codes.
2. Code of practice for protection of structures against lightning: BS EN 62305.
1.5 COORDINATION
A. Coordinate installation of lightning protection with installation of other building

systems and components, including electrical wiring, supporting structures and
building materials, metal bodies requiring bonding to lightning protection
components, and building finishes.
B. Coordinate installation of air terminals attached to roof systems with roofing work as
necessary to interface installation of lightning protection system with other works.
PART 2 - PRODUCTS
2.1 LIGHTNING PROTECTION SYSTEM COMPONENTS
A. Lightning Protection System Components: Provide Lightning Protection System

material and components of types, sizes, ratings for class of service indicated, which
comply with Manufacturer's Standard materials, design, and construction in
accordance with published product information, and as required for complete
installation and as indicated on the relevant layouts/drawings. Where type,

components or materials are not otherwise indicated, comply with requirements of
BS EN 62305.
B. Provide air terminals, bonding plates, conductors, connectors, conductor straps,

fasteners, earthing plates, earthing rods, rod clamps, splicers and other components
required for a complete system that meets the Standards specified in this Section.
C. Roof Main Conductors: Bare annealed copper strips of cross sectional area 25 mm x
3 mm. any location where the tape is in view of general public, PVC covered tape
(color to the approval of the Engineer) shall be used.
D. Ground Rod: Solid copper clad steel minimum 20 mm diameter x minimum 3.6 m
length (in 1200 mm sections).
1. Driving Head: High strength steel.

2. Couplings: Long length silicon bronze, internally threaded.
3. Threads: Rolled onto rod to ensure uniform layers of copper and strength.
E. Inspection (Earth) Pit: Precast concrete construction of appropriate dimensions, with

heavy duty cover and brass plate engraved 'Earth Pit Below' inset in cover.
F. Bonding Conductors: High conductivity, bare annealed copper tape, 20 x 3 mm

minimum dimensions, or 50 mm2 soft drawn stranded copper cables covered with
PVC of approved color.
G. Accessories: Supports, joints, fasteners, clamps, bonds, test links, etc., are to be
copper or copper alloy and specially manufactured for the purpose. Clamps and
connectors are to be specifically designed and sized for clamping and connecting to
the various shapes and surfaces of bonded metalwork. Provide bimetallic connectors
between different materials. Galvanized or plated steel nails, screws and bolts will
not be accepted on copper installations.
H. Flexible Bonding Straps: Flexible annealed copper braid, 20 x 3 mm, suitable for
bonding flat surfaces, cut to length required and with drilled flat terminals for bolted
connections. Provide special bimetallic alloy terminals for joining to aluminum
conductive parts.
I. Down Conductors: High conductivity, copper tape 25 x 3 mm or 70 mm2 soft drawn

stranded copper cable, bare or covered with PVC of approved color.
J. Test Links: Two-bolt split-coupling, copper alloy, made to join two ends of down
conductor specified. Plate indicating position and number of electrodes is to be fitted
above each test link.
K. Surge Protection Device (SPD): containing at least one non-linear component

intended to limit transient over voltages and divert surge currents.
2.2 DESIGN CRITERIA
A. Provide horizontal conductors around periphery (or parapet), and along inner edges
of roofs that are higher than adjacent parts, unless they fall in zone of protection of a

higher conductor. Install horizontal conductors in a mesh of proper size for the
protection level required. Join all elements of lightning protective system together.
Additionally, provide air termination horizontal loops around building façade for
structures above 60m and 120m as per the standard requirement; bonded to steel
reinforcement and exposed metal parts as specified and required by the standard.
B. Space the down conductors at 10m or 15m or 20m according to relevant class of
lightning protection system. Every down conductor is to:
1. Have test link above earth for testing earth termination network.
2. Be protected against corrosion.
3. Terminate in an earth electrode (horizontal or vertical as per design require-
ments).
4. Be insulated and installed in PVC conduit from test link to electrode connec-
tion point (to reduce potential gradient at earth level which otherwise would
be lethal to humans or animals).
C. Air termination network may be connected to earth via steel reinforcement of

concrete structure, at the positions required and in conformity with specified
Standards for down conductors. Ensure good contact between reinforcing bars
during construction, by fixing the bars with tying wire, for both vertical to vertical
bars, and horizontal to vertical bars.
D. Provide additional earth pits as necessary to achieve a maximum resistance to earth

of 10 Ohm.
E. Provide reference earth electrode for testing purposes. It is to be possible to

completely isolate this electrode from the earth termination network for testing
footing/earth ring resistance at various positions. This electrode is to be provided in a
earth pit with special marking.
F. Provide bonding between the earth termination network of the lightning protection
system and earth networks of all other services to ensure a common earthing
system. The resistance to ground should, in this case be the lowest value needed for
any of the individual services. Combined resistance to ground of whole network is
not to exceed 10 Ohm.
G. Interconnect and bury ground electrode conductors at least 0.6 m below ground
surface and minimum 1.0 m from building foundations.
H. Joints and interconnections in earth termination network are to be exothermic welds

except that down conductor is to be connected by a single or multi-conductor bolted
U- connector clamp at earth pits.
I. Bond all metalwork in or on outside of structure to the lightning protection system at

points above the test joint (test link) to avoid side flashing. Metalwork includes but is
not necessarily limited to: water pipes, tanks, sign structures, communication
supports, metal sheaths and exposed parts of electrical installations, vents, exterior
metal staircases, metal window frames, vent pipes, steel doors or door frames, main
earthing terminal or bar of electrical installation and reinforcing bars of concrete
structures if these are in continuous electrical contact.

J. Bond metal leaving or entering a structure (having system continuity such as water
K. piping, etc.), as follows:
1. As directly as possible to the earth termination.

2. Near point at which service entering or leaving the structure.
3. At nearest earth point or at nearest main earthing terminal or bar of protec-
tive earthing system.
If direct bonding is not acceptable by authorities and/or parties concerned, SPDs

shall be used.
L. Surge Protection Devices where specified or required are to be as follows:
1. SPD’s test requirements to be compliant with
a. IEC 61643-1 for power systems,

b. IEC 61643-21 for telecommunication and signaling systems.
2. Selection and installation of a coordinated SPD protection to comply with
a. IEC 61643-12 and IEC 60364-5-53 for protection of power systems,

b. IEC 61643-22 for protection of telecommunications and signaling sys-
tems.
3. Unless otherwise indicated, following are typical applications for using various
types of SPDs
a. SPD type I: Main distribution boards.

b. SPD type II: Sub distribution boards.
c. SPD type III: Terminal equipment.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install conductors with direct paths from air terminals to ground connections. Avoid
sharp bends and narrow loops.
B. Conceal the following conductors:
1. Retain some or all of five subparagraphs below depending on degree of con-

cealment desired for lightning protection components. If deleting all five,
there will be no restrictions on exposed conductors.
2. System conductors.
3. Down conductors.
4. Interior conductors.
5. Conductors within normal view from exterior locations at grade within 60 m of
building.
6. Notify Architect at least 48 hours in advance of inspection before concealing

lightning protection components.
C. Exothermic-welded connections are considered more permanent than crimped or

bolted connections. If exothermic-welded connections are desired, retain paragraph
below. Edit if single-ply membrane roofing is not used or if exothermic connections
are only required in underground portions of system.
D. Cable Connections: Use approved exothermic-welded connections for all conductor

splices and connections between conductors and other components.
E. Retain paragraph below for single-ply membrane roofing.
F. Delete two paragraphs and associated subparagraphs below if NFPA 780 compliance
is specified; retain if specifying bonding requirements that exceed minimum UL 96A
requirements. See Editing Instruction No. 3 in the Evaluations. Coordinate with
Drawings for counterpoise requirements, if any.
G. Bond lightning protection components with intermediate-level interconnection loop

conductors to earthed metal bodies of building at 20m intervals.
H. Down conductors are to follow most direct path between air terminals and earth pit,
avoiding sharp bends and narrow loops. Where necessary, the formation of loops in
down conductors shall not violate the code restrictions in terms of the gap formed
across the loop.
I. Mechanical Protection of Down Conductors: Provide PVC conduit, starting 0.3 m

below earth and to a height of 1.9 m above earth. Test link is to be positioned 2 m
above earth.
J. Clean and treat contact surfaces with non-corrosive compound. Protect joints
between dissimilar metals from moisture by inert, tenacious material, and with
overlapping joints not less than 30 mm long. Provide as few joints and bonds as
possible and make mechanically and electrically effective by clamping, bolting or
exothermic welding. Cross-sectional areas of joints and bonds are not to be less than
that of main conductor.
K. Bond exposed metal parts of structure to lightning protective system if clearance

between any element of lightning system and metal part is less than 1800 mm or the
distance allowed by the specified Standard, whichever is smaller.
L. Extend 150 mm below top of earth rod inside the inspection/earth pits. Cover earth
rod connector with suitable protective compound, which can be easily removed for
inspection. Connector is not to be covered with backfill material and is to remain
clean.
3.2 CORROSION PROTECTION
A. Do not combine materials that can form an electrolytic couple that will accelerate
corrosion in the presence of moisture unless moisture is permanently excluded from
junction of such materials.

B. Use conductors with protective coatings where conditions would cause deterioration
or corrosion of conductors.
A. Provide inspections as required to obtain a proper operation for the lightning

protection system.
3.4 TESTING
A. Upon completion of installation of lightning protection system, test resistance-to-

ground (earthing connection) with resistance tester. Where tests indicate resistance-
to-ground is over 10 ohms, take appropriate action to reduce resistance to 10 ohms
or less, by driving additional, properly spaced, ground rods, and treating soil in
proximity to ground rods with common salt, Copper Sulphate or Magnesium
Sulphate. Then retest to demonstrate compliance without any additional cost to the
Employer.
B. Perform resistance-to-ground tests of lightning protection system periodically, at six

month intervals or less, following time of substantial completion during maintenance
period and submit written report indicating results. Where resistance is greater than
10 ohms, chemically treat soil to reduce resistance to 10 ohms or less, then retest to
demonstrate compliance without any additional cost to the Employer.
3.5 PERSONNEL TRAINING
A. Train Client's building maintenance personnel in procedures for testing and

determining resistance-to-ground values of Lightning Protection System. Instruct
maintenance personnel in preparation and application of chemical solution for each
surrounding grounding rods for reducing ohmic resistance to required levels.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. LIGHTING
CAIRO - EGYPT 265100 - 2874 0

CONTENTS
SECTION 265100
LIGHTING
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 General 5
2.3 Lighting Fittings, General 6
2.4 Led (Light Emitting Diode) Lighting Fixtures 7
2.5 Lamps 8
2.6 Drivers 9
2.7 Emergency Lighting Power Unit 9
2.8 Exit Signs 11
2.9 Lamps 11
2.10 Landscape Lighting 11
PART 3 EXECUTION 11
3.1 General 11
3.2 Inspection 11
3.3 Installation 12
3.4 Installation Supervision 13
Lighting Section 265100

SECTION 265100 - LIGHTING
PART 1 GENERAL
A Drawings and general provisions of Contract including General Conditions,

work of this Section.
1.2 SUMMARY
A This section covers partially the work of indoor lighting and ancillary fittings and the
work of outdoors lighting as required by the Contract and includes the following
items:
1. Lighting Fittings (Luminaires)

2. DRIVERS
3. Lamps
B Indoor lighting and ancillary fittings of service areas in all project locations are
covered under this section.
C Extent of lighting work and ancillary fittings covered by this section are indicated on
Drawings.
D Related Sections
E The following sections include requirements, which relate to work of this section:
1. Division 26 Section “Grounding and Bonding“

2. Division 26 Section “Conductor and Cables“
3. Division 26 Section “Raceways, Boxes and Cabinets“
4. Division 26 Section “Wiring Devices“
1.3 SUBMITTALS
A Submit the following in accordance with Conditions of the Contract, Division-1

Specification Sections, Submit 3 Complete Sets of:
1. Original catalogs showing all luminaires technical specifications and

components.
2. Material lists reading: name of product, its trade and origin of Manufacturing
and equipment data for LED module, Driver, housing, wire and diffuser as
follows:
a. LED module Data: Trade, model, origin, type, wattage, lumen, color
rendering, color temperature, lifetime and efficacy.
b. Driver Data: Trade, model, origin, type, P.F, ignition time, approval

mark and number of lamps per ballast
c. Luminaire Data: Body, diffuser, number of drivers, wire type and
temperature rating
3. Fittings shop drawings including wiring details of luminaire, Drivers, etc.
B Detail layout shop drawings are coordinated with all other trades (architectural,
HVAC, fire alarm, firefighting, etc.) These drawings shall identify, but not limited to,
the following:
1. Wiring connections between lighting fixtures, switches, home runs up to the

panel board.
2. The circuit reference, wiring size, conduit size and run, junction boxes.
3. The supply source type (normal, emergency).
4. The switching device tag number.
5. Mounting details.
C Product Certificates.
1. Test report for LED of the luminaire according to IES LM-80, measuring the
lumen depreciation of solid-state lighting sources, such as LED packages,
modules and arrays.
2. Test report for luminaire according to IES LM-79, Electrical and Photometric
tests.
3. Test Report for luminaire according to LM82, Characterization of LED Light
Engines and LED Lamps for Electrical and Photometric Properties as a Function
of Temperature
4. Thermal management test report, in situ temperature measurement testing
(ISTMT) according to TM-21-11.
D Samples of the specified products
1. Submit sample for each type of lighting fixture specified in the lighting fixtures
schedule for approval.
2. Spare parts data
3. Detailed painting procedure to meet requirements
E Calculations as per proposed Vendor’s software to verify the design, layout, furniture
and code lux values.
1. Lighting calculation sheets (by computer run) of the selected Manufacturer

showing that its luminaire quality, technology and characteristics shall provide
the requested illumination levels, minimum shadows and glare which are
expected by the design and drawings.
2. Technical photometric data collection:
a. Plots of: isocandela, zonal flux, isolux and isoluminance

b. Tables of: intensity distribution, electrical measurements

A Reference Standards: The work to be performed under this section shall be in strict
compliance with the applicable regulations and standards.
B Manufacturers: Firms regularly engaged in the manufacture of lighting fixtures,

Drivers, and lamps, whose products have been in satisfactory use in similar service
for not less than 5 years.
C Standards Compliance: Comply with the following standards:
1. IES LM-80-08: Approved Method for Measuring Lumen Maintenance of LED

Light Sources.
2. IES LM-79-08: Approved Method: Electrical and Photometric Measurements
of Solid- State Lighting Products.
3. IES LM-82-12: Approved Method for Characterization of LED Light Engines and
LED Lamps for Electrical and Photometric Properties as a Function of
Temperature.
4. IES TM-21-11: Projecting Long Term Lumen Maintenance of LED Light Sources.
5. IEC 62717: LED Modules for general lighting – Performance requirements.
6. IEC 62504: General lighting - Light emitting diode (LED) products and related
equipment - Terms and definitions.
7. IEC 62031: LED modules for general lighting - Safety specifications.
8. IEC 61000: Electromagnetic compatibility (EMC).
9. IEEE C62.41.2: Recommended Practice on Characterization of Surges in Low-
Voltage AC Power Circuits.
D In case of conflict among the referenced standards and codes, the more stringent
provision will govern.
E In case of conflict among the specifications, drawings and BOQ, the more stringent
provision will govern.
A Materials and products shall be securely packed for delivery, with waterproofed type
providing protection against excessive heat, humidity and water damages.
B Great care shall be taken in storing luminaires on Site to prevent unnecessary

damage by stacking too many luminaires, causing disfiguration of the canopies. The
Contractor shall be responsible for any damage to the luminaires and shall replace
any damaged luminaires free of charge.
PART 2 PRODUCTS
2.1 MANUFACTURERS


2.2 GENERAL
A Provide all new lighting fittings, wall brackets, lamps, poles, auxiliary lighting units
and other fixtures and materials, including proper space, and complete the interior
lighting installations as shown on Drawings, specified and required.
B Equipment shall have the Manufacturer's corrosion resistant finish. Lighting

equipment shall be completely fabricated, assembled, wired, checked and tested at
the factory.
C Luminaires have been selected to provide the illumination levels in accordance with
Lighting Handbook, IES. If the space envelope and/or furniture layout of any facility
is changed from Drawings, the Contractor shall adjust the lighting layout for that
space to maintain these standards.
D All luminaries shall be manufactured to IEC 60598-1 and 60598-2.
E All luminaries supplied by the Contractor shall be photometrical tested.
F The Contractors shall produce upon request, the photometric data for any luminaire
specified or supplied.
G All luminaries shall be provided with a lamp compatible with the control gear used.
H Luminaries shall not be suspended by their flexible cord. A separate means of

suspension shall be provided.
I All flexible cords shall be anchored at both ends such that the cord is free from
strain.
J Any plastics used in the luminaire shall be light and UV stable and shall be suitable
for their application.
K All sheet steel components shall be suitably pre-treated and electrostatically spray-
painted using acrylic polyester or epoxy powders.
L Non-compatible materials shall not be used in contact with each other.
M Louvers shall be restrained to prevent them from failing out of the body of the
luminaire under normal conditions and when relamping. Metal louvers shall be
earthed to the body of the luminaire or the earth terminal.
N Diffusers shall be restrained to prevent them from falling out of the body of the
luminaries under normal conditions and when relamping.
O Luminaries fitted with high frequency or electronic control gear shall be

disconnected before the circuit is tested for insulation resistance.
P All lights have on their packaging a description of what they are and a position
number which matches that in the project manual.

Q Exact specifications for heat technology and thickness, can be obtained personally
from the applicant.
R If the supplier or contractor should have doubts about the quality of any materials,
construction, equipment or installations from other companies particularly with
regard to accident, prevention, and if these things will affect what is defined in the
project manual, he shall immediately report this in writing.
S In the above case, if such a written notification is submitted, the contractor‘s

guarantee and responsibility for the completion of the installation still applies.
T When submitting the tender, the bidder shall provide the following technical
specifications
U For the prototypes and the series lights in the form of a report:
1. LOR of the luminaire ηLB in %

2. Light distribution curve in the following levels: C0-C180, C45-C225 and C90-
C270
3. Examination certificate and confirmation that they meet the required design
& protection standards set out.
V The lights shall be examined before delivered to ensure they are capable of the
required performance;
W After the award of the contract this shall be verified by laboratory testing. The client
reserves the right to have these tests carried out by an institution of his own
choosing
X For all areas, luminance calculations and luminance distribution graphs conforming
to the applicable statutory requirements shall be presented and must be approved
(horizontal and vertical).
2.3 LIGHTING FITTINGS, GENERAL
A lighting equipment shall be surface, recessed and pendant types as indicated in

schedules and individual lighting fittings specifications. Lighting fittings shall be
complete including all the required components, ballasts, lamps, wiring, hardware,
fasteners suspensions and supports.
B Wiring: Connection to the Main Circuit Wiring Shall Be 3-Wire of A Minimum Core
Size of 3 Mm2, Earthing Shall Be Connected. The Wiring from Ceiling Rose Shall Be
Heat Resisting.
C The Contractor shall not order any lighting fitting until final approval of the type,
color and surface finish has been given by the Engineer.
D Lamps and Lamp-holders: Lamps shall be provided for each lighting fitting. Service
bases wattage and mounting shall be compatible with the fitting specified. Lamps
operating voltage shall be single phase, 220 V, 50 Hz.

2.4 LED (LIGHT EMITTING DIODE) LIGHTING FIXTURES
A Provide LED lighting fixtures shall be in accordance with the Fixture Schedule.
B LED lighting fixtures and drivers shall be from the same manufacture and shall be
tested and certified as whole Luminaire.
C A minimum life time 50,000 hrs at L70. At ambient temperature of 40 °C in

accordance to IES TM-21-11 for indoor LED lighting luminaires.
D A minimum life time 50,000 hrs at L70. At ambient temperature of 50 °C in

accordance to IES TM-21-11 for Outdoor LED lighting luminaires.
E Lighting fixtures used in MRI areas shall be non-ferrous materials
F Ingress protection for indoor, and outdoor luminaires shall be as indicated on the
drawings.
G The LED luminaire shall be designed and suitably rated to ensure correct operation
and continuous trouble free service under the prevailing climatic conditions. The
luminaire shall be designed to withstand the effects of direct sun exposure during
the day and dusty weather conditions including the occasional sand storm. The
luminaire manufacturer shall guarantee the performance and life time claims of;
lumen maintenance and luminaire life of the luminaire under the stated climatic
conditions.
H The luminaire control gear (driver) shall be produced by a prominent manufacturer

of semiconductor components and comply with IEC 62384 DC or AC supplied
electronic control gear for LED modules - Performance requirements, IEC 61347-1
General and safety requirements and IEC 61347-2-13 : LED Particular requirements
for DC or AC supplied electronic control gears for LED modules. The manufacturer
shall confirm that the packaged driver assembly is fabricated from high quality
integrated circuit components including long-life electrolytic capacitors and provide
data relating to the reliability of the device, in the climatic conditions stated in this
specification.
I LED fixtures shall be modular backlight and allow for separate replacement of LED
lamps and drivers. User serviceable LED lamps and drivers shall be replaceable from
the room side.
J The classification of the risk group shall meet the requirements of IEC 62471 and The
LED binning shall be as defined by ANSI in the C78.377 standard - MacAdam color
ellipse.
K Housing:
1. Maximum temperature values of the LED must be fulfilled by an adequate

dimensioning of a thermal design (either by a sufficient cooling surface,
suitable materials, proper connection to the housing and no active cooling).
2. The housings must be designed so that the required protection levels are met
according to product and field of application, in order to comply with the
operating conditions of the LED according to the data sheet.

L Lenses:
1. Reflectors and lenses must be designed so that they do not affect neither the
electrical (e.g. risk of short circuits in misplaced metal reflectors) nor the
mechanical stability of the LED (eg. by damaging the LED components).
2. Optical components, each according to the product and the field of
implementation, must be protected against damage by radiation (clouding of
the lens), mechanical stress, etc.
3. Solder Connections must be produced according to the data sheet and shall
not affect the function of the LED.
M Binning:
1. In the manufacturing process the LEDs and their component features are
subject to a relatively large dispersion in different areas. The selection of the
LEDs according to different finely scaled classes is called "binning".
2. A detailed list of the binnings and the associated data and diagrams of a LED
must be provided by the manufacturer in order to understand the
photometric and electro technical measurement values.
N Luminaires must be tested to IES LM-79, IES LM-80 and IES LM-82 standards, with
the results provided as required in the Submittals paragraph of this specification.
2.5 LAMPS
A All Lamps shall be of wattage and types as shown on the Drawings.
B LED lamps shall have a color temperature as indicating in the lighting schedule for
indoor installation and outdoor installation or as indicated in the drawings, a CRI of
80 minimum, and a lumen maintenance L70 rating of 50,000 hours minimum.
C LED lamps shall comply with NEMA SSL 4 “SSL Retrofit Lamps: Suggested Minimum
Performance Requirements”.
D Adequate spacing shall be left between wall and bracket-mounted lighting bulbs.
E The fixed wiring to a fitting shall terminate adjacent to the fitting in a conduit box.
Final connection to the fitting being carried out silicon rubber insulated pull through
flexible conduit.
F Final connections between fixed wiring systems and lighting fittings shall in all cases
be carried out in heat resisting flexible cables. Under no circumstances shall cables
insulated with general purpose PVC be used for final connections to any lighting
fittings.
G The flexible cables used for final connections shall be type selected for temperature
duty and current/mass supported in accordance with IEC Regulations, except that no
cable shall be less than 2.5 mm2 cross section.

2.6 DRIVERS
A LED drivers shall be electronic-type, labeled as compliant with radio frequency

interference (RFI) requirements of FCC Title 47 Part 15.
B Drivers shall comply with IEC 61347-2-13 and CE marking
C LED driver shall be Class2 comply with UL1310 Standard for Safety which requires
the output voltage to pose no risk of fire or electric shock which makes secondary
circuit protection unnecessary.
D Drivers shall be UL8750 class 1 or 2 listed for their intended purpose.
E Drivers shall have a total individual Luminaire Harmonic Distortion (THD) of ≤20% in
accordance with ANSI C82.77
F Drivers shall have a Power Factor (PF) ≥0.95.
G Drivers shall be rated for the ambient temperature from -20°C to +50°C
H Efficiency of Drivers shall be ≥85
I Electromagnetic Compliance of drivers shall comply with FCC Title 47 Part 15 Class A
J The Lifetime of drivers shall be up to 50,000 hours in ambient temperature of up to

+50 °C
K Drivers shall be Certified and marked with CE / ENEC
L Guarantee of drivers, 5 five years.
M Drivers shall be Suitable for emergency lighting system with central battery
according to IEC 61347-2-13.
N Drivers shall comply with the requirements of IEC 61000-4-5 for surge immunity, 4 kv
for outdoor lighting.
O Individually fused drivers shall have their fuses accessible from outside of the fixture
chassis.
P Luminaires shall be equipped with an LED driver(s) that accepts the voltage as
indicated on the "Luminaire (Lighting Fixture) Schedule". Individual driver(s) shall be
replaceable.
2.7 EMERGENCY LIGHTING POWER UNIT
A Internal Type: Self-contained, modular, battery-inverter unit, factory mounted

within lighting fixture body and compatible with ballast with battery kit 3 hours
unless otherwise indicated in the drawings.
1. Emergency Connection: lamp shall operate continuously with the required

lumen output of each. Connect unswitched circuit to battery-inverter unit and

switched circuit to fixture.
2. Selector switch and Indicator Light: Visible and accessible without opening
fixture or entering ceiling space.
a. Selector switch in unit housing, simulates loss of normal power and

demonstrates unit operability.
b. Indicator Light
3. Battery: Sealed, maintenance-free, lead sealed acid type.

4. Charger: Fully automatic, solid-state, constant-current type with sealed power
transfer relay.
2.8 EXIT SIGNS
A Exit signs shall be manufactured to meet the appropriate requirements of IEC or

DIN/VDE standards.
B Viewing Distance to be according to BS 5266
C All “Exit” signs and fire safety signs shall be of the pictogram type utilizing the
pictograms as give in IEC or DIN/VDE Standards. Where wording is incorporated on
the signs it shall be in accordance with IEC or DIN/VDE Standards.
D Sizes of lettering shall comply with IEC or DIN/VDE Standards.
E Exit Signs shall be connected to BMS as indicated in the drawings and BMS Schedules
F Exit sign shall be interface with BMS where the following critical status and alarms
for each exist signs shall be sent to BMS for remote monitoring via volt-free contacts
or serial interface over standard protocol communication as approved
1. On/Off status
2. Auto/Manual and trip status.
3. On/off control
4. Battery status
G Description: Internally Lighted Signs:
1. Self-Powered Exit Signs (Battery Type): Integral automatic charger in a self-

contained power pack with battery kit 3 hours unless otherwise indicated in
the drawings.
a. Battery: Sealed, maintenance-free, lead sealed acid type.

b. Charger: Fully automatic, solid-state type with sealed transfer relay.
c. Operation: Relay automatically energizes lamp from battery when
circuit voltage drops to 80 percent of nominal voltage or below. When
normal voltage is restored, relay disconnects lamps from battery, and
battery is automatically recharged and floated on charger.
d. Test Push Button:
e. Indicator Light:

2.9 LAMPS
A General: Lamps Shall Be Of Wattage And Types As Shown On The Drawings.
B Lamps: LEDs, 70,000 hours minimum rated lamp life at 50°C ambient
C Lamps shall be furnished and installed in all lighting fixtures supplied.
D The housing shall be designed to maintain an internal ambient temperature below

that of the lowest temperature rating of any piece of equipment installed therein
E Manufacturer shall provide data to demonstrate the hour lumen depreciation factor
at the minimum 50°C temperature. The method of calculation of lumen depreciation
for more than 70,000 hrs. shall be reviewed by the Engineer and declared consistent
with their data by the LED chip manufacturer.
2.10 LANDSCAPE LIGHTING
A Landscape lighting shall be in compliance to IEC-60598-1 used for walkways,

roadways, illumination of trees and decorative effects.
B Landscape lighting ingress of protection shall be IP65
C The Contractor shall install supplies to positions of luminaires shown on the

landscape lighting drawing. Wherever possible outlets shall terminate in a
waterproof type socket for final connection by plug and flexible cable.
D Each luminaire type shall be independently switched, luminaires shall be supplied

form distribution boards as shown on the drawings or directed by the consultant.
E Garden Lighting fixture shall be with electrostatic painting with body of the
Aluminum – die cast, ingress protection IP65
F All fixtures installed in the Landscape Lighting System shall be suitable for outdoor
installation.
G Type of lamps used in landscape lighting shall be as indicated on the drawings
PART 3 EXECUTION
3.1 GENERAL
A Provide all equipment installations and wiring installations including connections as

indicated, specified and required. Assure proper fits for all equipment and materials
within the spaces shown on Drawings.
3.2 INSPECTION
A Inspect each assembly and related accessories for damage, defects and

completeness prior to installation.
B At early stage of the construction, inspect a sample area to verify that the Lux level is
as per approved calculation
3.3 INSTALLATION
A Where a conduit wiring system is specified for the wiring to totally enclose lighting
fittings such as bulkhead fittings etc., and the wiring passes through the fittings or
the fittings are mounted directly to a conduit box housing, the circuit wiring shall be
carried out in silicone rubber insulated cable enclosed in a separate conduit.
B Under no circumstances shall totally enclosed lighting fittings be mounted on

conduit boxes housing PVC wiring.
C Adequate spacing shall be left between wall and bracket-mounted lighting bulbs.
D The fixed wiring to a fitting shall terminate adjacent to the fitting in a conduit box.
Final connection to the fitting being carried out silicon rubber insulated pull through
flexible conduit.
E Final connections between fixed wiring systems and lighting fittings shall in all cases
be carried out in heat resisting flexible cables.
F Under no circumstances shall cables insulated with general purpose PVC be used for
final connections to any lighting fittings.
G The flexible cables used for final connections shall be type selected for temperature
duty and current/mass supported in accordance with IEC Regulations, except that no
cable shall be less than 2.5 mm2 cross section.
H Multi-core sheathed flexible cables pulled through on a conduit or trunking shall be

secured to the respective termination by means of a cable gland, screwed into the
conduit spout.
I Mounting and electrical connection:
J The luminaire has to be mounted at the wall with a gap of 5mm below the bottom
edge of the wall.
K For maintenance it must be able to change the LED modules in the luminaire as easy
as possible without any additional maintenance tools. Therefore it is designed that
the LED modules can be taken off for easy maintenance.
L The luminaire housing is mounted at the wall with three distance cylinder. These
mounting cylinders are very important because the walls are not always straight.
Therefore it is necessary to have a gap Between the wall and luminaire. The final
length of the distance cylinder in the construction drawing of the manufacturer has
to be approved by the architect and lighting consultant.
M The distance from the LED-module to the light output holes (Φ10mm) in the

luminaire cover has to be exact 10mm.
N Final details and developments have to be done by the luminaire manufacturer and
to be approved by the client and the lighting specialist.
O Any design / construction drawings have to be coordinated and agreed with the
lighting specialist, engineer and client.
P Mounting and the electrical connection must be independently coordinated with the
responsible trades (electrical, ceiling, static etc) and lighting specialist, engineer and
client.
Q The operating devices for normal and emergency operation are located in the
luminaire housing. For each luminaire it is necessary to have operating devices for
normal and emergency operation as described under point 1.3.
R All required connection cables between the LED module and operating devices have
to be delivered with the luminaire and connected via appropriate plugs and have to
be pre wired and connected ready for installation.
S The luminaire manufacturer has to coordinate the control cable type from the
operating devices to the nearest electrical room with the lighting control system
supplier.
3.4 INSTALLATION SUPERVISION
A Provide the services of a trained and experienced supervision to perform the

following duties:
1. Supervise the installation

2. Inspect and correct all installations
3. Prepare and submit the final test report for all lighting systems


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. EXTERIOR LIGHTING
CAIRO - EGYPT 265600 – 2874 0

CONTENTS
SECTION 265600
EXTERIOR LIGHTING
Page
PART 1 - GENERAL 2
1.2 Summary 2
1.3 Definitions 2
1.4 Structural Analysis Criteria For Pole Selection 2
1.5 Submittals 3
1.6 Informational Submittals 3
1.9 Warranty 5
PART 2 - PRODUCTS 5
2.1 Manufacturers 5
2.2 General 5
2.3 Street Lighting Luminaire 6
2.4 Optional Photoelectric Relay 8
2.5 Required Data In Catalog 8
2.6 Luminaire Support Components 8
2.7 Lighting Poles 9
2.8 Decorative Poles 9
3.1 General 9
3.2 Inspection 10
3.3 Pole Installation 10
3.4 Grounding 11
Exterior Lighting Section 265600

SECTION 265600 - EXTERIOR LIGHTING
PART 1 - GENERAL

Section.
1.2 SUMMARY
A. This Section includes the following:
1. Adjust list below to suit Project.

2. Exterior luminaires with lamps and ballasts.
3. Luminaire-mounted photoelectric relays.
4. Poles and accessories.
5. Luminaire lowering devices.
1. Division 26 Section "Interior Lighting" for exterior luminaires normally mount-

ed on exterior surfaces of buildings.
1.3 DEFINITIONS
A. CRI: Color-rendering index.
B. HID: High-intensity discharge.
C. Luminaire: Complete lighting fixture, including ballast housing if provided.
D. Pole: Luminaire support structure, including tower used for large area illumination.
E. Standard: Same definition as "Pole" above.
1.4 STRUCTURAL ANALYSIS CRITERIA FOR POLE SELECTION
A. Dead Load: Weight of luminaire and its horizontal and vertical supports, lowering
devices, and supporting structure, applied as stated in AASHTO LTS-4.
B. Wind Load: Pressure of wind on pole and luminaire, calculated and applied as per
IEC 2006 Edition -Exposure C, basic wind speed go mph

1.5 SUBMITTALS
A. Product Data: For each luminaire, pole, and support component, arranged in order
of lighting unit designation. Include data on features, accessories, finishes, and the
following:
1. Physical description of luminaire, including materials, dimensions, effective

projected area, and verification of indicated parameters.
2. Details of attaching luminaires and accessories.
3. Details of installation and construction.
4. Luminaire materials.
5. Photometric data based on laboratory tests of each luminaire type, complete
with indicated lamps, ballasts, and accessories.
a. Photometric data shall be certified by manufacturer's laboratory with a

current accreditation under the National Voluntary Laboratory Accredi-
tation Program for Energy Efficient Lighting Products.
6. Photoelectric relays.
7. Ballasts, including energy-efficiency data.
8. Lamps, including life, output, and energy-efficiency data.
9. Materials, dimensions, and finishes of poles.
10. Means of attaching luminaires to supports, and indication that attachment is
suitable for components involved.
11. Anchor bolts for poles.
12. Manufactured pole foundations.
B. Point-wise compliance statement to the specifications, duly signed by the

manufacturer/ manu-facture’s authorized representative and the contractor.
C. Shop Drawings: Include plans, elevations, sections, details, and attachments to other
work.
1. Detail equipment assemblies and indicate dimensions, weights, loads, required

clearances, method of field assembly, components, and location and size of
each field connection.
2. Anchor-bolt templates keyed to specific poles and certified by manufacturer.
3. Design calculations, certified by a qualified professional engineer, indicating
strength of screw foundations and soil conditions on which they are based.
4. Wiring Diagrams: For power, signal, and control wiring.
D. Samples: For products designated for sample submission in the Exterior Lighting
Device Schedule. Each Sample shall include lamps and ballasts.
1.6 INFORMATIONAL SUBMITTALS
A. Pole and Support Component Certificates: Signed by manufacturers of poles,

certifying that products are designed for load requirements in AASHTO LTS-4-M and
that load imposed by luminaire and attachments has been included in design. The
certification shall be based on design calculations by a professional engineer.

B. Qualification Data: For qualified agencies providing photometric data for lighting
fixtures.
C. Field quality-control reports.
D. Warranty: Sample of special warranty.
A. Luminaire Photometric Data Testing Laboratory Qualifications: Provided by

manufacturers' laboratories that are accredited under the National Volunteer
Laboratory Accreditation Program for Energy Efficient Lighting Products.
B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in

NFPA 70, Article 100, by a testing agency acceptable to authorities having
jurisdiction, and marked for intended use.
C. Standards Compliance: Comply with the following standards:
1. IES LM-80-08: Approved Method for Measuring Lumen Maintenance of LED

Light Sources.
2. IES LM-79-08: Approved Method: Electrical and Photometric Measurements of
Solid- State Lighting Products.
3. IES LM-82-12: Approved Method for Characterization of LED Light Engines and
LED Lamps for Electrical and Photometric Properties as a Function of
Temperature.
4. IES TM-21-11: Projecting Long Term Lumen Maintenance of LED Light Sources.
5. IEC 62717: LED Modules for general lighting – Performance requirements.
6. IEC 62504: General lighting - Light emitting diode (LED) products and related
equipment - Terms and definitions.
7. IEC 62031: LED modules for general lighting - Safety specifications.
8. IEC 61000: Electromagnetic compatibility (EMC).
9. IEEE C2, "National Electrical Safety Code."
10. IEEE C62.41.2: Recommended Practice on Characterization of Surges in Low-
Voltage AC Power Circuits
11. NFPA 70.
A. Store poles on decay-resistant-treated skids at least 12 inches (300 mm) above grade
and vegetation. Support poles to prevent distortion and arrange to provide free air
circulation.
B. Handle wood poles so they will not be damaged. Do not use pointed tools that can
indent pole surface more than 1/4 inch (6 mm) deep. Do not apply tools to section of
pole to be installed below ground line.

1.9 WARRANTY
A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to

repair or replace products that fail in materials or workmanship; that corrode; or that
fade, stain, perforate, erode, or chalk due to effects of weather or solar radiation
within specified warranty period. Manufacturer may exclude lightning damage, hail
damage, vandalism, abuse, or unauthorized repairs or alterations from special
warranty coverage.
1. Warranty Period for Luminaries: Five years from date of Substantial Comple-
tion.
2. Warranty Period for Metal Corrosion: Five years from date of Substantial
Completion.
3. Warranty Period for Color Retention: Five years from date of Substantial Com-
pletion.
4. Warranty Period for Poles: Repair or replace lighting poles and standards that
fail in finish, materials, and workmanship within manufacturer's standard war-
ranty period, but not less than three years from date of Substantial Comple-
tion.
PART 2 - PRODUCTS
2.1 MANUFACTURERS

2.2 GENERAL
A. Comply with UL 1572, UL 1598 and listed for installation in wet locations. Comply
with IESNA RP-8 for parameters of lateral lighting distribution patterns and shall
meet ambient conditions of 50ºC, 90% humidity.
B. Metal Parts/Components: Corrosion resistant Aluminum body, free of burrs and

sharp edges.
C. Stainless steel hinges and exposed hardware.
D. Housing: Rigidly formed, weather and light-tight enclosure with integral control
gear.
E. Doors, Frames and Accessibility: Easily accessible and usable, self blocking, smooth,
free of light leakage, permits relamping without use of tools and without risk of
accidental falling of parts. Removable doors for cleaning or replacing lens. Designed
to disconnect ballast when door opens. Easy access to lamp, gear tray, tilt
adjustment and lamp adjustment.
F. Plastic Parts: High resistance to yellowing and other changes due to aging, exposure

to heat and UV radiation.
G. Luminaire Parts Reflectance:
H. 85% for white surfaces (minimum)
I. 83% for specular surfaces (minimum)
J. 75% for diffusing surfaces (minimum)
K. Seal Gasket: Use heat and aging-resistant, removable non glued, silicon resilient
gaskets to seal and cushion lenses and refractors in luminaire doors.
L. Bowl: Interchangeable type made of tempered glass or UV-resistant polycarbonate
M. Luminaire Wiring: Use 105ºC moisture and heat-resistant silicon rubber wires,
2.3 STREET LIGHTING LUMINAIRE
A. General:
1. Luminaires must be tested to IES LM-79 and IES LM-80 standards, with the re-
sults provided as required in the Submittals paragraph of this specification.
2. IES LM-79 : Electrical and Photometric Measurements of Solid-State Lighting
Products
3. IES LM-80 : Measuring Lumen Maintenance of LED Light Source
4. Luminaire drive current value must be identical to that provided by test data
for luminaire.
5. LED components and sub components shall meet the new standard IES LM-84,
IES LM-85, IES TM-26 and IES TM-28.
B. MATERIALS AND COMPONENTS
1. Exterior LED luminaires supplied shall be complete with the proper Reflectors,
diffusers, house side shields, louvers, glassware, gaskets, pole arms, Collars,
shims, wiring, control, conduit, hardware, drivers, photo controls, and Other
appropriate devices, parts and accessories to be properly installed for an exte-
rior weatherproof lighting installation.
C. POLES AND STANDARDS
1. Poles for LED luminaires shall be as indicated on the Drawings with factory fin-
ish as shown in the "Luminaire (Lighting Fixture) Schedule". Poles shall be fac-
tory wrapped with heavy weatherproof paper for protection during handling
and shipping.
2. Contractor shall furnish hot-dipped galvanized anchor bolts, templates, ground
rods, conduit elbows, and base information, etc., for the installation of con-
crete bases as detailed on the Drawings.
3. Poles shall be of the height and with brackets, etc. as indicated in the drawings
"Luminaire (Lighting Fixture) Schedule".

D. (DRIVERS)
1. LED drivers shall be electronic-type, labeled as compliant with radio frequency

interference (RFI) requirements.
2. Drivers shall be rated for the ambient temperatures in which they are located.
3. Outdoor fixtures shall be equipped with drivers rated for reliable starting to -
20 degrees F. Indoor fixtures located in areas with direct sunlight or above
normal ambient temperatures shall have drivers rated at 65 degrees C mini-
mum.
4. Individually fused drivers shall have their fuses accessible from outside of the
fixture chassis.
5. Induction lamp drivers shall be electronic and comply with radio
frequency interference (RFI) requirements of FCC Title 47 Part 15 and be rated
for a total harmonic distortion (THD) of less than 20 percent at all input volt-
ages.
6. Luminaires shall be equipped with an LED driver(s) that accepts the voltage as
indicated on the "Luminaire (Lighting Fixture) Schedule". Individual driver(s)
shall be replaceable.
7. Driver(s) shall be UL8750 class 1 or 2 listed for their intended purpose.
8. Driver(s) shall have a minimum efficiency of 85%.
9. Driver(s) shall reliably start at minimum ambient temperatures from -40 deg. C
to +40 deg. C with THD of <=20%.
E. ILLUMINATION
1. Illumination values for roadways and sidewalks shall be set to achieve the rec-
ommended values of standard:
a. CIE 115 and BS EN 5489

b. ANSI/IES RP-8-14, Roadway Lighting
c. IES RP-20-14, Lighting for Parking Facilities
d. IES RP-33-14, Lighting for Exterior Environments
e. The calculation of illumination shall be performed by computer pro-
grams.
F. FOUNDATIONS
1. Pole base foundations shall be precast concrete or cast-in-situ as detailed on

the Drawings and as specified herein.
2. Precast concrete foundations shall be designed and fabricated by an experi-
enced and acceptable precast concrete manufacturer. The manufacturer shall
have been regularly and continuously engaged in the manufacture of precast
concrete units for at least 10 years.
3. The precast concrete units shall be designed to withstand design load condi-
tions in accordance with the applicable industry design standards. Design must
also consider stress induced during handling, shipping, and installation in order
to avoid product cracking or other handling damage. Design loads for precast
concrete units shall be indicated on the shop drawings.

2.4 OPTIONAL PHOTOELECTRIC RELAY
A. UL listed, factory mounted to the luminaire, single throw, designed and factory set to
turn the light unit on at 15 to 30 lux and OFF at 50 to 100 lux with 15-sec. minimum
time delay.
2.5 REQUIRED DATA IN CATALOG
A. Utilization factor curves to road side and kerb side
B. Isolux curves with respect to pole height
C. Polar diagrams
D. Lateral distribution and aiming data
E. Weight and windage area figures
F. Ballast losses
G. Inlet diameter
H. Wiring terminal type and permitted cable area (CSA)
2.6 LUMINAIRE SUPPORT COMPONENTS
A. Wind-load Strength of Total Support Assembly: Adequate to carry support assembly

plus luminaires at indicated heights above grade without failure, permanent
deflection, or whipping in steady wind of 100 mph (160 km/h) with a gust factor of
1.3. Support assembly includes pole or other support structures, brackets, arms,
appurtenances, base, and anchorage and foundation.
B. Mountings, Fasteners and Appurtenances: Corrosion-resistant items compatible

with support components.
C. Materials: Will not cause galvanic action at contact points.
D. Mountings: Correctly position Luminaire to provide indicated light distribution.
E. Anchor Bolts Nuts, and washers: Hot-dip galvanized after fabrication unless stainless
steel items are indicated.
F. Anchor Bolt Template: Steel
G. Pole/Support Structure Bases: Anchor type with hold-down or anchor bolts, leveling
nuts, and bolt covers. The design strength of concrete for pole foundation shall be
3000-psig (20.7 M Pa), 28-day compressive strength.

2.7 LIGHTING POLES
A. Construction: Galvanized steel with a minimum yield of 317 MPa, one-piece

construction up to 12 m in length with welded escalating rails, and access Handhole
(with hinged door) in pole wall as per drawings.
B. Pole of area lighting shall withstand the weight of 4 luminaires (explosion proof type)
plus one person in operation and the resultant moment of these weights at the
indicated height and wind.
C. Pole Earthing: Provide a 12 mm welded threaded lug, for steel poles, accessible
through hand hole and listed for copper conductor connection.
D. Pole Finish: Grind welds and polish surfaces to a smooth, even finish.
E. Hot-dip galvanize after fabrication to comply with ASTM A123.
2.8 DECORATIVE POLES
A. Pole Material:
1. Cast ductile iron.

2. Cast gray iron, according to ASTM A 48/A 48M, Class 30.
3. Steel tube, covered with closed-cell polyurethane foam, with a polyethylene
exterior.
B. Mounting Provisions:
1. Bolted to concrete foundation.

2. Embedded.
C. Fixture Brackets:
1. Cast ductile iron.

2. Cast gray iron.
D. Pole Finish: As selected by Architect from manufacturer's full range.
PART 3 - EXECUTION
3.1 GENERAL
A. Provide all equipment installations and wiring installations including connections as

indicated, specified and required. Assure proper fits for all equipment and materials
within the spaces shown on Drawings.

3.2 INSPECTION
A. Inspect each assembly and related accessories for damage, defects and
completeness prior to installation.
3.3 POLE INSTALLATION
A. Alignment: Align pole foundations and poles for optimum directional alignment of
luminaires and their mounting provisions on the pole.
B. Clearances: Maintain the following minimum horizontal distances of poles from

surface and underground features unless otherwise required:
1. Fire Hydrants and Storm Drainage Piping: 60 inches (1520 mm).

2. Water, Gas, Electric, Communication, and Sewer Lines: 10 feet (3 m).
3. Trees: 15 feet (5 m) from tree trunk.
C. Concrete Pole Foundations: Set anchor bolts according to anchor-bolt templates

furnished by pole manufacturer. Concrete materials, installation, and finishing
requirements are specified in Division 03 Section "Cast-in-Place Concrete."
D. Foundation-Mounted Poles: Mount pole with leveling nuts, and tighten top nuts to
torque level recommended by pole manufacturer.
1. Use anchor bolts and nuts selected to resist seismic forces defined for the ap-
plication and approved by manufacturer.
2. Grout void between pole base and foundation. Use non shrink or expanding
concrete grout firmly packed to fill space.
3. Install base covers unless otherwise required.
4. Use a short piece of 1/2-inch- (13-mm-) diameter pipe to make a drain hole
through grout. Arrange to drain condensation from interior of pole.
E. Embedded Poles with Tamped Earth Backfill: Set poles to depth below finished
grade, but not less than one-sixth of pole height.
1. Dig holes large enough to permit use of tampers in the full depth of hole.
2. Backfill in 6-inch (150-mm) layers and thoroughly tamp each layer so compac-
tion of backfill is equal to or greater than that of undisturbed earth.
F. Embedded Poles with Concrete Backfill: Set poles in augered holes to depth below
finished grade, but not less than one-sixth of pole height.
1. Make holes 6 inches (150 mm) in diameter larger than pole diameter.
2. Fill augered hole around pole with air-entrained concrete having a minimum
compressive strength of 3000 psi (20 MPa) at 28 days, and finish in a dome
above finished grade.
3. Use a short piece of 1/2-inch- (13-mm-) diameter pipe to make a drain hole
through concrete dome. Arrange to drain condensation from interior of pole.
4. Cure concrete a minimum of 72 hours before performing work on pole.

G. Poles and Pole Foundations Set in Concrete Paved Areas: Install poles with minimum
of 6- inch- (150-mm-) wide, unpaved gap between the pole or pole foundation and
the edge of adjacent concrete slab. Fill unpaved ring with pea gravel to a level 1 inch
(25 mm) below top of concrete slab.
H. Raise and set poles using web fabric slings (not chain or cable).
3.4 GROUNDING
A. Ground metal poles and support structures according to Division 26 Section

"Grounding and Bonding for Electrical Systems."
1. Install grounding electrode for each pole, unless otherwise indicated.

2. Install grounding conductor pigtail in the base for connecting luminaire to
grounding system.
B. Ground nonmetallic poles and support structures according to Division 26 Section

"Grounding and Bonding for Electrical Systems."
1. Install grounding electrode for each pole.

2. Install grounding conductor and conductor protector.
3. Ground metallic components of pole accessories and foundations.
A. Inspect each installed fixture for damage. Replace damaged fixtures and
components.
B. Illumination Observations: Verify normal operation of lighting units after installing

luminaries and energizing circuits with normal power source.
1. Verify operation of photoelectric controls.
C. Illumination Tests:
1. Measure light intensities at night. Use photometers with calibration refer-

enced to NIST standards. Comply with the following IESNA testing guide(s):
2. IESNA LM-5, "Photometric Measurements of Area and Sports Lighting."
3. IESNA LM-50, "Photometric Measurements of Roadway Lighting Installations."
4. IESNA LM-52, "Photometric Measurements of Roadway Sign Installations."
5. IESNA LM-64, "Photometric Measurements of Parking Areas."
6. IESNA LM-72, "Directional Positioning of Photometric Data."
D. Prepare a written report of tests, inspections, observations, and verifications

indicating and interpreting results. If adjustments are made to lighting system, retest
to demonstrate compliance with standards.


ISSUED FOR
COMPLETED WITHIN THEIR ENTIRELY. TENDER/QUOTATION x
PURCHASE
CONSTRUCTION

NO. BY BY BY
0 March 2022 A.H. 22 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. STRUCTURED CABLING SYSTEM
CAIRO - EGYPT 271000 – 2874 0

CONTENTS
SECTION 271000
STRUCTURED CABLING SYSTEM
Page
PART 1 INTRODUCTION 2
1.1 SCOPE 2
1.3 System Description 3
1.4 External Links /Connectivity 5
1.5 Interface Requirements With Bms 6
1.6 References And Compliance 6
1.7 Abbreviations & Definitions: 7
1.10 Contractor Responsibility & Submittals 9
PART 2 PRODUCTS 15
2.1 General 15
2.2 Products Minimum Technical Requirement 15
PART 3 INSTALLATION 19
3.1 Installation Of Basic Wiring System Materials 19
3.2 Grounding: 20
3.3 System Labelling 21
3.5 Coordination With Other Divisions 21
Structured Cabling System Section 271000

SECTION 271000 – STRUCTURED CABLING SYSTEM
PART 1 INTRODUCTION
1.1 SCOPE
A This document provides the minimum technical specifications / requirements for the
structured cabling system that shall be installed in the project as indicated in
drawings and relevant documents.
B The WORK of this Part is integral with the whole of the Project Documentation and is
not intended to be interpreted outside that context.
C This Part of the WORK shall be read and executed in conjunction and coordination
with all other Sections of this Specification and other Services/Trade Contractors.
D This section applies to the structured cabling system, as indicated on accompanying

layout drawings and as required by this specification.
E The Contractor is required to complete any further technical or construction

drawings which are not already provided but that are required to complete the
construction contract, together with all Shop Drawings and Specialist drawings
according to specific manufacturer requirements indicating specific product part
number and typical installation details according to official manufacturer installation
instructions.
F The contractor is fully responsible to achieve the design intent indicated in the design
package including drawings, specifications and BOQs.
G Contractor is fully responsible for supplying, installing, testing, commissioning, put

into operation a complete structured cabling system as indicated in the drawings to
achieve system requirements indicated in related plans, risers, BOQ, specifications
and all related contract documents including all necessary accessories to construct
fully functional end-to-end integrated system including-but not limited to-the
following:
1. F/UTP Cat6A Copper Cable.

2. RJ45 CAT6A Patch Panel.
3. F/UTP CAT6A Patch Cords (Rack & Work area patching)
4. Management panel
5. RJ45 CAT6A Jacks/outlets
6. Single mode fiber optic cable - SMF
7. OM4 Multi-Mode fiber optic cable-MMF
8. Fiber Optic Patch Panel
9. LC Fiber Optic Patch Cords
10. Fiber Terminal Box – FTB
11. Optical Distribution Frame – ODF
12. IT Racks & Cabinets
13. Labeling System
14. Power Distribution Unit-PDU
15. Metal Cable Trunk

A Contractor must refer to all other related packages for coordination purposes. For
any missing information or contradicting information, contractor must submit RFI
(Request for information) to the design Engineer. No action or interpretation of the
design documents shall be considered valid for construction until it is approved by
the design Engineer through a reply to the RFI.
1.3 SYSTEM DESCRIPTION
A The work to be carried out under this section shall comprise the supply, installation,
testing, commissioning and setting to work all items that are necessary for a
complete structured cabling system as per specifications and drawings. Contractor
shall develop a comprehensive structured cabling system including, but not limited to
the items indicated throughout the design package including specification , drawings
and BOQ
B All hardware requirements given are the minimum requirements. Contractor’s

product shall meet or exceed these requirements. Additionally, the hardware
selected shall meet the operational, functional, and performance requirements
specified herein.
C At this point that the performance requirements in this specification are subject to
change due to market updates. Therefore it is the Contractor’s responsibility to
ensure that Hardware and Operating System (where applicable) information is
updated at time of hardware selection or installation.
D Updated equipment specifications shall be equal to or greater than the functionality

and performance stated in this document and shall be approved by the Engineer
prior to being ordered.
E The Service level agreement (SLA) is considered integral part of this specification.
F The structured cabling system shall comply with EIA/TIA and IEC standards.
G All telecommunication systems shall be IP based including Voice, Video (IPTV &CCTV)
and all low current systems controllers with Ethernet interface.
H Structured cabling system shall be provided to serve IP-based systems but not limited
to the following:
1. Administration LAN.
2. Security LAN.
3. Wireless network.
4. IP Telephony.
5. IP-CCTV.
6. IPTV.
7. Access Control System.
8. Building management system.
I The network shall support 1GbE/ 10GbE Gigabit Ethernet for the project (data
services and fast internet connectivity).

J The system shall cover all passive elements necessary to construct a complete Local
Area Network (LAN) that will serve the entire facility.
K All application servers (operator and hospitality) and software applications shall be
provided by the client.
L All the incoming public network service cables shall be terminated at entrance facility
room.
M Separate IT rooms/closets will be distributed in every floor for according to area

occupancy/function. All cable shall be 4-pair category 6A F/UTP, unshielded twisted
pair cable within the room. The system backbone shall be fiber optic cables.
N IT Rooms/closets:
1. The Telecom Rooms will house all horizontal Category 6A cabling along with
the fiber optic backbone cabling and the active network equipment. All of the
Telecom Rooms are being designed to meet the following requirements where
ever possible:
I. Protected power supply and earthing.

II. Air-conditioning to maintain an ambient temperature at the optimum
operating temperature for all equipment installed.
III. Wiring and network cabinets.
2. All Telecom Room (TR) entrance doors shall open outward.

3. The Main Equipment Room for the building will be access controlled with CCTV
coverage and be equipped with suitable fire extinguishing equipment.
4. Lighting in the equipment room should be installed to provide a suitable
working environment. Lights should if possible be connected to the emergency
power supply for the main building.
5. The flooring will be anti-static in this and all other telecom spaces. All cable
ways will be on overhead cable trays. Accurate heights for this space are
critical at the detailed design stage to ensure both standard sized racks and
overhead basket/ladder tray can be accommodated.
6. Wall linings for the IT rooms shall extend from the finished floor to the ceiling
and shall have at least one or two walls with fire rated void-free plywood 2.4m
high with a minimum thickness of 19mm (¾ inch).
7. The plywood shall be securely fastened to wall-framing members to ensure
that it can support attached equipment.
O The Data Connectivity:
1. The data connectivity shall be based on two main connections:
I. Backbone Connections.
II. Horizontal Cabling connections
P Fiber Optic Backbone Cabling:
1. Fiber optic cables shall be used to provide backbone cable links between the
Data center and each IT rooms/closets located in the project.

2. Within our design we are conscious for the requirement of the infrastructure
to support today’s as well as tomorrow’s technology and bandwidth
requirements. The design of the fiber backbone infrastructure is therefore
based on the use of single mode fiber optic cable as well as OM4 grade cable
where extended distances need to be accommodated in the design. This will
be included within the design intent.
3. The fiber backbone infrastructure for the project LAN shall be designed in a
hierarchal star topology with all cables emanating from either the Main
Equipment Room or the fiber entry point to the plot. There will be an
individual fiber optic cable routing to each wiring IT cabinet within each
telecom room. The fiber optic cables will be terminated on 10Gbit grade LC
fiber optic modules mounted within a rack mounted patch panel within each of
the wiring center cabinets at both ends.
Q Balanced twisted pair Category 6A horizontal cabling:
1. The horizontal cabling in the project will be balanced twisted pair category 6A
cabling (F/UTP).
2. The horizontal category 6A cabling will support but not be limited to the
following applications where applicable:
I. All IP Voice services in all areas

II. Fixed port High Speed internet access
III. All data outlets for the Admin Local Area Network
IV. WiFi access points
V. IPTV outlets
VI. Floor boxes and limited quantity AV niches
VII. BMS system
VIII. CCTV - IP Camera locations
IX. Access Control central control equipment locations
3. The cable will support up to 1Gbps modulation up to a distance of 90m on the

channel and 100m on the link from switch port in IT rooms to an end user
outlet on the floor.
4. All category 6A cable installed will be specified at LSZH (Low Smoke Zero
Halogen) sheath type.
5. All data outlets shall be terminated on CAT 6A patch panels.
6. The Client shall provide all requirements of the telecommunication service
provider to be taken into account during the various design stages.
R Wiring and network cabinets:
1. Wiring and network cabinets will all be 600mm x 800mm and 42U high if floor
mounted or where is a small amount of horizontal cabling wall mounted
600mm x 600mm and 12 high.
1.4 EXTERNAL LINKS /CONNECTIVITY
A Contractor shall coordinate to perform all necessary external connections and

interfaces necessary to connect the system to external interfaces

1.5 INTERFACE REQUIREMENTS WITH BMS
A Contractor must follow all Monitor and control points indicated in the I/O Schedules
attached to the Building management system specifications
1.6 REFERENCES AND COMPLIANCE
A All works shall be performed in strict accordance with the drawings, specifications
and stipulations of the Local Building and safety Codes, TIA/EIA the National Fire
Protection Association (NFPA), International Electrical Commission (IEC) and other
related international standards
1. National Telecommunication Regulation Authority (NTRA) standards and

specifications.
2. Local Electrical Standard

3. Local Safety Standard
4. Standards of local authorities having jurisdiction
5. Electrical Component Standard: Provide work complying with applicable
requirements of NFPA 70 "National Electrical Code"
6. IEC Compliance: Comply with applicable requirement standards pertaining to
system and wiring
7. Related British Standards
8. ANSI/TIA/EIA 568-D & ISO/IEC 11801:Ed. 2.1
9. ANSI/TIA/EIA-569-D: Commercial Building Standard for
Telecommunications Pathways and Spaces
10. ANSI/TIA/EIA-606-C: Administration Standard for the Telecommunications.
11. ANSI/TIA/EIA-607-C: Commercial Building Grounding and Bonding
Requirements for Telecommunications.
12. TIA-942- "Telecommunications Infrastructure Standard for Data Centers”
13. ANSI/TIA-5017: Telecommunications Physical Network Security Standard.
14. ISO/IEC-11801 – “Information Technology – Generic Cabling for Customer
Premises”.
15. ISO 11801 Amendment 1 (2008) and ISO 11801 Amendment 2 (2010)
16. EIA-310-E “industry standard for 19-inch, rack cabinets”.
17. UL (Underwriter Laboratories) Product Safety Standards:
I. UL 514A (Metallic Outlet Boxes).

II. UL 514B (Conduit, Tubing, and Cable Fittings).
III. UL 514C (Nonmetallic Outlet Boxes and Covers).
IV. UL 1242 (Electrical Intermediate Metal Conduit - Steel).
V. UL 1653 (Electrical Nonmetallic Tubing).
VI. UL 1990 (Nonmetallic Underground Conduit).
VII. UL 50 and UL 486A
18. BICSI TDMM Manual Latest edition

19. Equal codes and standard could be accepted, which should be listed in detail
as an alternative. Such alternative standards shall be indicated in detail
together with their equivalent IEC, NFPA and UL. A copy of the approved
alternative standard shall be available for submittal upon request, free of
charge.

1.7 ABBREVIATIONS & DEFINITIONS:
A TGB: Telecommunication Grounding Busbars
B TMGB: Telecommunication Main Grounding Busbar
C LSZH: Low smoke zero halogen
D ELV/ICT: Extra Low Voltage /Information and Communication Technology (systems

(which are referred to as light current systems or low current systems).
E F/UTP: Foiled Twisted Pair.
F PDU: Power Distribution Unit.
G LSZH: Low smoke zero halogen.
H MDF: Main Distribution Frame.
I OTDR: Optical Time Domain Reflectometer.
J SCS: Structured Cabling System.
K SDK: Software Development Kit
L SMFO: Single Mode Fiber Optic.
M MMFO Multi-Mode Fiber Optic
N WI-FI: Wireless Fidelity.
A MANUFACTURER QUALIFICATIONS: Manufacturing firms of structured cabling system

shall be regularly engaged in manufacturing of the systems of type, size and
characteristics similar to those required by the Contract for this project and whose
products have been in satisfactory service in similar projects for not less than five (5)
years.
B INSTALLER & CONTRACTOR QUALIFICATIONS:
1. Engage an experienced contractor who is a factory-authorized sales and

service representative to perform the work of this section. The contractor firm
shall have at least five (5) years of successful installation experience of related
systems similar to that required for this project.
C APPROVED VENDOR /MANUFACTURER LIST
1. Contractor is required to comply with the approved vendor list. Any deviation
must be documented and approved by the design engineer through the official
approval procedure updated at the time of the project.
2. The Supplier/Installer/Manufacturer must be registered with ECG through the
ECG Official procedure prior to submitting the technical material submittal.

3. The Contractor must follow the approved vendor list for the project. Approved
equal manufacturers must be submitted to the Design Engineer for Approval
through the official registration procedure.
4. Supplier /Installer must submit Official letter from the manufacturer indicating
the level of partnership and support level given to the system
supplier/installer.
5. Supplier/Installer must submit detailed reference list indicating similar projects
installations indicating, location P/N and Quantities of installed items.
D TRAINING:
1. Engage a Manufacturer-authorized and trained service representative to train

the Employer's maintenance and operational personnel on procedures and
schedules for operating, adjusting, troubleshooting and servicing the system.
2. Local representative shall provide, in depth, equipment service and
programming on site training to selected Employer’s personnel for -at least -
one week.
3. Training of maintenance, support and hardware teams including engineers,
supervisors and technician shall be in scope to ensure that all trainees who
completed the program shall be capable of operating and/or maintaining the
equipment, systems, software/hardware and facilities furnished and installed
under this contract and to ensure a smooth transition between construction
and operations activities.
4. Maintenance training shall cover all on-site routine, preventive, and remedial
maintenance of the system/ subsystem.
5. Training manuals and technology training for all systems shall be in English
only, except operator familiarization training, which shall be provided in
English and Arabic.
E Warranty: Provide warranty for the system for at least 25 years starting from the first
day of system handing over to the operation team. SLA (Service level agreement)
shall be submitted and approved by the operator.
F Licenses: The systems shall be provided with all necessary licenses and allow for any
future upgrade software /firmware. Online notifications should be included to allow
for any software versions upgrades according to service level agreement with project
operator.
G Source Limitations for the System and Components: Obtain all system components
from single source from single manufacturer. Any deviation must be supported with
documented reasons which shall be assessed and approved by the Engineer.
H Electrical Components, Devices, and Accessories: Listed and labeled as defined in

related international codes and standards, by a qualified testing agency approved by
the Engineer, and marked for intended location and application.
A Deliver products in factory containers. Store in clean, dry, closed space in original
containers. Protect products from fumes. Handle very carefully to avoid shocks or
damage.

B Software packages should be supplied in manufacturer's sealed standard packages
C Inspection shall be performed in two stages, first time upon receiving the equipment,
devices and cables on site before storing and second time after installation according
to installation phases.
D Environmental Limitations: Do not deliver or install cables, devices and equipment

until wet work in spaces is complete and dry, and temporary HVAC system is
operating and maintaining ambient temperature and humidity conditions during the
remainder of the construction period.
E Do not install any software programs unless all necessary hardware

(servers/workstations) have been installed, tested and ready for any required
software installations.
1.10 CONTRACTOR RESPONSIBILITY & SUBMITTALS
A General: Submit the necessary complete sets of documentation indicating type, size,
rating, style, catalogue number, Manufacturers names, and/or catalogue data sheets
for all items to ensure compliance with specifications. This documentation shall be
subject to the approval of the Engineer and no equipment shall be ordered without
his approval for all equipment and devices, which are shown on documents
(drawings, specs …etc). Any document submitted by the Contractor during the tender
stage shall not be considered as technical submittal, it shall be used only to approve
the manufacturer name. During technical submittal stage, Contractor shall submit all
required technical document for study and approval.
B For any missing or mismatch between various drawings sets in all disciplines,
contractor must issue RFI (Request for Information) to the Design Engineer to provide
the proper corrective action.
C Shop Drawings: Submit shop drawings & Composite drawings showing equipment,
device locations, labeling, part number and connecting wiring of the systems,
including riser diagrams. Shop drawings shall include, but not be limited to the
following:
1. Complete pin to pin one-line riser diagram(s) showing all approved equipment,
size, type and number of all conductors, interconnection between the system
and all other related systems.
2. Installation details for all system components. Installation details drawings
shall show all accessories used in installation such as back boxes, glands,
washers, etc.
3. Complete Grounding details as per system manufacturer requirements.
Indicating connections with dedicated grounding system including connections
with telecommunication grounding bus bars as part of overall grounding and
bonding system including telecom main grounding bus bar.
4. Exact location of every single component of the system in coordination with all
other works (Electromechanical, Arch., and Civil).
5. Colored Composite drawings for all MEP systems showing all coordinated MEP
works

6. Signature of all involved contractor engineers representing different disciplines
(Electromechanical, Arch, and Civil etc.) to confirm their approval of such
locations, installations and coordination.
7. Complete sequence of operations and functions of the system.
8. All drawings and technical material submittals should be submitted in both
softcopy and hardcopy formats .No of copies shall be according to contract
documents requirements (at least three copies shall be submitted)
9. [Detailed Rack elevations showing all internal patch panels, active switches,
cable managers, blank plates,…etc]
D Material Submittal: shall include, but not be limited to, the following:
1. Contractor and System integrator shall stamp and approve the system material
submittal prior to submitting to the Engineer.
2. Pin to pin connection diagram
3. Complete one-line riser diagram(s) showing all equipment and the size,
connections, type and number of all equipment
4. Include programming and installation manuals
5. Complete sequence of operations and functions of the system
6. Complete system wiring diagrams for components and interfaces to
equipment supplied by others
7. A listing of the manufacturer's authorized, local representative responsible for
installation, coordination and service
8. Compliance sheet item by item providing a comparison between each item
specifies each item submitted. Contractor must indicate clearly any deviations
from design & items specifications-if exists-indicating the reason of deviation.
Such deviations must be approved by the Design Engineer.
9. Detailed Technical Data sheets with highlighted part numbers must be
submitted.
10. [All System cables must be approved by system manufacturer .Contractor
must provide a letter from the manufacturing approving the cables connected
to the manufacturer devices/equipment]
11. BOQ in ECG Format complete with quantities and products part numbers.
12. The submitted BOQ must be mapped to ECG BOQ .i.e Each item in ECG BOQ
should be followed by The equivalent manufacturer Part numbers fulfilling the
requirements of ECG BOQ item .this shall include all hardware and software
licenses and services that fulfill the ECG Item requirements.
13. Compliance Response on this specification document (in every page in this
specifications document) with project approved vendor list. Any deviations
from the project approved vendor list must be approved by the Design
Engineer.
14. All Specifications and BOQs must be stamped by the contractor declaring fully
compliance.
E Product Data: Submit Manufacturer's technical product data, including specifications

and installations for each type of the system equipment. Include standard or typical
riser and wiring diagrams, operation and maintenance instructions for inclusion in
maintenance manuals.
1. Compliance sheet to the specification with cross reference to related items in

data sheet, point by point, indicating deviations – if any – reasons for such
deviations, also indicate any extra features / specifications.

2. Complete description data including UL listing or any equivalent standards for
all system components
3. Provide all system related calculations supported by manufacturer specific
software and perform all necessary calculations validating the shop drawing
system distribution and related installations.
4. Complete description of system operations and functions of each system
component.
5. Manufacturer's technical product data sheets, including quantities and
specifications of every item, specification of every device, system component,
quantities, software and installations for each unit of equipment.
6. Contractor shall submit a list of the Manufacturer's authorized, local
representative responsible for installation coordination and service, pre-
qualification for the system provider and installer.
7. Complete description and data including related standards for all system
components.
8. Documents indicating system expandability options included in the submitted
products and system included redundancy features.
9. Documents indicating that the supplied system components are the latest and
most updated products from the system manufacturer and software versions
are the latest produced by the system manufacturer.
10. Integration documents approved and stamped by overall project systems
integrator. Such documents should illustrate that the system will satisfy the
project system integrator requirements in terms of software interface
protocols and hardware interfaces to achieve fully interoperable systems.
11. All technical material submittals must be provided in both hard copy and soft
copy. The softcopy must allow for searching capabilities. The technical material
submittal will be rejected if the softcopy was not included.
12. Testing & commissioning procedures according to system manufacturer
requirements and calibration certificate for testing equipment
13. Contractor shall verify distance limitations imposed by communication
protocols prior to installations and submit this in a dedicated document with
the submittal
F Maintenance Data: Submit maintenance data and parts lists for each type of the
installed system including furnished specialties and accessories. Include this data,
product data, and shop drawings in maintenance manual; in accordance with
requirements of other relevant documentation.
G Instruction Manuals: The Contractor shall provide with the assistance of the
equipment manufacturer and its authorized, local representative. In addition, one
approved copy of the system submittal, complete operating instructions; pertinent
system orientation documents and system service.
H Delivery, Storage and Handling: Deliver products in factory original, unopened

containers. Store in clean, dry and shaded space in original containers. Handle
carefully to avoid damage.
I System Initial Configurations: Contractor must perform all necessary system software
configurations-as required- based on the project operator/client requirements.
Detailed configuration plan must be submitted for the client approval prior to
configuration.

J System Calculations: Provide all system related calculations supported by
manufacturer specific software and perform all necessary calculations validating the
shop drawing system distribution and related installations. All System related
calculations must be submitted for the Engineer Approval
1. Provide calculations to provide filling ratio of cable trays and conduits. The
filling ratio shall not exceed 40% of cable trays/conduits cross sectional area.
2. Provide Optical Power budget calculations for all fiber cable links.
K System supplier & Installer qualifications documents: System supplier & Installer
should submit the required certifications indicating that the system supplier and
installer company is certified from system manufacturer to perform all system
supplying, installations, testing and commissioning supported by system installers
CVs and related manufacturer certifications. The system supplier should be involved
in a strong relationship with system manufacturer with proven reference of similar
projects. The system supplier & installer should submit reference of similar projects
and abide by all requirements in project documents (specifications, drawings, BOQ,
and method of measurements)
L Composite Coordinated drawings: illustrating all MEP devices and equipment.

Contractor shall validate all system components power requirements and indicate on
drawings that all system power requirements have been coordinated with electrical
team.
M Working environment documents: indicating the working environment according to

system manufacturer regarding temperature and humidity are achieved and
coordinated with HVAC team.
N Finalized Reflected ceiling drawings: illustrating all works in the ceilings after
finalizing the coordination process.
O Testing & commissioning plan:
1. All testing procedures must be submitted for Engineer approval according to

manufacturer testing procedures
2. Submit testing and commissioning procedures including required test
equipment for all of the system components as well as the overall system
performance.
3. All testing equipment and all necessary additional equipment / devices
necessary to perform or create a testing environment to simulate the full
system operation with its full capacity, are considered in the contractor scope
of work without any extra fees.
4. Testing devices calibration certificates.
5. Test instruments shall meet or exceed applicable requirements in ANSI/TIA-
568.D.2, ANSI/TIA-1152 and to be calibrated once in the year prior of the
testing date.
6. Testing results shall be submitted in both soft and hard copies for 100% of the
system components. Testing shall take place in the engineer presence.
7. Testing shall be performed under normal operation conditions for the building
i.e in the presence of ambient Electromagnetic interference sources.
8. System components factory tests certificates should be submitted with field
testing

9. The cables shall be tested & verified to fulfill the ISO/IEC requirements for
both backbone and horizontal cabling system. The contractor has to provide
the proposed testing procedure including along with testing equipment.
10. The minimum required parameters to be tested according to the TIA/EIA are
as following:
I. Wire map
II. Cable length
III. Delay skew
IV. Propagation delay
V. NEXT
VI. Attenuation
VII. Return loss
VIII. ACR
IX. ELFEXT
X. Power sum NEXT
XI. Power sum ACR
XII. Power sum ELFEXT
11. Testing results should include the following:
I. Date of Calibration
II. Cable ID
III. Date/time
IV. Selected testing limits
V. Cable type
VI. Operator name
VII. Software version
VIII. Limits version
IX. Used NVP (Nominal Velocity of Propagation)
12. The testing will be required to provide measurements of the installed

condition and overall performance of the entire cabling system.
13. Performing OTDR (Optical Time Domain Reflectometer) testing regarding
irregularities such as severe bend and assuring uniformity of cable attenuation
and connector insertion loss.
14. The tester shall have integrated OLTS along with OTDR functions to perform
loss/length certification measurements, OTDR auto analysis and end face
inspection.
15. Documentation for all end faces is a must, the connector end face has to be
shown on the testing sheet.
16. in addition to the above testing procedure it is required to have power budget
calculations shall be provided with testing documents
17. Testing shall be performed at least for 1310 & 1550 wave lengths or single
mode and verified with the wave lengths used by the switching equipment as
required.
18. Testing results should include the following:
I. Date of Calibration
II. Cabling link
III. Test wavelengths
IV. Fiber identification.

V. Fiber length
VI. Fiber attenuation
P Close out documents :Required documents shall include but not limited to the
following :
1. As built drawings: During the construction of the system, the Contractor shall
put in writing all his remarks, during the progress of work, concerning any
suggested alterations from the shop drawings in wiring routes, locations of
equipment or devices which arise from coordination between the system and
other activities on related shop drawing plans. As built drawings and
documents shall include updating for all of the drawings, documents,
calculations, data sheets..etc previously submitted in shop drawing stage to
reflect what is exactly executed on site.
2. During executing the work and preparing the drawings, no execution of
alterations shall be allowed before receiving a written approval from the
Engineer.
3. All alterations shall be registered and filled by the Contractor and extra copies
shall be submitted to the involved parties (Engineer, Project Manager, Site,
etc.).
4. Complete as-built draft set of Drawings and equipment schedules shall be
prepared fifteen (15) days after completion of work for the engineer’s
approval. The as built draft shall include all previously approved alterations
and technical data sheets of installed equipment, devices…..etc. Final originals
and copies of the as-built Drawings shall be submitted in accordance with
Contract documents.
5. As built documents shall also include: Operation and maintenance manuals
including; updated data sheets for installed equipments, operation
instructions, programming procedures Electronic circuits for every device and
equipment, troubleshooting repair guide, and the required spare parts list for
5 years of operation, along with the circuit diagram. Selected spare parts shall
be provided without any extra cost.
Q EXTRA MATERIALS
1. Furnish extra materials that match products installed –if-necessary-and that

are packaged with protective covering for storage and identified with labels
describing contents.
2. Contractor must supply all required programming and reprogramming tools
with all access rights to the trained maintenance and operation team assigned
by the client who will be responsible for system maintenance and operation.
3. A Separate maintenance contract along with Service level agreement shall be
proposed by the contractor according to the client operator team
requirements.
4. The Contractor shall provide spare part list as indicated in the BOQ. The spare
part list should be agreed with project operator according to SLA (Service Level
Agreement).

PART 2 PRODUCTS
2.1 GENERAL
A The structured cabling system will be composed of the following items:
1. F/UTP Cat6A Copper Cable.

2. RJ45 CAT6A Patch Panel.
3. F/UTP CAT6A Patch Cords (Rack & Work area patching)
4. Management panel
5. RJ45 CAT6A Jacks/outlets
6. Single mode fiber optic cable - SMF
7. OM4 Multi-Mode fiber optic cable-MMF
8. Fiber Optic Patch Panel
9. LC Fiber Optic Patch Cords
10. Fiber Terminal Box – FTB
11. Optical Distribution Frame – ODF
12. IT Racks & Cabinets
13. Labeling System
14. Power Distribution Unit-PDU
15. Metal Cable Trunk
B The above components shall be provided with the appropriate numbers and
capacities to serve the whole project and achieve the design intent. The locations of
various system components are shown on the drawings. Other components and
accessories deemed necessary and essential for system operation and integration
which are not shown on drawings are deemed essential and integral part of the
design intent which should be included in the contractor submitted solution to
achieve end to end fully functional integrated system.
C All notes on the drawings are integral part of the contract document and must be
read in conjunction with all design package documents (specification ,BOQs...etc)
D The following general requirements shall be fulfilled in the provided system. Bidders
shall state clearly any deviations/omissions or additions from the desired
specifications, drawings and BOQs. Such deviations-If Exist- must be assessed and
approved by the Design Engineer.
2.2 PRODUCTS MINIMUM TECHNICAL REQUIREMENT
Contractor Must fill

this column with
comply / Partially
STRUCTURED CABLING SYSTEM – MINIMUM REQUIREMENTS
comply (indicating
deviation or equiva-
lent features/items)
F/UTP CAT6A copper Cable-LSZH:
 Cables 4 Pairs (8 - wires) F/UTP CAT 6A [LSZH] [Solid Copper] [Overall

Screen] [500 MHz].
 Category: CAT 6A
 Characteristic Impedance: 100-ohm.
 Conductor: Solid bare copper.
 Insulation: PE.
 Bandwidth: 500 MHz
 Jacket Material: LSZH
 Shielding: F/UTP (Foiled/Unshielded Twisted Pair)
RJ45 CAT6A Patch Panel
 Loaded with (24) RJ45 modules

 F/UTP cat6A RJ45 Snap-In connection modules
 Flat style
 19” rack mounted type
 1U
 Stainless Steel, powder coated steel
 Connected with grounding and bonding
 Earthing kit
 Labeling Bar Covered with Plastic Cover for each port
F/UTP CAT6A Patch Cords (Rack & Work Area Patching)
 Patch cords Cat 6A [ 1 meter] [LSZH] Stranded type for rack patching.
 Patch cords Cat 6A [ 3 meters] [LSZH] Stranded type for work area patch-
ing.
Management panel
 19” rack mounted type

 1U
 Stainless Steel , powder coated steel
RJ45 Cat 6A Jacks/Outlets Including Cables, [coordination for first fix includ-
ing conduits, pull boxes] Face plates, Modular Jacks, Patch Cords and all
needed fixation accessories including the below general requirements:
 Cables 4 Pairs (8- wires) F/UTP Cat 6A [LSZH][Solid Copper][Overall

Screen][500 MHz]
 Face plates [ports according to drawings] [Iconable] [Label with plastic
cover] for each port
 Blank plate for unused ports
 RJ45 Modular Jack Cat 6A.
 Characteristic Impedance: 100 ohm.
 Cable Shielding: F/UTP (Foiled/Unshielded Twisted Pair)
 Cable Outer Jacket: PVC
 Patch cords Cat 6A [ 3 meter] [LSZH] Stranded type for work area

 Face plate and Back box dimensions shall be coordinated with ID and con-
tractors
Note: MPTL [Modular Plug Terminated Link] direct connection with no
patch cords Will be used for CCTV, all panels and controllers.
Single Mode Fiber Optic Cable - SMF:
 [Single mode] [Indoor Tight Buffer] Sizes: [4/6/12/24 Core].

 [9/125] µm(Micrometer) Core/Cladding diameter.
 ITU [G.657 A2/B2] SMF standard for GPON applications.
 Maximum Allowable Attenuation: 0.4 dB/Km @1310 nm & 0.4 dB/Km
@1550 nm.
 All related connectors and pig tails must fully comply with G.652D re-
quirements.
 All SFP Cable Mechanical characteristics shall comply with international
telecommunication union standard [ITU-T G.652D].
OM4 Multi-Mode Fiber Optic Cable - MMF:
 [Multi-mode] [OM4] [12 Core].

 [50/125] µm(Micrometer) Core/Cladding diameter.
 ITU [G.651.1] for MMF standard
 Maximum Allowable Attenuation: 2.5 dB/Km @850 nm & 0.8 dB/Km
@1300 nm.
 All related connectors and pig tails must fully comply with G.651.1 re-
quirements.
 All MMF Cable Mechanical characteristics shall comply with international
telecommunication union standard [ITU-T G.651.1].
Fiber Optic Patch Panel:
 19” rack mounted type.

 1U
 LC type with LC/LC couplers according to the number of cores termi-
nated on the patch panel.
 Drawer-style with all steel construction, cable strain reliefs, cable entries and
management rings.
 Fiber adaptors color shall follow TIA/EIA-568-C3 standard.
 No. of cores for each FOPP as per drawings.
LC Fiber Optic Patch Cords:
 Jacket Material: LSZH

 Connector type: LC duplex connector patch panel side
 Fiber Type: OS1 for SMF & OM4 for MMF
 Cable type: Tight Buffered

Fiber Terminal Box - FTB:
 Wall mount Fiber optic enclosure

 Constructed of steel material
 Dimension: up to 350 x 300 x 60 mm [W x H x D]
 Dust/debris protection
 Lockable key
 c/w all fiber adaptor panels [LC or SC type]
 c/w all splicing trays, fiber cassette and holders
 Allowing for fiber optic splicing inside enclosure
 Up to 24 fiber optic connections
 Color & shape as per project ID
Optical Distribution Frame - ODF:
 ODF Wall mounted fiber optic enclosure located inside IT rooms.

 Used for fiber optic splicing between FTB box and main fiber optic rack in-
side MTR room.
 Constructed from galvanized steel metal sheets with minimum thickness
of 1.5 mm.
 Dimension: 600 x 600 x 300 mm [W x H x D]
 Mounted at level min. 1200 mm from F.F.L
 c/w all passive fiber optic splicing, patching modules, fiber optic rings, cas-
settes, splicing trays, LC/SC adaptors/couplers, etc.
 Provided with opening holes from top & bottom sufficient to accommo-
date the incoming/outgoing terminated fiber optic cables.
 Equipped with perforated double sided doors for ventilation.
 Compliance with TIA 568, & ISO 11801 codes & standards.
IT Rack / Cabinets:
 Dimension: [600x800mm-WxD] for distribution IT rack and [800x1200mm-

WxD] for server rack.
 Height: 24U for distribution rack and 42U for server rack
 Construction: Galvanized steel
 Blank panels for unused rack space.
 Lockable perforated front/rear doors for maximum air flow.
 Removable lockable side panels.
 4 Nos. Sidewall compartment / pockets.
 Top & bottom cable exit.
 Fixed front & rear wheels.
 Equipped with PDU & grounding busbars [TGB & TMGB]
 All other necessary accessories.

Labeling System:
 Installed on both ends of all cables

 Uniquely numbered label for each cable
 Labels shall comply with below:
 Machine printed
 Easy and clean to read
 Waterproof
 Permanent ink (non-permanent shall not be accepted)
 Size shall suit every equipment required to be labeled
Power Distribution Unit (PDU):
 Internal mains power (230V-50/60Hz-63A) distribution system

 For Server rack: Two vertical mounted power distribution unit strips with
integral surge protection connected to two redundant UPS source.
 For distribution IT rack: one vertical mounted power distribution unit
strips with integral surge protection connected to single UPS source.
 shall have adequate no. of receptacles as per required.
 receptacles shall be according to IEC-60320 (IEC-320) Plugs and Connect-
ors.
Metal Cable Trunk:
 Metal, Non-Perforated type

 Protected against corrosion by hot-dip galvanized steel.
 Cable trunk sizes as indicated on drawings.
 Cable trunk shall be provided with dedicated compartment as required for
segregation between horizontal cabling and backbone cabling.
 Vertical cable trunk shall be provided vertically in all IT shafts.
 c/w all cable trunks fitting, section, supports and all related accessories
Note:
Contractor shall provide detailed cable tray sizing calculations & routing ac-
cording to number of entire cables and coordination with all other utilities in
corridors with filling ratio not exceed 40%.
PART 3 INSTALLATION
3.1 INSTALLATION OF BASIC WIRING SYSTEM MATERIALS
A Install the system as indicated, in accordance with equipment manufacturer's written

instructions (official installation manuals) and complying with applicable local

standards of installation. Installation of equipment and devices that pertain to other
Works of the Contract shall be closely coordinated with the appropriate trades.
B Pulling Cable: Do not exceed manufacturer's recommended pulling tensions. Do not

install bruised, kinked, scored, deformed, or abraded cable. Do not splice cable
between normal termination points. Remove and discard cable where damaged
during installation and replace it with new cable.
C Identify system components, wiring, cabling, boxes, panels and terminals. Comply
with requirements for system identification according to project operator
requirements.
D System labeling scheme must be submitted to the End user project operator for
approval. Operator teams labeling requirements should be considered.
E Install framed operation instructions in visible locations as required.
F As recommended by manufacturers & any specific Operator standards, unless more

stringent requirements are indicated. Ground equipment and conductors to
eliminate shock hazard and to minimize ground loops, common-mode returns, noise
pickup, cross talk, and other impairments. Install Grounding system in complete
accordance with system manufacturer's requirements and BICSI TDMM manual
instructions.
G All System Cables should be LSZH produce no toxic gases in case of fire.
H Cables should be listed for the system specific application and installation
requirements
I All wires and cables shall be listed and/or approved by a recognized testing agency &
System manufacturer through official letter supported with all necessary calculations,
documentations and testing certificates.
J Embedded conduits shall be PVC and all exposed conduits shall be EMT conduit
K All wiring shall be color coded and cabled. Junction boxes shall be color coded and
include wiring identification numbering.
L Wires and cables shall provide sufficient resistance to the spread of fire and generate
no hazardous smoke to human life.
M Wiring System shall include all indoor and outdoor cables necessary for complete
system installations.
3.2 GROUNDING:
A All grounding and bonding requirements mentioned in ANSI-J-STD-607-A/B for all

installations using TGBS and TGBMS Should be followed in complete accordance with
system manufacturer grounding requirements documents that should be included in
the technical material submittal.

3.3 SYSTEM LABELLING
A System labelling scheme must be submitted to the End user for approval. Operator
teams labelling requirements should be considered.
A Contractor shall submit proposed required testing and commissioning procedures

according to Manufacturer's requirements. For parameters and features that are
factory tested all related certificates from the manufacturers and third party
organizations must be submitted for the End user Representative approval.
B Manufacturer's Field Service: Engage a factory-authorized service representative to

inspect, test, and adjust components, assemblies, and equipment installations,
including connections.
C Visual Inspection: Conduct visual inspection prior to testing.
D Reacceptance Testing: Perform reacceptance testing to verify the proper operation

of added or replaced devices and appliances.
E The system will be considered defective if it does not pass tests and inspections.
F Prepare test and inspection reports.
G Maintenance Test and Inspection: Perform tests and inspections listed for weekly,
monthly, quarterly, and semi-annual periods. Use forms developed for initial tests
and inspections.
H Annual Test and Inspection: One year after date of Substantial Completion, test the
system complying with visual and testing inspection requirements. Use forms
developed for initial tests and inspections.
I Engage a factory-authorized service representative to train end user maintenance

personnel to adjust, operate, and maintain the system.
J System manufacturer and his authorized, local representative shall provide, in depth,
system service on site training to selected Employer’s personnel for two weeks.
3.5 COORDINATION WITH OTHER DIVISIONS
A Contractor shall coordinate to provide the necessary required power (DC &A) for all
equipment after determining the manufacturer equipment exact part number and
hence submit any necessary modifications (if needed) according to selected
equipment manufacturer instructions.
B The System supplier shall be responsible for coordination and exchange information
with the Suppliers of other systems and equipment which shall communicate with, in
order to achieve the required specified functions and achieve the AHJ requirements,
operator requirements and related international codes and standards. Contractor
must coordinate with all other MEP disciplines to perform all manual override and
systems reset and return to normal operation, a detailed document shall be
submitted for the engineer’s approval. This process is valid in all stages of the project
C A detailed integration document –approved and stamped by project system

integrator-must be submitted illustrating all integration issues and how they are
addressed in the submittal to achieve all interfacing requirements.
D LAN Coordination
1. Coordinate service entrance arrangement with local service provider.

2. Meet jointly with telecommunications and LAN equipment suppliers, local
exchange carrier representatives, and engineer to exchange information and
agree on details of equipment arrangements and installation interfaces.
3. Record agreements reached in meetings and distribute them to other
participants.
4. Adjust arrangements and locations of distribution frames, cross-connects, and
patch panels in equipment rooms to accommodate and optimize arrangement
and space requirements of telephone system and LAN equipment.
5. Adjust arrangements and locations of equipment with distribution frames,
cross-connects, and patch panels of cabling systems of other communications,
electronic safety and security, and related systems that share space in the
equipment room.
E Grounding and Bonding coordination:
1. All equipment, Racks, panels and cable shields must be bonded with access to
an approved ground connection (clean earth) using TGB "Telecommunication
Grounding” according to TIA-607-C.
END OF SECTION-271000


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. DATA NETWORK ACTIVE EQUIPMENT
CAIRO - EGYPT 272000 - 2874 0

CONTENTS
SECTION 272000
DATA NETWORK ACTIVE EQUIPMENT
Page
1.1 SCOPE 2
1.4 System Architecture 4
1.5 Data Communications Wireless Access Points 5
1.6 Encompassing Design 7
PART 2 PRODUCTS 15
2.1 General 15
3.2 Grounding: 23
Data Network Active Equipment System Section 272000

SECTION 272000 – DATA NETWORK ACTIVE EQUIPMENT
PART 1 INTRODUCTION
1.1 SCOPE
data network active equipment system that shall be installed in the project as
indicated in drawings and relevant documents.
D This section applies to the data network active equipment system, as indicated on
accompanying layout drawings and as required by this specification.

instructions.

into operation a complete data network active equipment system as indicated in the
drawings to achieve system requirements indicated in related plans, risers, BOQ,
specifications and all related contract documents including all necessary accessories
to construct fully functional end-to-end integrated system including-but not limited
to-the following:
1. 24 Ports Access Switch [10/100/1000 POE+]

2. 48 Ports Access Switch [10/100/1000 POE+].
3. Core Switch.
4. IP-PBX.
5. Employee IP Telephone Set.
6. Utility IP Telephone Set.
7. SERVER ROOM FIREWALL.
8. INTERNET FIREWALL.
9. Router.
10. WIRELESS LAN CONTROLLER
11. WIRELESS Access Point
12. Network Management Software

complete data network active equipment system as per specifications and drawings.
Contractor shall develop a comprehensive data network active equipment system
including, but not limited to the items indicated throughout the design package
including specification , drawings and BOQ

specified herein.

F The LAN will perform all switching and routing functions for voice, video and data
services serving the buildings in scope. The network shall serve all IP based services
such as VOIP, IP CCTV and IPTV...etc.
G Various network traffic will be managed using various techniques such as using
Virtual LANs to segregate various traffics. The network shall provide the required
control to prioritize traffic as required using various queuing techniques according to
networking related standards.
H The Data Network will perform all switching and routing functions for voice, video,
data services & applications. The network shall serve all IP based services that run on
the facility network.
I The Local Area Networks shall be based on a multilayer, fault tolerant, campus wide
TCP/IP network. Multilayer access switches shall be utilized at the network access to
connect the IP devices for the facility network. The access switches shall be stackable
24/48-port 10/100/1000 Base-T POE+ (Power over Ethernet 802.3at). All connections

are indicated on the network riser diagrams. The POE + shall be supported on switch
ports. Contractor shall utilize the appropriate power supply to provide the POE+ on
each port according to POE+ calculation whish shall be submitted by the contractor
for engineer approval.
J The network must support and include all features that provide fundamental
switching, and advanced switching capabilities such as PIM , BGP,OSFP.
K The network must support and include Network segmentation capabilities through
VXLAN.
L The network must support and include Automation, telemetry and visibility and
provide high availability and resiliency.
M The Switches shall provide very fast switching, intelligent high performance platform
for deploying numerous concurrent intelligent services without degrading the overall
performance of the network.
N The network must support and include IOT integration and secured using MACsec.
1.4 SYSTEM ARCHITECTURE
A The LAN shall be based on a collapsed core design consisting of three layers:
1. Core layer.
2. Distribution layer.
3. Access layer.
B Core Layer:
1. The core will be located at the heart of the network and shall provide very fast
switching, intelligent high performance platform for deploying numerous
concurrent intelligent services without degrading the overall performance of
the network.
2. Core Switches will be located at the center of the network and shall provide
very fast switching, intelligent high performance platform for deploying
numerous concurrent intelligent services without degrading the overall
performance of the network. The core switches shall perform various functions
using various service modules for WAN interfaces, security firewalls…etc.
separate core switches shall be used for each network.
C Distribution Layer:
1. Distribution switches will be located at the Main Telecom rooms (MTR) in the
ground floor of each building; they will connect access switches with the core
switches to give access to the project network. Each distribution switch shall
be connected to core switches via two uplinks.
D Access Layer:
1. Multiple access switches shall be provided for each Equipment Room. The
edge switches shall be capable of being stacked to provide inter-switch

connectivity via dedicated ports designed for this purpose (i.e. ideally does not
utilize Network ports).
2. Access switches will be located at the wiring closets (telecommunication
closets/IT rooms), they will provide users with access to the network. The
Access switches shall support power over Ethernet on all ports. Each Access
switch/Access switch stack shall be connected to the core switches via two
uplinks (Each Uplink is from different switch).
3. Access Switch Stack (when used) should consist of maximum 4 Switches as
indicated on the drawings.
E Server Access Layer:
1. Each server cabinet in the data center room shall be connected to the modular
core switches in the data center room via CAT6A copper cables & OM4 Multi-
mode fiber optic cables as indicated on riser diagram [End Of Row / Middle Of
Row – EOR/ MOR].
F The LAN shall be resilient and redundant with automatic fail-over to insure that
performance and high-availability objectives are met without manual intervention.
Recovery mechanisms must be deployed as part of the network implementation and
must be tuned to achieve less than 1 second recovery time. All switches shall be
interconnected and configured as indicated on network riser diagrams and plans
taking into consideration all required redundancy features on both software and
hardware levels.
G All network equipment shall be both IPV4 and IPV6 capable. Contractor, if directed by
the Engineer, shall implement IPV6 with backward compatibility to IPV4.
Notwithstanding, the contractor shall define all IP addresses static ranges and
dynamic ranges as well as subnets and subnet masks.
1.5 DATA COMMUNICATIONS WIRELESS ACCESS POINTS
A The contractor shall supply, install, test and commission a fully functional Wireless
LAN system as detailed within this specification and drawings, including but not
limited to:
1. WLAN Controllers
2. WLAN Management System integrated with the network overall unified
management platform
3. WLAN indoor Access Points
4. External antennas.
5. Mounting hardware for the Wireless Access Points and antennas.
B Indoor Access Points shall be capable of being connected using 10/100/1000Mbps

POE+ Access Switch via 2 ports.
C Site Surveys
1. The Contractor shall complete site surveys at the appropriate time to ensure
their design for quantity and location of Access Points achieves the desired
coverage before any installation commences.

2. The site survey shall determine whether external antennas are required to
control the RF coverage in selected areas and also provide a baseline for the
optimal locations to install the required APs. The site survey shall take into
consideration the signal attenuation caused by the building materials as well as
interference caused by adjacent APs.
3. The contractor / supplier shall use the appropriate wireless access point (WAP)
antennas to provide the required coverage for all project areas as indicated.
Active Equipment vendor shall use specific manufacturer software design and
testing tool to determine the dead zones and add/modify WAP locations and
numbers to achieve full coverage of the project areas with WI-FI coverage. Any
additional WAP needed to have a total coverage shall be provided including all
related cabling without any extra cost.
4. Contractor must provide complete heat maps indicating coverage patterns and
all parameters to validate and ensure network performance utilizing Approved
Manufacturer software to generate the heat maps. All heat maps coverage
patterns must be submitted for the Engineer approval.
5. While building the model, the contractor is required to consider the
construction material, columns and walls, assumptions regarding the building’s
model (e.g. walls and material thickness) shall be stated.
6. Site Survey to verify the achieved radio signal strength in all required areas.
7. The heat map report must include the specifications of the access point and
the design technology (e.g. WLAN Technology Wave2, frequency, bandwidth,
MIMO, transmission data rate, etc.) used in the calculations.
D The following minimum requirements shall be followed for the wireless network:
1. General Areas (Parking, Cafeteria, lobbies, etc.)
-67 dbm coverage in 95% of the area

Min. 10 Mbps data rate
2. Offices
-64 dbm in 95% of the area

Min. 24 Mbps data rate
3. Critical areas (audiovisual, etc.)
-60 dbm in 95% of the area

Min. 24 Mbps data rate (data rate should be maximized in critical areas)
E Roaming and Mobility Groups
1. Mobility shall be inherently provided to allow users to access the WLAN from
multiple specific locations.
2. In the areas of coverage roaming shall be enabled to allow users to move
seamlessly through the WLAN whilst unnoticeable transition of AP association
takes place.
3. The network shall be scalable with regard to roaming to ensure that as the
network grows roaming is still possible seamlessly across all WLAN areas.
4. The WLAN shall provide Layer 2 and Layer 3 roaming ability.
5. The WiFi network shall allow for VOIP to run on the wireless network and
ensure service continuity throughout the project areas.
1.6 ENCOMPASSING DESIGN
A The contractor shall develop a fully working design for the LAN cognizant of all the
systems to be supported, as well as adopting good engineering practice for future
expansion to ensure that emerging technologies can be supported / adopted for use
on the network in the near future.
B The contractor shall review the system specifications for the listed systems and
ensure that the particular requirements for each of the systems are incorporated into
the design of LAN.

1. Ethernet
2. Fast Ethernet
3. IEEE 802.3ad Gigabit-Ethernet channeling
4. IEEE 802.1q VLAN Ethernet
5. IEEE 802.1p Class of Service (CoS)
6. IEEE 802.1d Spanning-Tree Protocol
7. IEEE 802.1w Rapid Spanning-Tree Protocol
8. IEEE 802.3af Power over Ethernet
9. IEEE 802.3ad Gigabit-Ethernet channeling
10. IEEE 802.1q VLAN Ethernet
11. IEEE 802.1p Class of Service (CoS)
12. IEEE 802.1d Spanning-Tree Protocol
13. IEEE 802.1s Multiple Spanning-Tree Protocol (Layer 2 load sharing on
redundant links)
14. IEEE 802.1w Rapid Spanning-Tree Protocol
15. IEEE 802.3af Power over Ethernet
16. IEEE 802.1x network security standards.
17. IEEE 802.11 ac- Wi-Fi

charge.

E Gbps: Giga bit per second
F Tbps: Tera bit per second
G Mpps: Million packet per second
H Bpps: Billion packet per second
A MANUFACTURER QUALIFICATIONS: Manufacturing firms of data network active

equipment system shall be regularly engaged in manufacturing of the systems of
type, size and characteristics similar to those required by the Contract for this project
and whose products have been in satisfactory service in similar projects for not less
than five (5) years.

supplier/installer.
D TRAINING:

one week.
English and Arabic.
operator.

damage.



following:
washers, etc.
works

submitted.
Engineer.
compliance.


component.

components.
the submittal

configuration.


1. The contractor shall provide network bandwidth calculations based on
available information to confirm that the LAN has sufficient capacity at
Mechanical Completion to support day one requirements.
2. The contractor shall perform availability calculations to demonstrate that the
LAN meets the client requirements for availability.
3. The ICT Network shall provide a minimum availability level of 99.99%.
4. The contractor shall create / Setup an appropriate VPN and VxLAN structure to
support the installed applications.
and abide by all requirements in project documents (specifications, drawings ,BOQ,
L Composite Coordinated drawings: illustrating all MEP devices and equipment

.Contractor shall validate all system components power requirements and indicate
on drawings that all system power requirements have been coordinated with
electrical team.


performance.
system operation with its full capacity , are considered in the contractor scope
of work without any extra fees .
testing
following :

Engineer.
etc.).
Contract documents.
Q Software Service Agreement
1. Technical Support: Beginning with Substantial Completion, provide software

support for 3 years
2. Upgrade Service: Update software to the latest version available at the Project
completion. Install and program software upgrades that become available
within 3 years from date of Substantial Completion. Upgrading software shall
include operating system. Upgrade shall include new or revised licenses for
using of software.
3. Provide 30 days' notice to Owner to allow scheduling and access to system and
to allow Owner to upgrade computer equipment if necessary.
4. System manufacturer must provide all necessary software development kits
(SDKs) necessary to perform all integration requirements.
5. Contractor /System integrator must coordinate to handle all necessary SDKs,
APIs to achieve all necessary integration requirements.
R EXTRA MATERIALS


requirements.
Agreement).
PART 2 PRODUCTS
2.1 GENERAL
A The data network active equipment system will be composed of the following items :
1. 24 Ports Access Switch [10/100/1000 POE+]

2. 48 Ports Access Switch [10/100/1000 POE+].
3. Core Switch.
4. IP-PBX.
5. Employee IP Telephone Set.
6. Utility IP Telephone Set.
7. SERVER ROOM FIREWALL.
8. INTERNET FIREWALL.
9. Router.
10. WIRELESS LAN CONTROLLER
11. WIRELESS Access Point
12. Network Management Software
Contractor
Must fill
LAN-SWITCHING NETWORK MINIMUM REQUIREMENTS this col-
umn with
comply /

Partially
comply
(indicating
deviation
or equiva-
lent fea-
tures /
items)
24 Ports Access Switch [10/100/1000 POE+] [Minimum Requirements]
 [24] Port 10/100/1000 Base-T, POE+ On Ports as per POE+ calculations.

 [ 10G-SR] SFP+ Ports.
 Switching Capacity: 128 Gbps.
 Forwarding Rate/Throughput: 95.2 Mpps.
 POE power supply: 370 Watt.
 Fully manageable edge switch
 Grounding kit.
 Console & power cords.
 All needed accessories necessary for installation.
48 Ports Access Switch [10/100/1000 POE+] [Minimum Requirements]
 [48] Port 10/100/1000 Base-T, POE+ On Ports as per POE+ calculations.

 [ 10G-SR] SFP+ Ports.
 Switching Capacity: 176 Gbps.
 Forwarding Rate/Throughput: 130.9 Mpps.
 POE power supply: 740 Watt.
 Fully manageable edge switch
 Grounding kit.
 Console & power cords.
 All needed accessories necessary for installation.
Core Switch [Minimum Requirements]
Chassis
 Minimum number of slots:4
 Line cards slots: 4
 Switch fabric module slots: Two Management modules / supervisors
 In addition to maximum number of supported fabric modules are included to provide the switch
maximum switching capacity.
 Power supply & redundant power supply: Included (Maximum number of power modules must
be supplied)
 Fan tray: Included (Maximum number of Fan tray modules must be supplied)

Modules
 48 port [ 1 / 10 GE ] [ SFP / SFP+ ] Module
 16X10G Base-SR [SFP+]
 2X10G Base-LR [SFP+]
 2X40G Base-SR4 [QSFP+]
Power Supplies
 Redundant power supply Included: YES (in all slots)
 Power supply slot: 3 slots
 Hot swappable: YES
Fans
 Fan tray / Module: Included (Maximum capacity)
 Air Flow: Front to Back
Performance
 Fabric Switching capacity: At least 1 Tbps per line card
 Forwarding rate /Throughput: At least 1 Bpps per line card
Supported Standards:
 802.3az (Energy efficiency)
 IEEE 802.1s (Multiple STP)
 IEEE 802.1w (Rapid STP)
 IEEE 802.11ac (Wi Fi)
 IEEE 802.1x (Security)
 IEEE 802.3ad (Link Aggregation)
 IEEE 802.1D Spanning Tree Protocol
 IEEE 802.1p CoS prioritization
 IEEE 802.1Q VLAN
 IEEE 802.3z 1000BASE-X specification
 OSPF
 BGP
 PIM
 IPv6 Routing
 Intermediate System-to-Intermediate System (IS-IS) Protocol
 Policy-Based Routing
 VXLAN
 BGP eVPN control plane
 Locator/ID Separation Protocol (LISP)
 Multiprotocol Label Switching (MPLS)
 Layer 3 Virtual Private Network (VPN)
 Layer 2 Ethernet over MPLS (EoMPLS)
 Layer 2 Virtual Private LAN Services (VPLS)

Accessories:
 Console cables
 Power cords
 Grounding Kit
IP-PBX [Minimum Requirements]
 IP PBX core system [40/4] internal/external line.

 Power supply & redundant power supply.
 Integration of IP telephone system.
 Integrated automatic call distribution (ACD), voice mail system
 Included gateway for external lines & fax server.
 Support all required IP telephone standards [G.711, G.729, T.37, DHCP, DCL, DNS, TCP/IP, …,
etc.]
 Supported with full manufacturer standard calling features [call forwarding, call hold, call park,
calling line ID, call transfer, call waiting, etc].
 Support PRI services, analog CO trunks, DID, digital trunks: T1/E1 and PRI/BRI (coordinated with
service provider).
 All other accessories according to operator requirements.
Employee IP Telephone Set [Minimum Requirements]
 Design: Easy to use interface.

 Display: 2-Lines 396 x 162 pixels graphical backlit display.
 Mounting: tabletop.
 Speaker: full-duplex speakerphone.
 Volume control.
 Ethernet connections: two RJ-45 ports 10/100BASE-T
 Programmable line keys: (2) minimum
 Buttons: Standard dial pad, Navigation, Select, Redial, Mute, Volume Up/Down, and Speaker-
phone
 Call features: forward, pickup, waiting, transfer, music on hold, redial, Conference, join, Time
and date display, Speed dial, Caller ID.
 Audio Codec: G.711 & G.729
 Power over Ethernet (PoE): IEEE PoE 802.3af
 Registered for using with IP-PBX server.
 License shall be included.
Utility IP Telephone Set [Minimum Requirements]
 Design: Easy-to-use interface

 Display: 2-Lines 128 x 32 pixels graphical display
 Mounting: Wall mounted, wall-mount kit should be provided for all wall mounted sets
 Volume control
 Ethernet connections: one RJ-45 ports 10/100BASE-T

 Buttons: Standard dial pad, Navigation, Select, Redial, Mute, Volume Up/Down, and Speaker-
phone
 Call features: forward, pickup, waiting, transfer, music on hold, redial
 Audio Codec: G.711 & G.729
 Power over Ethernet (PoE): IEEE PoE 802.3af
 Registered for using with IP-PBX server.
 License shall be included.
SERVER ROOM FIREWALL – [Minimum Requirements]
 Switching Capacity: NGFW Firewall throughput (With IPS & Application visibility): 10 Gbps
 Concurrent session: 1.5 Million
 New sessions per second: 56,000
 Hard drive capacity maximum capacity
 2x10GE SFP+ Ports c/w 10G-SR Transceivers & 18xGE RJ45 Ports.
 Expansion slots for future network modules accepting [ 1/10G ] [Network module not included]
 Licenses for Threat defense/prevention, Malware and URL for 3 Years
 [Power supply] [and Redundant power supply is included]
 Fan tray / Module [Maximum No of fans Included]
 [Console cables] [Power cords] [Grounding Kit]
 Service Is included for all Firewalls
INTERNET FIREWALL – [Minimum Requirements]
 Switching Capacity: NGFW Firewall throughput (With IPS & Application visibility): 5 Gbps
 Concurrent session: 700,000
 New sessions per second: 35,000
 Hard drive capacity maximum capacity
 5xGE RJ45 Ports.
 Expansion slots for future network modules accepting [ 1/10G ] [Network module not included]
 Licenses for Threat defense/prevention, Malware and URL for 3 Years
 [Power supply] [and Redundant power supply is included]
 Fan tray / Module [Maximum No of fans Included]
 [Console cables] [Power cords] [Grounding Kit]
 Service Is included for all Firewalls
Router – [Minimum Requirements]
 3x1000 Base-T Ports.

 2xSFP Ports.
 3 slots including required cards (coordinated with service provider).
 Memory: maximum memory at all memory slots.
 Power supply with redundant power supply included.
 Fan tray/modules included.
 All supported LAN/WAN protocols.

 Included power cords, console cable & grounding kit.
WIRELESS LAN CONTROLLER
 Interfaces: 2X 10 GE Ports
 Max Access point No: 1024
 Throughput: 20 Gbps
 Max No of access Users: 10,000
 Including console cables, power cords, grounding kit
 Redundant hot swappable power supply Included
WIRELESS Access Point
 Interfaces: 2x10/100/1000 Base-T autosensing (RJ45)

 Management console port (RJ45)
 1 USB ports (enabled via future software).
 Two Gigabit Ethernet links for connection with access Layer.
 Max. Throughput: 2.5Gbps
 Mounting kits and all accessories
 Power cords
 Grounding Kit
Protocols:
 802.11a/b/g/n/ac/ac wave2,
 4x4 MIMO with min. three spatial streams and shall be utilized to provide the required coverage
 Support Quality of Service and include security policies supporting WEP, WPA, 802.1X support
 Allowing detecting wireless security threats, interference and combating rogue access, Band
steering, Load balancing
 AP must support full RF Interference detection & avoidance techniques
Note:
Contractor shall add/Adjust all necessary access points including all accessories and connections to
ensure full Wi-Fi coverage.
Network Management Software
 The NMS shall be suitable to support all the LAN hardware/Software using Software defined
networking technologies including but not limited to:
 LAN switches
 Routers
 Wireless LAN controllers
 Wireless access points
 IP telephony server/appliances
 IP gateways
 Integration with the server management platform

 Required is a management platform that integrates all of the above components, with the
following characteristics:
 Centralized fault and event browser (consolidated syslog, traps, and events and alarms).
 Embedded troubleshooting workflow for quick problem isolation and remediation.
 Simple Network Management Protocol (SNMP)-based polling to identify availability and
performance issues.
 Configuration backup, software image management, compliance, and change manage-
ment required to maintain and update network devices.
 Complete and thorough inventory of equipment details - chassis, module, and interface.
 Provides a single menu for discovery status, device status, user tracking, and inventory
dashboards.
 Reports are centralized in a single menu, simplifying navigation and access to detailed re-
ports and information.
 Reports can be easily scheduled to run immediately or daily, weekly, or monthly and can
be viewed online or optionally exported to a file or comma-separated value (CSV) file.
 Dashboards provide up-to-date status on configuration, inventory, and monitoring for
troubleshooting purposes.
 The network management should collect data used to generate current and historical reports
that help network administrators to analyze the utilization and availability levels of devices
in the network for the following items:
 CPU Utilization
 Device availability
 Memory utilization
 Interface availability
 Interface utilization
 Interface error rate
 Threshold violation
 Should provide graphical interface for the while network and distribute configuration as re-
quired.
Spare parts Available on site
 5% of all Transceivers types

 5 % of Access switches of all types
 10 % Redundant power supplies for Access switches
Warranty [3 Years including SLA]
 Warranty 3 years starting from system final testing and commissioning and final acceptace tests
for the whole system including Service Level Agreement [SLA] covering:
 -Telephone tech support [8 hours x 5 days]
 -Software updates
 -Site visit including overall system check and provide maintenance report every 3 Monthes
 -Critical Spare Parts Necessary for full system operation Next Business day site delivery
Software Licenses Subscriptions that require renewal after three years to maintain full system op-
eration
Contractor must state in THE OPPOSITE CELL the details of such licesnes [if applicable] indicating
features that will be lost in case subscription is not renewed. if such licenses are not applicable con-
tractor shall type [NOT APPLICABLE] ##
PART 3 INSTALLATION


requirements.

instructions.
requirements
3.2 GROUNDING:




and inspections.





ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. MASTER ANTENNA TELEVISION
CAIRO - EGYPT SYSTEM 274133 - 2874 0

CONTENTS
SECTION 274133
MASTER ANTENNA TELEVISION SYSTEM
Page
1.1 SCOPE 2
1.6 Abbreviations & Definitions 4
PART 2 PRODUCTS 11
2.1 General 11
3.2 Grounding: 14
Master Antenna Television System Section 274133

SECTION 274133 – MASTER ANTENNA TELEVISION SYSTEM
PART 1 INTRODUCTION
1.1 SCOPE
Master Antenna Television system that shall be installed in the project as indicated in
D This section applies to the Master Antenna Television system, as indicated on


instructions.

into operation a complete Master Antenna Television system as indicated in the
to-the following:
1. Dish Antenna.
2. VHF/UHF antenna.
3. Quattro Low Noise Block (LNB).
4. IF Multi-Switch
5. TV Box
6. RG6 Coaxial Cable

complete Master Antenna Television system as per specifications and drawings.
Contractor shall develop a comprehensive Master Antenna Television system

specified herein.

F Master Antenna Television Network (MATV) shall be provided for the project by
installing satellite antenna dish farm on the roof top of the building.
G The system will be based on receiving the 4 universal satellite bands [i.e. Ku band;
H/H, H/L, V/H, V/L] via quarto type LNB and distribute them to cascaded IF multi
switch network as indicated on drawings.
H Each IT room will be provided with IF multi-switch/cascaded multi-switches as to

receive the TV signals from the satellite dishes and distribute them to tenant TV
boxes.
I Each tenant will get his own IF-receiver [intermediate frequency RX; 850 MHz – 2150
MHz] allowing to receive & modulate all satellite band channels & terrestrial
channels to be selected and viewed on the LED TV screens.



5. UL Compliance: Comply with requirements of UL 50 and UL 486A
system and wiring.
charge.
1.6 ABBREVIATIONS & DEFINITIONS

E MATV: Master Antenna Television
F VHF: Very High Frequency.
G UHF: Ultra High Frequency
H IF: Intermediate Frequency
A MANUFACTURER QUALIFICATIONS: Manufacturing firms of Master Antenna

Television system shall be regularly engaged in manufacturing of the systems of type,
size and characteristics similar to those required by the Contract for this project and
whose products have been in satisfactory service in similar projects for not less than
five (5) years.

supplier/installer.
D TRAINING:

one week.
English and Arabic.
operator.
damage.


following:

washers, etc.
works
9. Satellite dishes mounting and earthing details including concrete pads,
mounting poles,…etc.
submitted.
Engineer.

compliance.


component.
components.
the submittal


configuration.

1. Head End signal strength calculations should be provided for all TV outlet.

electrical team.


performance.
testing
following :
Engineer.
etc.).
Contract documents.
including; updated data sheets for installed equipment, operation instructions,
programming procedures Electronic circuits for every device and equipment,
troubleshooting repair guide, and the required spare parts list for 5 years of
operation, along with the circuit diagram. Selected spare parts shall be
provided without any extra cost.
Q EXTRA MATERIALS

requirements.
Agreement).

PART 2 PRODUCTS
2.1 GENERAL
A The Master Antenna Television system will be composed of the following items :
1. Dish Antenna.
2. VHF/UHF antenna.
3. Quattro Low Noise Block (LNB).
4. IF Multi-Switch
5. TV Box
Contractor Must fill this

column with comply / Par-
MASTER ANTENNA TELEVISION SYSTEM Minimum requirements tially comply (indicating
deviation or equivalent fea-
tures/items)
Dish Antenna
 Parabolic solid aluminum antenna type

 c/w fixing base, LNB and all other required accessories.
 Able to receive the digital TV channels.
 Diameter: 180 cm.
 Dish concrete base shall be strong enough to face the
wind load.
 Adjustable gain for clear reception.

VHF/UHF Antenna
 Element type used for receiving VHF & UHF local chan-
nels
 VHF range: 174 - 230 MHz
 UHF range: 470 - 862 MHz
 Maximum Gain: 7dB (VHF) & 13dB(UHF)
 Back/Front ratio: 20/20 (VHF/UHF)
 Half power beam horizontal: 49°/38° (VHF/UHF)
Quattro Low Noise Block (LNB)
 Input Frequency: 10.7 - 12.75 GHz

 Output Frequency: 950 – 5450 MHz
 Noise Figure: typical 0.7 dB
 Return Loss: > 9 dB
 Impedance: 50 Ω
 Supply voltage: 5.2 V DC
IF Multi-Switch
 Cascaded type
 Input [SAT+TERR]: 8+1
 Frequency Range TERR: 5-862 MHZ
 Frequency Range SAT: 950-2400 MHZ
 Through Loss TERR: 5.5 dB
 Through Loss SAT: 1.3 – 3.4 dB
 Subscriber Output: 24
 Gain TERR: 14dB [for active multi-switch]
 Gain SAT: 15 dB [for active multi-switch]
TV Box
 TV metal enclosure
 Including 4 port BNC types adaptor connector
 RJ6 Coaxial cable In/Out
RG6 Coaxial Cable
 Bare copper (BC) suitable for carrying power & TV signal

along the cable path
 Inner conductor: Cu blank
 Dielectric foam: PE
 Cable Jacket: LSZH
 Screening attenuation:
 > 85 dB (30-1000 MHz)
 > 90 dB (1000-2000 MHz)
 > 75 dB (2000-3000 MHz)
 Min. Attenuation:
 1.5 dB/100m at 5MHz

 6.3 dB/100m at 100MHz
 13.3 dB/100m at 400MHz
 18.8 dB/100m at 800MHz
 19.6 dB/100m at 860MHz
 30.8 dB/100m at 2150MHz
 32.8 dB/100m at 2400MHz
RG11 Coaxial Cable
 Bare copper (BC) suitable for carrying power & TV signal

along the cable path
 Inner conductor: Cu blank
 Dielectric foam: PE
 Cable Jacket: LSZH
 Screening attenuation:
 > 90 dB (30-1000 MHz)
 > 85 dB (1000-2000 MHz)
 > 80 dB (2000-3000 MHz)
 Min. Attenuation:
 0.8 dB/100m at 5MHz
 8.9 dB/100m at 400MHz
 11.4 dB/100m at 800MHz
 13.5 dB/100m at 1000MHz
 22.7 dB/100m at 2400MHz
PART 3 INSTALLATION


requirements.

instructions.
requirements
3.2 GROUNDING:




and inspections.




ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. PUBLIC ADDRESS SYSTEM
CAIRO - EGYPT 275116 – 2874 0

CONTENTS
SECTION 275116
PUBLIC ADDRESS SYSTEM
Page
1.1 SCOPE 2
PART 2 PRODUCTS 12
2.1 General 12
3.2 Grounding: 18
Public Address System Section 275116

SECTION 275116 – PUBLIC ADDRESS SYSTEM
PART 1 INTRODUCTION
1.1 SCOPE
public address system that shall be installed in the project as indicated in drawings
and relevant documents.
D This section applies to the public address system, as indicated on accompanying

layout drawings and as required by this specification.

instructions.

into operation a complete public address system as indicated in the drawings to
achieve system requirements indicated in related plans, risers, BOQ, specifications
following:
1. Audio Matrix & Controllers.

2. Power amplifiers/ preamplifiers.
3. Program sources (DVD player with AM/FM tuner).
4. Digital Message Recorder.
5. Paging Microphone/call stations
6. Ceiling Loudspeakers 3/6 watt
7. Horn Speaker 25 watt
8. Column Speaker 20 watt
9. Monitor module panel
10. Surveillance & Change over Unit
11. Volume Control.
12. PA Rack.

complete public address system as per specifications and drawings. Contractor shall
develop a comprehensive public address system including, but not limited to the
items indicated throughout the design package including specification , drawings and
BOQ

specified herein.

F The public address System shall be used to provide background music, public
announcements and voice evacuation.
G The system will be centralized where the main rack will be located. Remote
equipment will be interconnected to the central equipment to accommodate
centralizing the audio sources and to permit centralized master control of all PA
systems.
H The system design shall incorporate multiple loudspeaker circuits grouped into zones
such that volume levels can be accurately set between different areas and different
themed music content can be used to differentiate areas.
I The public Address system will be independent of the Fire Alarm system and an
interface will be provided between the PA system and the fire alarm system, in order
to mute any sound program and start the evacuation message in the event of an
alarm condition. Local civil defense codes and regulations shall take precedence.
J The Interface equipment shall be included in the public address & sound Systems to
communicate with the Fire Alarm system for receiving STOP signal in case of fire.

K Mounting/spacing of public address/Background music speakers shall meet the
approximate ambient sound levels for various types of environment.
L The objective in design of the PA system is to provide the operator with the following
facilities and features:
1. Individual zone call.

2. General call.
3. Emergency call.
4. Background music.
M Building Areas covered by the PA system shall include:-
1. Main Entrance
2. Reception
3. Lobbies & Lounges
4. Public Circulation Areas & Waiting rooms.
N Zoning:
1. The PA system will be configured into logical zones based on the building
layout and fire zones.
2. Zone wires for speakers should not exceed the maximum tolerable power
losses required by manufacturers and related codes.
3. Each alarm Zone shall be fed from and audio amplifier independently.
O All system PA speakers used for evacuation shall be fire rated type complete with fire
dome back boxes and all used sound cables shall be LSZH flame retardant type that
produce no toxic gases in case of fire as required by codes/standards.

A [The PA matrix and amplifiers shall be interfaced with the BMS for alarm and fault
statuses.]
B Contractor must follow all Monitor and control points indicated in the I/O Schedules

system and wiring
7. Testing Procedures for Protective Signaling Systems
8. BOCA National Building Code
charge.

E PAS: Public Address System.
F SPL: Sound Pressure Level.
G BGM: Background Music.
H THD: Total Harmonic Distortion
A MANUFACTURER QUALIFICATIONS: Manufacturing firms of public address system

shall be regularly engaged in manufacturing of the systems of type, size and
years.


supplier/installer.
D TRAINING:

one week.
English and Arabic.
operator.


damage.


following:
washers, etc.

works
submitted.
10. [All System cables must be approved by system manufacturer. Contractor
Engineer.
compliance.


component.
components.
the submittal


configuration.

1. Sound and noise levels provided in these specifications are for GUIDANCE and
the Contractor is responsible for measuring the noise level in all the public
areas and re-adjusts the type, power, distribution of the loud speakers and its
sound levels accordingly.
2. The contractor shall carry out an acoustic modeling and simulation to confirm
the sound level throughout the building before finalizing the speaker locations
and shall get approval from the engineer/Client before ordering the
equipment.
3. Locations of speakers indicated on the drawing are not final. The specialist
sub-Contractor shall carry out acoustic modeling and simulate to find the final-
position of the speakers in coordination with the client. Each zone shall be
individually configurable for all channels / audio sources.
4. Amplifier sizing, SPL and intelligibility calculations should be provided.

electrical team.


performance.
testing.
following :
Engineer.
etc.).
Contract documents.
Q EXTRA MATERIALS

requirements.

Agreement).
PART 2 PRODUCTS
2.1 GENERAL
A The public address system will be composed of the following items:
1. Audio Matrix & Controllers.

2. Power amplifiers/ preamplifiers.
3. Program sources (DVD player with AM/FM tuner).
4. Digital Message Recorder.
5. Paging Microphone/call stations
6. Ceiling Loudspeakers 3/6 watt
7. Horn Speaker 25 watt
8. Column Speaker 20 watt
9. Monitor module panel
10. Surveillance & Change over Unit
11. Volume Control.
12. PA Rack.

PUBLIC ADDRESS SYSTEM Minimum requirements tially comply (indicating
tures/items)
Audio matrix & Controllers
 19-inch rack mounted located inside the PA racks

tures/items)
 Size: 4/8 or 8/8 independent zone expandable
 Microprocessor based includes signal generator to pro-
duce minimum of [6] chime tones
 c/w digital sound processor (DSP)
 Modular type with input/output capacity as required
 Accept at least [4] microphones /line, [3] music source,
call stations and emergency inputs.
 c/w GUI, LCD screen and control buttons.
 Provide TCP/IP connectivity
 c/w dry contacts and software interface to be interfaced
with required systems.
 Allowing to receive command signal from fire alarm sys-
tem to mute all the paging / background music outputs
and broadcast the recorded evacuation message.
 Minimum Specs:
 Frequency response: 20 Hz to 20 KHz
 Gain control: > 55 dB
 Microphone phantom P.S: included 48 VDC
 Total Harmonic Distortion [THD]: <0.01%
 Dynamic range: >103 dB
 Temp: -10°C to +45°C
Power Amplifiers / Preamplifiers
 19-inch rack mounted located inside PA racks

 Class-D Technology
 Power as indicated on drawings with at least 20% spare
capacity.
 Monitoring circuit protection from faults, short-circuit,
over-voltage & clip-limiting.
 including dry contact for interface connection with re-
quired systems.
 Provide balanced floating output of 70V and 100V for
loudspeaker connection.
 Shall have built-in feedback suppressor
 Minimum Specs:
 Frequency response: 20 Hz to 20 KHz
 Total Harmonic Distortion [THD]: Less than 1% at
rated power output
 Noise level: -60 dB min. below rated output
 Output: 2Ω / 4Ω / 8Ω (ohms) & 70V rms / 100V rms
root mean squarer balanced line.
 Input sensitivity: matching the pre-amplifier output
and capable of full rated power.

tures/items)
 Controls: ON/OFF, input levels, bass (LF < 1000 Hz)
and treble (HF > 1000 Hz) control
 Indicators: LED indicators for power, signal and faults
Program Source [DVD player with AM/FM tuner]

 CD/DVD media player with Bluetooth receiver and
AM/FM tuner
 Frequency Response: 20Hz – 20KHz
 THD: < 0.01%
 S/N ratio: > 85 dB
 c/w remote control
 Tuner receiving range: FM (87.5 – 108) MHz, AM (522-
1620 KHz)
 Bluetooth Supported codecs: SBC, MP3, AAC, Aptx
Digital Message Recorder

 Shall have pre-recorded messages for fire alarm evacua-
tion announcement able to have at least 8 pre-recorded
message simultaneously
 shall have SD/USB recorder
 playable format: WAV, MP3 & AAC
 Frequency Response: 20Hz – 20KHz
 THD: < 0.01%
 S/N ratio: > 85 dB
Paging Microphone/Call Stations
 Located at the main reception desks or control rooms as

indicated on drawings.
 Equipped with heavy metal base with rubber feet ensur-
ing stability on any flat surface.
 Unidirectional condenser type c/w electronic chime cir-
cuit.
 c/w phantom powered with built-in pre-amplifier.
 Green LED indicator for microphone activation.
 Equipped with external call station extension for max.
no. of 15 free programmable zone number key/call
switch with all zones key switch

tures/items)
Ceiling Loudspeakers 3/6 Watt
 Ceiling flush mounting loudspeakers including back box-

es and matching transformers.
 Fire rated type c/w fire dome back box
 Power tapping: 6/3/1.5 W
 SPL/1W (4KHz)/1m: 95 dB (SPL min.)
 Frequency range: 20 Hz to 20 KHz
 Rated voltage: 100V
 Connectors: Screw terminal block
 Material: Aluminum or other approved equal
 Temp: 25°C to +55°C
Horn Speakers 25 Watt
 Wall mounting loudspeakers including back boxes and

matching transformers.
 Power tapping: 25/12.5/6.25 W
 Rated voltage: 100V
 Weatherproof IP rating: 65
 Temp: 25°C to +55°C
Column Speakers 20 Watt
 Wall mounting loudspeakers including back boxes and

matching transformers.
 Power tapping: 20/10/5/2.5 W
 Rated voltage: 70V, 100V
 Temp: 25°C to +55°C

tures/items)
Monitor Module Panel:

 Monitoring each power amplifier output by means of
view meter, indicating LEDs and built in speaker.
 Operate on 70/100 V matched with the power amplifier
output.
 shall have transformer insulated
 c/w selector switch to select required channel to be
monitored.
Surveillance and Changeover Unit:

 Automatically changeover the fault duty amplifier to the
working stand-by power amplifier.
 Modular type with sufficient input/output channel cards
to supervise all speaker zones.
 LED indicator for power, changeover, fault/ buzzer con-
trol
Volume Control:
 Transformer Attenuator
 Power tapping: 10,20,35,50,100 W R.M.S
 Rated voltage: 70/100 volt
 Steps: 6 steps
Public Address Rack [PAR]:
 19-inch rack, size (600x600mm), 36U.

 Equipped with glass door with lock & Automatic Fans.
 Equipped with bottom wheel c/w breaks
 Support front and back opening.
 c/w sliding plates and blank panels
 c/w all related accessories [power strips, earthing kit,
screws, nuts, etc]

PART 3 INSTALLATION


requirements.

instructions.
requirements

3.2 GROUNDING:




and inspections.



END OF SECTION – 275116


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. ACCESS CONTROL SYSTEM (ACS)
CAIRO - EGYPT 281300 – 2874 0

CONTENTS
SECTION 281300
ACCESS CONTROL SYSTEM
Page
1.1 SCOPE 2
PART 2 PRODUCTS 11
2.1 General 11
3.2 Grounding: 18
Access Control System (ACS) Section 281300

SECTION 281300 – ACCESS CONTROL SYSTEM
PART 1 INTRODUCTION
1.1 SCOPE
access control and integrated security management System that shall be installed in
the project as indicated in drawings and relevant documents.
D This section applies to the access control and integrated security management
System, as indicated on accompanying layout drawings and as required by this
specification.

instructions.

into operation a complete access control and integrated security management
System as indicated in the drawings to achieve system requirements indicated in
related plans, risers, BOQ, specifications and all related contract documents including
all necessary accessories to construct fully functional end-to-end integrated system
including-but not limited to-the following:
1. Access Control Server

2. Access Control Workstation
3. A4 Laser Printer
4. Card Issuing Printer
5. Intelligent Door Controller
6. Smart proximity Card Reader
7. Fingerprint Reader with Keypad for time attendance
8. Door Sensor
9. Magnetic Door Lock
10. Request to exit button
11. Emergency break glass
12. Proximity Cards

complete access control and integrated security management System as per
specifications and drawings. Contractor shall develop a comprehensive access control
and integrated security management System including, but not limited to the items
indicated throughout the design package including specification , drawings and BOQ

specified herein.

F The Access Control system is security system, which shall control access to the
building and to certain areas, as well as giving an alarm in case of unauthorized
activities in order to achieve maximum-security in the project.
G The Access Control Systems shall be IP based.
H The criteria of the system shall be based on using proximity card readers for control
access.
I The system shall be capable of saving events for extended periods of time and shall
be extendable for future extension of the project.
J Readers shall cover all service rooms (Elec. Room, Control Room, IT Rooms, etc.) and
all other areas as required by the client.
K The Access Control System shall interface with the Fire Alarm System, CCTV System
and Building Management System (BMS).

L The door controllers shall be fully stand-alone processor capable of making all access
control decisions without any involvement of host computer.
M Intelligent Door control equipment shall be used to communicate with the computer
digitally in order to relay the captured data and to control the door lock. Every door
controller shall have its own battery and power supply to feed the internal
electronics and the electronic lock as well. Door controllers shall achieve the door
capacities shown in the drawings.
N The door controller shall be provided with all necessary I/O Extension modules to
provide all necessary hardwired interfaces with other devices/systems.
O The configuration of the system operating parameters shall be in accordance with

the facility requirements.
P System operating parameters shall be protected from unauthorized changes.
Q The operation of the electronic access control system shall be in compliance with the
applicable fire and building codes.

A [The Access control server shall be software interfaced with BMS in order to report
all system status and alarms]

5. NFPA 731 - Standard for the Installation of Electronic Premises Security
Systems.
6. UL Compliance: Comply with requirements of UL 50, UL 486A, UL294.
system and wiring

charge.

E NFPA: National Fire Protection Association.
F BMS: Building Management system.
G UL: Underwriter laboratories.
H EPS: Emergency Power Supply.
I ISMS: integrated security management system.
J ACS: Access Control System.
K LPR: License Plate Recognition.
L RFID: Radio Frequency Identification.
M RTE: Request to Exit.
A MANUFACTURER QUALIFICATIONS: Manufacturing firms of access control and

integrated security management System shall be regularly engaged in manufacturing
of the systems of type, size and characteristics similar to those required by the
Contract for this project and whose products have been in satisfactory service in
similar projects for not less than five (5) years.


supplier/installer.
D TRAINING:

one week.
English and Arabic.
E Warranty: Provide warranty for the system for at least 3 Years starting from the first
operator.


damage.


following:
washers, etc.

works
submitted.
Engineer.
compliance.


component.
components.
the submittal


configuration.

1. Battery calculation to support all door controller peripheral devices including

readers, locks, sensor,…etc.

electrical team.


performance.
testing

following:
calculations, data sheets,...etc previously submitted in shop drawing stage to
Engineer.
etc.).
Contract documents.
Q EXTRA MATERIALS

requirements.
Agreement).
PART 2 PRODUCTS
2.1 GENERAL
A The access control and integrated security management System will be composed of
the following items:
1. Access Control Server
2. Access Control Workstation
3. A4 Laser Printer
4. Card Issuing Printer
5. Intelligent Door Controller
6. Smart proximity Card Reader
7. Fingerprint Reader with Keypad for time attendance
8. Door Sensor
9. Magnetic Door Lock
10. Request to exit button
11. Emergency break glass
12. Proximity Cards

ACCESS CONTROL SYSTEM Minimum requirements tially comply (indicating
tures/items)
Access Control Server
 Internationally branded (Compaq HP, IBM, DELL EMC, etc.)

with the latest state of the art hardware & software specifi-
cations at the time of purchase.
 ACS server shall include system software modules & data-
base modules which shall be used to store all relevant sys-
tem transactions, logs. Reports, etc. as per system manufac-
turer requirements.
 ACS Hardware shall be specifically designed for high reliabil-
ity, high availability and fault tolerant File Server applica-
tions. The server shall include such minimum features as dual
tures/items)
processors and hot swappable redundant components.
 Interfaced with BMS & CCTV, parking management system
and all other required system.
 ACS server shall be connected to door controller via TCP/IP
network also accept serial RS 232/485 connection via server
COM port.
 ACS software shall include but not limited to the below:
 Alarm monitoring
 GUI graphical display
 Report generation
 Anti-pass back algorithm
 Visitor assignment
 Time attendance
 Operator commands
 Database download
Access Control Workstation
 GUI terminal PC workstation with the latest state of the

art hardware & software specifications at the time of
purchase
 Performing all system monitor & control functions.
 Internationally branded GUI as per manufacturer re-
quirement.
 GUI indicating building floors graphics stored floor by
floor in a form of AutoCAD or BMP wherever suits the
system software to enable on-screen control for door
locks.
 Pre-loaded with latest state-of-art licensed software as
per manufacturer requirements.
 Customizable device icon and colors to visually represent
each event type.
 GUI terminal shall be provided with minimum 21” LED
Screen, optical mouse, full function keyboard and all re-
quired accessories.
 Operator Login/Logout/Change Password features to ac-
cess the system.
 Logs in history of any operator changes in the work-
station.

tures/items)
A4 Laser Printer
 Functions: print only

 Resolution (black): min. 1200 dpi (Dots Per Inch)
 Duty Cycle: Up to 80,000 pages
 Print Technology: Laser
 Display: Including 2-line backlit LCD graphic display
 Number of print cartridges: 1 (black)
 Paper Trays: Two
 Connectivity Standard: 1 Hi-Speed USB 2.0; 1 Host USB; 1 Gi-
gabit Ethernet 10/100/1000 Base-T Network
 Memory Standard: 256MB - DRAM
 Print Speed (black): Up to 40 ppm (pages per minute)
Card Issuing Printer
 Photo imaging color camera with video capture

 Card Design Software
 Video Badge System
 Photo-quality Laser printer
 Label printer
 Laminator
 Landscape or portrait design
 Selection of a photo from live image or file
 Up to 4 user fields can be included on the badge
 Import of company logo
 Simple drag and drop design
 Compatibility with any Microsoft windows printer
Intelligent Door Controller
 No. of Doors: (4) and/or (8) as indicated.

 Connectivity: On-board Ethernet 10/100Base TCP/IP connec-
tion
 Serial interface RS 232/485 for door controller networked
communication
 Memory: 8MB RAM
 Relay Output: 4 Form-C relay outputs, 5 A at 30 VDC
 I/O Modules: according to controlled doors
 Battery backup: Non-volatile storage of 50,000 events
 PIN Code: Up to 9-digit user PIN codes
 LED Indicator: Bicolor reader status LED support plus beeper
control, or 2-wire LED support
 Status Indicators: 2 dedicated inputs for tamper and power
failure status

tures/items)
 Door Monitoring: Door contact supervision (open/closed)
and push-button monitor for each door
 Door lock control: Strike control and auxiliary output for each
door
 Regulator: On-board regulator
 Listed: ANSI/UL 294 listed
Smart Proximity Card Reader
 Contactless smart card reader

 Producing beep buzzer for card reading indication
 Typical reader range: 10-14 cm
 Authentication: Card only
 Indicators: Multi-color LEDs and Multi-tone buzzer
 Frequency Range: 13.56 MHz full duplex operation
 Power Supply: 12VDC feed from door controller
 Display: LCD display
 Relays: Including internal relays
 IP enclosure: IP55 for indoor type & IP 65 for outdoor type
 Supported Technologies: iCLASS, MIFARE, Desfire, ..etc.
Fingerprint Reader with keypad for Time Attendance
 CPU: 533 MHz DSP

 Memory: 8MB flash + 8MB RAM
 Fingerprint Sensor: 500 dpi optical sensor
 Identification speed: 2000 match in 1 second
 Fingerprint capacity: min. 5000 finger print (allowing 2
fingerprints per user)
 Log capacity: 50,000 events
 RF reader technology: Support Mifare (13.56 MHz)
 Authentication: Fingerprint and/or PIN and/or Card
 Network interface: TCP/IP, RS485
 I/O: 2 inputs for exit switch and door sensor
 Internal relays: Including internal relays
 Indicators: Multi-color LEDs and multi-tone buzzer
 Power supply: 12VDC
 Display: LCD display
 Keypad: 3x4 Keypad, 3 navigation keys
Door Sensor
 Activating range: Switching distance: 10 mm

 Current rating: Not more than 75 mA at 24VDC
 Mounting: Recessed mount suits the door types

tures/items)
 Wire connection: Two wire connection with min. 3.5 m
long cable
 Contact Relays: N/O and N/C clean contact alarm outputs
plus tamper alarm
 Supervisory: EOL) end-of-line supervisory resistors to in-
dicate alarm status
 Alarms: Supervised inputs shall sense contact conditions
of SAFE, ALARM, and FAULT
Magnetic Lock
 Single/double door type and take its power from door

controller.
 Holding force: at least 300Kg coordinated with door
hardware
 Protection degree (IP): not less than IP44.
 Locking systems shall be installed in accordance with the
manufacturer's instructions
Request to Exit Button
 Stainless-steel switch enclosures

 Located on the egress at the secured door side
 Shall release the active door lock independently of the
access control system, in the direction of egress
 Shall be readily accessible and clearly identified by a sign
that reads “PUSH TO EXIT”
 Powered from door Controller
Emergency Break Glass
 Used to open the door in case of emergency

 Connected directly to the door lock to de-energize the
lock
 Break glass color and shape asper project ID
Proximity Cards:
 RF smart card type with operating frequency 13.56 MHz

 Construction: PVC or composite polyester/PVC construc-
tion
 Technology: Proximity cards with photo identification
capability
 Surface: Graphic quality surface for use with direct image
printer
 Size: Same size & thickness as standard credit card
tures/items)
 Reader range: Up to 12.5 cm
PART 3 INSTALLATION


requirements.

instructions.
requirements

3.2 GROUNDING:




and inspections.


END OF SECTION -281300


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. PARKING MANAGEMENT SYSTEM
CAIRO - EGYPT 281303 - 2874 0

CONTENTS
SECTION 281303
PARKING MANAGEMENT SYSTEM
Page
1.1 SCOPE 2
PART 2 PRODUCTS 11
2.1 General 11
3.2 Grounding: 16
Parking Management System (PMS) Section 281300

SECTION 281303 – PARKING MANAGEMENT SYSTEM
PART 1 INTRODUCTION
1.1 SCOPE
Parking Management System that shall be installed in the project as indicated in
D This section applies to the Parking Management System, as indicated on


instructions.

into operation a complete Parking Management System as indicated in the drawings
to achieve system requirements indicated in related plans, risers, BOQ, specifications
following:
1. Parking Management System Server

2. Parking Area Controller
3. Ultrasonic Directional Sensor
4. Master display Sign
5. Entrance terminal unit
6. Exit terminal unit
7. Long Range Card Reader [LCR]
8. Car Barrier System

complete Parking Management System as per specifications and drawings.
Contractor shall develop a comprehensive Parking Management System including,
but not limited to the items indicated throughout the design package including
specification, drawings and BOQ

specified herein.
change due to market updates. Therefore, it is the Contractor’s responsibility to

F The Parking Management System shall be provided for the project to provide
convenient & comfortable parking solution for the project.
G The system shall be designed only to alert the users if there is available parking
space/lot in the overall parking floors in the project or at any dedicated parking floor
inside the building.
H System architecture will be based on main parking management server located inside
server room and parking area controller located inside IT rooms which shall be
connected to the system server via TCP/IP network.
I The parking area controller is used for counting all vehicles entrance and exit the
facility parking, counting the number of vehicles entrance/exit and provide the
available free parking lots floor by floor on the main sign LED display located at main
entrances.
J The number of vehicles entrance or exit the project parking shall be detected via
means of underground loop detector located at each main entrance and exit lane
connected to the parking area controller along with ultrasonic directional sensor
positioned at all ramps transition from floor to another floor which will be connected
to its corresponding parking controller, providing at end that all vehicles entrance,
exit or moved from parking floor to another floor are detected and counted on the
main sign display.

K The parking area controller shall be considered as signal converter between RS-485
protocol used for connecting with system sensors/information displays and TCP/IP
protocol which is used for connecting with system server and main equipment.
L Parking system shall include also parking arm barrier and entrance/exit terminal unit
including long range RFID card reader located at all entrance/exit parking lanes
facilitating the employees and/or visitor entrance and exit to the project parking via
means of EFID tags/ car badges.

A The Parking Management System server shall be software interfaced with BMS in
order to report all system status and alarms]

5. NFPA 731 - Standard for the Installation of Electronic Premises Security
Systems.
6. UL Compliance: Comply with requirements of UL 50, UL 486A, UL294.
system and wiring
charge.


E NFPA: National Fire Protection Association.
F BMS: Building Management system.
G UL: Underwriter laboratories.
H EPS: Emergency Power Supply.
I PMS: Parking management system.
J LPR: License Plate Recognition.
K RFID: Radio Frequency Identification.
L UVSS: Under Vehicle Surveillance System.
A MANUFACTURER QUALIFICATIONS: Manufacturing firms of parking management

system shall be regularly engaged in manufacturing of the systems of type, size and
years.

supplier/installer.
D TRAINING:

one week.
English and Arabic.
operator.

damage.



following:
washers, etc.
works

submitted.
Engineer.
compliance.


component.

components.
the submittal

configuration.

1. Battery calculation to support all parking controller peripheral devices

including sensor, signage, I/O relays, etc.

electrical team.


performance.
testing
following:
calculations, data sheets,...etc previously submitted in shop drawing stage to
Engineer.

etc.).
Contract documents.
Q EXTRA MATERIALS

requirements.
Agreement).
PART 2 PRODUCTS
2.1 GENERAL
A The parking management system will be composed of the following items:
1. Parking Management System Server

2. Parking Area Controller
3. Ultrasonic Directional Sensor
4. Master display Sign
5. Entrance terminal unit
6. Exit terminal unit
7. Long Range Card Reader [LCR]
8. Car Barrier System

PARKING MANAGEMENT SYSTEM Minimum requirements tially comply (indicating
tures/items)
Parking Management System Server
 19-inch rack mounted server

 Server shall be synchronized hourly with the LAN time
server to maintain accuracy with the network time serv-
er.
 Shall be internationally branded (Compaq HP, IBM, DELL
EMC, etc.) with the latest state of the art hardware &
software specifications at the time of purchase.
 Hardware shall be specifically designed for high reliabil-
ity, high availability and fault tolerant File Server applica-
tions. The server shall include such minimum features as
dual processors and hot swappable redundant compo-
nents.
 PMS software shall provide real time monitoring of all
system status.
 PMS software acts to monitor and configure all devices
(sensors, displays, signal converters, crossing detectors).
 PMS software shall provide the capability of creating full
report of exact location by floors, areas, levels, totally
customized and about occupation and movement of ve-
hicles.
 PMS software can control a sum of areas with ultrasonic
sensors and area controllers to obtain a total counting of
a car park with covered sensors and uncovered loop de-
tectors areas.
 PMS system shall manage unlimited uncovered areas by
means of counting car at entrance and exit of aisles, are-
as, ramps, etc…

Parking Area Controller [PAC]
 Able to convert and manage information received from

sensors, display panels and crossing detectors and sent it
through TCP/IP to the network.
 intelligent device that store the information of all devices
connected at its communication line and sends that data
to the main computer for analyses and update the dis-
plays.
 Can control up to 75 equipment connected (sensor, dis-
plays, etc.)
 Controller can work standalone if the connection to main
server is down.
 Interface: RJ45 10/100 Base-T Ethernet connector to
main equipment & RX/TX RS-232 and RS-485 ports to
sensors/main display.
 Controlling at least 4 ultrasonic crossing sensors and 4
additional relays.
 LED indicators for TX & RX communication ports.
 Protocols: TCP/IP, UDP/IP, ARP, ICMP, SNMP,TFTP,
DHCP, BOOTP, HTTP and Auto-IP
Ultrasonic Directional Sensor [Crossing Sensor]
 Ultrasonic sensor is considered as vehicle flow detector in

which uses pair of ultrasonic sensors to gather information
about passing vehicles through ramps, zones and areas.
 Detection Technology: Ultrasound capsule for emission and
detection.
 Communication: Bus RS-485
 Communication baud rate: 4800 bps
 Protection level: IP44
 Connection: supply & data connector
 Including sensor cover box, microprocessor based and all re-
lated accessories
 Sensor mounting height, separation distance, installation
methods and fixation shall be according to manufacturer
recommendations.
Master Display Sign
 Technology: LED RGB SMD

 Communication: RS-485
 Communication Baud rate: 19,200 bps
 Text: 7 characters, 15-character scroll and diagram
 LED color: RGB
 Digit height: min. 120mm
 IP Protection: min. IP54
 Operating Temperature: -20°C to +60°C
 Material: Aluminum Casing
Entrance Terminal Unit c/w Thermal printer & Long Range Card Reader
[LCR]
 Aluminium or stainless steel cabinet suitable for outdoor ap-

plication
 Thermal printer with cutter for entrance unit
 LCD Display
 Long range reader
 RS232 or RS485 communication with loop detector
 Power supply unit
Exit Terminal Unit c/w receipt checker & Long Range Card Reader [LCR]
 Aluminium or stainless steel cabinet suitable for outdoor ap-

plication
 Omni-directional Laser scanner for exit unit
 LCD Display
 Long range reader
 RS232 or RS485 communication with loop detector
 Power supply unit
Long Range Card Reader [LCR]:
 Automatic vehicle identification

 Detection up to 10 m
 Protection class: IP66
 Operating frequency: 2.45 GHz / 120 KHz
 Built-in battery with lifetime up to 10 years
 Tamperproof mounting
 Operating Temp: -20 to +80°C
Car Barrier System
 Used for access control of car parking facility.

 Automatic rolling up/down the arm barrier for the en-
tered/exit vehicle/(s).
 Including barrier controller, raising arms, underground
loops/loop detector, manual reset switch & power supply
unit.
 Shall have straight raising arm with length not less than 4m
depending on each entrance/exit lanes.
 Shall be left-hand or right-hand system according to each en-
trance/exit lanes
 Color & shape as per building operator requirements.
Barrier Controller
 Barrier controller connected to parking controller through

TCP/IP connection.
 Barrier controller shall be modular type having all required
I/O interface modules allowing for connection with system
field devices/sensors (arm barriers, grounding loops, loop
detectors, etc.)
 Barrier controller shall have at least (8) digital inputs (two in-
puts per each lane), (4) relays outputs (potential, free, NO
contacts), RS-485 to TCP/IP signal converter, LED indicators &
RJ45 Ethernet port.
 Barrier controller shall be capable of sending alarm signal to
the PMS software in case of any intruder occurs or power
failure.
Underground Loop Detector
 Underground loops/loop detector shall be used to detect the

passing-through vehicles to automatically close the arm bar-
rier when leaving the entrance/exit lanes.
 Underground inductive loop detector shall be used to control
minimum of two inductive loops so as to activate a relay
when detecting a metal mass on the loop.
 Underground loop detector shall have the possibility of ad-
justing the sensitivity i.e. adjusting the pulse type during or
after detection.
Specifications:
 Barrier controller: Electronic controller with TCP/IP connec-

tion
 Motor and transmission: A.C motor with integrated thermal
overload protection
 Opening and closing time: 1.5 second for 90° motor
 Control & Alarm Input Signals: [open barrier/close barrier],
 Control & Alarm Output Signals: [barrier beam broken, barri-
er beam in final “open” position, barrier beam in final “close”
position]
 Power supply: 230 VAC / 50 Hz
 Housing: Stainless steel construction
 Arm Beam: min. 4m arm length
 Temperature range: 20°C to +60°C
 IP Protection: IP63
PART 3 INSTALLATION



requirements.

instructions.
requirements
3.2 GROUNDING:





and inspections.




ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. IP-CLOSED CIRCUIT TELEVISION
CAIRO - EGYPT SYSTEM 282300 – 2874 0

CONTENTS
SECTION 282300
IP-CLOSED CIRCUIT TELEVISION SYSTEM
Page
1.1 SCOPE 2
PART 2 PRODUCTS 12
2.1 General 12
3.2 Grounding: 19
IP-Closed Circuit Television System Section 282300

SECTION 282300 – IP-CLOSED CIRCUIT TELEVISION SYSTEM
PART 1 INTRODUCTION
1.1 SCOPE
IP-Closed circuit television system that shall be installed in the project as indicated in
D This section applies to the IP-Closed circuit television system, as indicated on


instructions.

into operation a complete IP-Closed circuit television system as indicated in the
to-the following:
1. IP Camera [Dome] [2MP] [Indoor Fixed] [Day/Night]

2. IP Camera [Dome] [2MP] [Outdoor Fixed] [Day/Night]
3. IP Camera [Wall] [2MP] [Outdoor Fixed] [Day/Night]
4. IP Camera [Wall] [2MP] [Outdoor PTZ] [Day/Night]
5. Video management Server & Software [VMS]
6. IP-CCTV Workstation
7. LED Screens
8. Keyboard with Joystick
9. Network Video Recording System – NVR

complete IP-Closed circuit television system as per specifications and drawings.
Contractor shall develop a comprehensive IP-Closed circuit television system

specified herein.

F The IPCCTV System shall be enterprise IP video security solution that provides
seamless management of digital video, audio and data through CCTV cameras across
the IP network enabling viewing and control of images from different points on the
network moreover Automatic digital recording of live video scenes shall provide user
activated, event activated, scheduled recording and video motion detection
activation including related data at locations need this function. The system is
intended for Security automated visual surveillance, alarm notification, recording
video and data for areas under observation.
G The system shall be based on digital high performance IP cameras transmitting digital
IP video signal to Digital Video management System and workstation to achieve
viewing and control of any camera image from different points at the Local Area
Network and via TCP/IP internet protocol. Signals coming from cameras shall be
routed to data switch connected to LAN backbone and stored on the network video
recorders also encoding algorithms schemes that secure no visible degradation from
PAL quality video.
H The cameras at far locations out of LAN 90 meter limiting distance, fiber optic
connections, media convertors,…etc. shall be provided wherever the cable length is
longer than 90m.
I The IP CCTV system shall display automatically, the alarm related live video scenes
and data of the detected events on selected workstations, as programmed and

configured. It shall activate recording. It shall also allow viewing real time live video
pictures.
J The IPCCTV system shall combine state-of-the art modular design and powerful user
programmable software together with versatile and flexible hardware options to
make it easy to integrate and extend the CCTV system and to be interfaced with
other security systems.
K The system shall be only programmed and configured by the authorized security
officials from the main IP CCTV workstation. Authorization to access the system
resources shall be made in levels (Administrator, Manager…etc.) as programmed.
L The system shall be supplied from the UPS source to ensure uninterrupted operation
in case of supply failure.
M The IP CCTV system shall utilize indoor/outdoor color TCP/IP network based digital
cameras. Cameras shall be controlled remotely for focus adjustment and camera
on/off. This shall be done using the appropriate software modules that run under the
management main software platform of the ISMS (Integrated Security Management
System) system and drive the cameras as configured by the ISMS server.
N The IP CCTV system shall display automatically, the alarm related live video scenes
and data of the detected events on selected workstations, as programmed and
configured. It shall activate recording. It shall also allow viewing real time live video
pictures.
O Network video recording hard drives of ample capacity shall record live video of all
cameras for archiving purposes. Various recording techniques according to
manufacturer specific solution shall be accepted according to manufacturer standard
range of products. Alarm events shall be recorded together with related data. It shall
include large amount of disk space to record for four weeks.
P Contractor is required to perform bandwidth calculations to assure that switches and

cables capacities shall handle required video traffic in the worst case scenario.
Q Contractor shall coordinate to determine the camera lens to achieve the required
field of view according to the camera locations.
R Surveillance – Power
1. Monitoring Workstations, Servers and Recording Devices will be supplied by

UPS (Uninterruptable Power Supply) power. Cameras will, in the main part,
have their power provided via POE from the converged network which is
maintained with UPS power.
S Surveillance – Transmission
1. The IPCCTV System shall utilize digital video transmission to allow IP Video
over standard Ethernet hardware. IP Video technology with Power over
Ethernet (PoE) that provides power and signal on same cable.
2. Route of fiber optic cables and scope of work from CCTV server to plot limit
with existing infrastructure services to be considered at different design stages.


A The CCTV server and network video recording systems shall be monitored by the
BMS in order to report all alarm and fault statuses.

3. Local Ministry Of Interior (MOI) requirement.
system and wiring
7. International Organization for Standardization – ISO
8. International Telecommunication Union - ITU
9. All equipment shall be manufactured by ISO 9000 certified companies.
10. CE: Conformance European
11. UL 983 Surveillance Cameras.
12. UL 2044: Standard for Commercial Closed-Circuit Television Equipment
14. NFPA-731: Standard for the Installation of Electronic Premises Security
Systems.
charge.


E CCTV: Closed Circuit Television.
F FOV: Field Of View.
G HD: High Definition.
H NVR: Network video Recorder.
I PTZ: Pan, Tilt, Zoom.
J RAID: Redundant Array of Independent Disks.
K VMS: Video Management System.
A MANUFACTURER QUALIFICATIONS: Manufacturing firms of IP-Closed circuit

television system shall be regularly engaged in manufacturing of the systems of type,
five (5) years.

supplier/installer.
D TRAINING:

one week.
English and Arabic.
operator.

damage.


following:
washers, etc.
works
9. Camera FOV and coverage pattern should be indicated on all floor plans for
each camera.

submitted.
Engineer.
compliance.


component.

components.
the submittal

configuration.

1. Storage and Bandwidth calculations.

2. Camera lens and Field of View (FOV) calculations.
3. Camera locations shown on the relevant drawings are indicative only. The
Contractor shall carry out a survey using a portable camera and a monitor to
identify the best position of each camera to achieve optimum coverage. This

survey shall be carried out once the structure is in place and before proceeding
with containment works. It is the responsibility of the Contractor to ensure
that where cameras are required, they coordinate with the positions with
lighting poles in close proximity ensuring that the aesthetics of the installations
and discreetness of the positioning is taken with the highest regard. The
cameras shall be installed to ensure the correct operation and security of the
Facility.

electrical team.


performance.
testing
following :

Engineer.
etc.).
Contract documents.
Q EXTRA MATERIALS

requirements.
Agreement).
PART 2 PRODUCTS
2.1 GENERAL
A The IP-Closed circuit television system will be composed of the following items :
1. IP Camera [Dome] [2MP] [Indoor Fixed] [Day/Night]

2. IP Camera [Dome] [2MP] [Outdoor Fixed] [Day/Night]
3. IP Camera [Wall] [2MP] [Outdoor Fixed] [Day/Night]
4. IP Camera [Wall] [2MP] [Outdoor PTZ] [Day/Night]
5. Video management Server & Software [VMS]
6. IP-CCTV Workstation
7. LED Screens
8. Keyboard with Joystick
9. Network Video Recording System – NVR

IP CCTV SYSTEM Minimum requirements tially comply (indicating
tures/items)
IP Camera [Dome] [2MP] [Indoor Fixed] [Day/Night] according to MOI

requirements [with onboard analytics]
 Image device 1/3 inch at least.

 CMOS progressive scan image sensor
 Automatic Gain Control
 Minimum illumination <or= 0.4 lux at color mode &<or= 0.08
lux at black white mode.
 IR illumination not less than 25m.
 Resolution [2 MP]
 Combatable Mega pixel lens, varifocal (3:9) or (2.8 : 12) mm
 Two simultaneous H264 /H265/MPEG-4 video streams one
of them at least - 25 F/S @Full resolution.
 The camera must conform to the ONVIF Profiles (G,S,T)
standard.
 Wide Dynamic Range Not Less Than 96 db.
 Focus: Auto/Manual Preferred.
 Support protocols; TCP/IP, UDP, UPNP, DNS, DHCP, RTP,
RTSP, NTP, IPv4/v6, SNMP, QOS, HTTP/HTTPS, SSH, SSL,
SMTP, FTP, ARP, ICMP
tures/items)
 Must support Power over Ethernet (PoE) 802.3af
 Network RJ45 Ethernet connector, Alarm In, Alarm Out
 Integrated IR LED with range of 25m.
 Multiple configurable streams in H.264 / H.265 and M-JPEG
 Up to 25/30 fps
 Day/Night Auto (adjustable), Color, Monochrome
 Alarm Inputs /Outputs: Min [ 1/1]
 Mounting kit included
IP Camera [Dome] [2MP] [Outdoor Fixed] [Day/Night]
 Ditto as above but with IP65 outdoor enclosure
IP Camera [Wall] [2MP] [Outdoor Fixed] [Day/Night] according to MOI

requirements [with onboard analytics]
 Image device 1/3 inch At least.

 CMOS progressive scan image sensor
 Auto Iris combatable Mega pixel lens, Varifocal (3:9mm)
/(2.8:12 mm)or (5:50mm).
 Minimum illumination <or = 0.4 LUX. In color (Day) <Or =
0.08 LUX at black/ white (Night).
 IR illumination not less than 25m for 3:9mm/ 2.8:12 mm lens
& 40 m for 5:50mm.
 Two simultaneous H264/H265/MPEG-4 video streams one of
them at least 25f/S @ full resolution.
 Wide Dynamic Range Not Less Than 96 db.
 Automatic White Balance.
 Support protocols; TCP/IP, UDP, UPNP, DNS, DHCP, RTP,
RTSP, NTP, IPv4/v6, SNMP, QOS, HTTP/HTTPS, SSH, SSL,
SMTP, FTP, ARP, ICMP
 Operating temperature 0 C + 50 C
 Enclosure IP 66 include fan and sun shield (if needed).
 SD memory card included with maximum capacity
 Mounting Kit included
IP Camera [Wall] [2MP] [Outdoor PTZ] [Day/Night] according to MOI re-

quirements [with onboard analytics]

tures/items)
 Image device 1/3 inch at least.
 Minimum illumination <or = 0.4 LUX. In color (Day) <Or =
0.08 LUX at black/ white (Night).
 Built In optical zoom lens not less than 30x.
 Two simultaneous H264 /H265 /MPEG-4 video streams one
of them at least - 25 F/S @Full resolution.
 Pan Angle 360° with continuous rotation.
 Tilt Angle 180°/90° with auto Flip.
 Wide Dynamic Range Not Less Than 96db.
 Automatic White Balance.
 Focus: Auto/Manual Preferred.
 Automatic Electronic Shutter.
 Supported protocols: TCP/IP, IPV4, SNMP, DHCP, IGMP,
UPNP, RSTB, QoS ..etc.
 Operating temperature 0 C + 50 C.
 Enclosure IP 66.
 SD memory card included with maximum capacity
 Mounting Kit Included
Video Management Server & Software [VMS]
 Internationally branded (Compaq HP, IBM, DELL EMC, etc.)

with the latest state of the art hardware & software specifi-
cations at the time of purchase.
 Designed for high reliability, high availability and fault toler-
ant File Server applications.
 Provide management and communications functions of the
integrated system.
 VMS shall control the CCTV system and any of the connected
equipment and devices through the LAN.
 Perform all necessary management and control functions on
the sub-server / Recording servers.
 Perform interfacing functions necessary for connection with
other related systems such as Fire Alarm system, access con-
trol system or any other related systems.
 VMS shall allow for simultaneously following operations:
 Recording Video.
 Displaying Live Video.
 Displaying Recorded Video.
 Time Lapse Recording.

tures/items)
 VMS shall not stop playback while:
 Recording.
 During live play back.
 Storing video.
 VMS shall support:
 Event based recording.
 Alarm activated recording.
 Customizable alarm specific recording.
 The above and/or recording continuously 24hrs a day.
 VMS shall include video motion detection module that can
monitor all the camera inputs in real time including se-
lectable regions of different sensitivities and ambient condi-
tions for motion trigger in any view.
 VMS software shall include configurable modules for opera-
tion, monitoring, reporting, alarm inputs /outputs and alarm
event recording
 VMS software should be connected to a LED monitor for full
control (record- play back- viewing) on control room.
 VMS Client software must be delivered for user’s work-
stations for full accesses to the system (live view – play re-
cording data – camera control, etc.
 VMS software should be supplied with Network Time Proto-
col (NTP) server.
IP-CCTV Workstation
 Latest state of the art hardware & software specifications at

the time of purchase
 c/w with two dual video card for 4x40” LED screens connec-
tions.
 Processor 3.4 GHz Intel Core i7 at least.
 Internal Memory 16 GB RAM at least.
 Video System graphics card with suitable of MB video RAM
1280 x1024 display resolution, and application programming
interface.
 True color (32-bit), digital video outputs.
 Video standard 1920X1080.
 Video decoding H264 /H265/MPEG-4.
 Video outputs DVI +HDMI.
 Full function keyboard and 3D optical mouse.
 PTZ Interface: On-screen.
 DVD Drive.
 Interface Gigabit Ethernet RJ-45 port, (1000Base-T).
 Auxiliary Interfaces USB 2.0.

tures/items)
 Supporting features:
 PTZ Control manually for Pan/tilt/Zoom
 PTZ Preset option with home positions for alarm activa-
tion
 Alarm trigger control
 PTZ multiple tours
 Automatic Zoom lens adjustment
 Controlling camera menu and setup
LED Screen
 Size: 40 or 42 Inch LED Screen as indicated

 Design: Flat Monitor Slim Design
 Resolution: 1920 x 1080 (Full high Definition, FHD)
 Aspect Ratio: 16:9
 Contrast Ratio: Not less than 1000:1
 Brightness: 250 cd/m²
 Power Supply: 220VAC / 50Hz
 Connectors: DVI/VGA, HDMI Interface, RJ45 & USB Inter-
face
 Speakers: Built-in speakers
 Mounting: Mounting Kit ( wall & tabletop)
Keyboard with Joystick
 Joystick Control of PTZ Functions.

 Preset Position and Pattern Control.
 Desktop keyboard with full switching and programming
capabilities.
 Backlit keys & easy-to-read Displays.
 Multilingual Support.
 Function keys: at least 8 keys
 Ports: USB
 Power: via USB interface
 Compatible with the operating software
Network Video Recorder [NVR]
 Manage and record all video streams from all IP-CCTV

cameras with the indicated recording specifica-
tions/durations.
 Standard 19” rack mounted
 Digitally recorded simultaneously information supplied
from the CCTV camera sources via TCP/IP connections.
 Provided with required storage media as per manufac-

tures/items)
turer standard such as Hard Disk Storage Array, Storage
Area Network (SAN Storage), Network Video Recorder
(NVR) or Network Attached Storage (NAS).
 Support RAID5 redundant storage protocol.
 NVR shall simultaneously record video, display live video,
and display recorded video.
 Video operations shall not stop the other recording func-
tions [playback, live viewing, or storage of video].
 Support event-based recording
 Continuous recording on 24- hours basis.
 The system should be supplied with Network Time Pro-
tocol (NTP) server.
 Recording Capabilities shall be according to MOI re-
quirements for at least 30 days continuously with 25 FPS
at full resolution for each camera.
PART 3 INSTALLATION


requirements.


instructions.
requirements
3.2 GROUNDING:





and inspections.


END OF SECTION - 282300


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. INTELLIGENT ADDRESSABLE FIRE
CAIRO - EGYPT ALARM SYSTEM 283100 - 2874 0

CONTENTS
SECTION 283100
INTELLIGENT ADDRESSABLE FIRE ALARM SYSTEM
Page
1.1 SCOPE 2
1.6 Sequence Of Operation 6
PART 2 PRODUCTS 15
2.1 General 15
3.2 Grounding: 23
Intelligent Addressable Fire Alarm System Section 283100

SECTION 283100 – INTELLIGENT ADDRESSABLE FIRE ALARM SYSTEM
PART 1 INTRODUCTION
1.1 SCOPE
intelligent addressable fire alarm system that shall be installed in the project as
D This section applies to the intelligent addressable fire alarm system, as indicated on

instructions.

into operation a complete intelligent addressable fire alarm system as indicated in
the drawings to achieve system requirements indicated in related plans, risers, BOQ,
to-the following:
1. Main Fire Alarm Control Panel

2. Satellite Fire alarm control panel
3. Repeater Panels
4. Graphical User Interface (GUI)
5. Event printer
6. Automatic telephone dialer
7. Automatic addressable Multi-Sensor detectors
8. Automatic addressable Fixed Heat detectors
9. Conventional Smoke detector
10. Conventional Heat detector
11. Projected beam detector
12. Addressable Manual fire-alarm station (indoor/outdoor)
13. Notification Appliances (Siren & Strobe)
14. Fire Alarm Interface Unit (IFU)
15. Addressable monitor module (indoor/outdoor)

16. Addressable control module (indoor/outdoor)
17. Addressable Zone Monitor Module
18. Fire fighter telephone
19. Telephone control module
20. Signal control module
21. Fire Alarm Cables
complete intelligent addressable fire alarm system as per specifications and
drawings. Contractor shall develop a comprehensive intelligent addressable fire
alarm System including, but not limited to the items indicated throughout the design
package including specification, drawings and BOQ

specified herein.
change due to market updates. Therefore, it is the Contractor’s responsibility to

F Intelligent Addressable fire alarm system, with automatic sensitivity control of

certain smoke detectors and multiplexed signal transmission, dedicated to fire-alarm
service only shall be provided.
G The system shall be a fully intelligent microprocessor based system that can
supervise space status and self-adjust its sensitivity in analogue form according to the
environmental conditions of the place and to address electronically every part of the
system to report its status, and to easily identify the source of fire.

H The Fire Alarm System shall be suitable for type of occupancy as defined by the local
building code and as required provided by the local fire Authority and by the
international codes.
I The Fire Alarm System shall be used to detect early start of fire and initiate the
appropriate annunciation, alarm, interlocking and counter measures commands as
described in this section.
J The Fire Alarm System shall supervise all the functions of the equipment and devices
including the connected safety related systems such as firefighting, smoke purge, etc.
K Fire alarm system shall be a fully addressable loop powered system. All fire alarm
devices should be loop powered for direct connection to the 2 core detection loop.
L All fire alarm devices should have built in short circuit line isolator provided as an
integral component to protect the system.
M Detectors on a remote location such as above false ceiling should be provided with
individual LED unit sited on a visible location by means of 2 core wire connection.
N The maximum covered area of one loop should not exceed manufacturer’s
requirements.
O All addressable fire alarm panels shall have alpha numeric display.
P Audible warning devices used for fire alarm system should have similar sound and be
distinct from any other audible alarm use for other purpose except in noisy areas
where high performance sounder is required.
Q The notification appliances including alarm sirens and strobe lights shall be located as
required to achieve acceptable audibility in all areas of the building.
R All FACPs serving different areas shall be connected to MFACPs by way of ring
networking cable. All message from panels should be transmitted in both directions
on the ring structure. Any wire-break or short circuit on the ring shall not affect data
transmission. The network shall be configured so that single panel, group of panels or
all panels on the network operate the same site configured cause and effect fire plan.
The network shall also be configured to allow master control from any one of the
control panels on the network.
S The contractor shall ensure that the fire sounder achieving 15 dB above ambient
noise in all areas & new redistribution of the bells will be approved accordingly.
T Fire extinguishing control panels (CP) shall be provided with built in programmable
relays.
U MFACP system shall be interfaced with access control system, public address system,
elevator control panel, firefighting and fire suppression system, HAVC, mechanical
systems and BMS system.
V Communication loop between MFACP and Satellite FAPs must be via SMFO cables or
as per system manufacturer specific communication requirements. Contractor shall
provide main fire alarm control panel & satellite panels with required fiber optic

communication cards allowing for linking all satellite panels to the MFACP as per
indicated on system layout drawings & risers.
W THE COMMUNICATIONS LINK BETWEEN SUB-PANELS
1. All control panels shall be inter-connected by a network, which usually serves

as a data highway.
2. The panels shall be interconnected in “loop” topology.
3. The communications link between sub-panels should be continuously
monitored.
4. A fault on the communications link between sub-panels should not affect the
operation of any sub-panel.
5. There will be no loss of communication to any sub-panel in the event of a
single open or short circuit on the communication loop.
6. All FACPs serving different areas shall be connected to MFACPs by way of ring
networking cable. All message from panels should be transmitted in both
directions on the ring structure. Any wire-break or short circuit on the ring
shall not affect data transmission. The network shall be configured so that
single panel, group of panels or all panels on the network operate the same
site configured cause and effect fire plan. The network shall also be configured
to allow master control from any one of the control panels on the network.
7. Communication loop between main and sub control panels must be standard
communication protocol as per system manufacturer specific communication
requirements.

A The Main Fire Alarm Panel shall have a data port to enable the transfer of
information to the Management level Network of the BMS. The communication shall
be uni-directional from the Main Fire Alarm Panel to the Management Level Network
only.
B The start and end of any message shall be uniquely identified and the message shall
indicate time, date, and zone of incidence, also indicating whether the fire alarm
system return to normal of fire alarm fault. In the event of a fire, the fire alarm
system shall communicate a list of all equipment shut down and start by fire alarm
system.
C There shall be no transfer of data from the Management Level Network of BMS to
the Fire Alarm System.
D The Fire Alarm System shall automatically shut down all terminal that serve the zone
of incidence in the event of a fire alarm and the BMS shall automatically restart
equipment following a return to normal message from the fire alarm system.

E All control functions of subsystems are soul responsibility of those systems control
panels such as firefighting panels, MCC panels, elevator panels…etc. All other
subsystems panels that are performing life safety controlling and monitoring
functions must be manufactured, installed, tested and approved according to related
fire codes and standards.
F The Fire Alarm System shall be fully interfaced with the Building Management System
(BMS) by means of software to monitor various points in the system. The BMS shall
receive all events, actions and reports from the MFACP through the appropriate
protocol. The protocol converter and software shall be included with MFACP, so as to
be fully compatible with the BMS. All addressing information must be transferred
between the systems and shown on Both Graphical interfaces showing the building
layout indicating the exact location of the monitored and controlled points alarms
and operation.
G Contractor must follow all Monitor and control points indicated in the I/O Schedules
attached to the Building management system specifications.
1.6 SEQUENCE OF OPERATION
A The system shall be interfaced with the following systems to achieve the integration
sequence of operation indicated below:
1. Fire-alarm signal initiation shall be by one or more of the following devices:
a. Manual stations.
b. Heat detectors.
c. Multi detectors.
d. Duct smoke detectors.
e. Verified automatic alarm operation of multi detectors.
f. Monitor Modules over any other System.
2. Fire-alarm signal shall initiate the following actions:
a. Continuously operate alarm notification appliances.

b. Identify alarm at fire-alarm control unit and repeater panel.
c. Transmit an alarm signal to the remote alarm receiving station.
d. Unlock electric door locks in designated egress paths if there is any
e. Release fire and smoke doors held open by magnetic door holders.
f. Activate voice/alarm communication system.
g. Switch heating, ventilating, and air-conditioning equipment controls to
fire-alarm mode.
h. Activate smoke-control system (smoke management) at firefighter smoke-
control system panel (If any).
i. Allow for manual override for smoke control system via HVAC dedicated
smoke control panel (If any).
j. Activate stairwell and elevator-shaft pressurization systems.
k. Close smoke dampers in air ducts of designated air-conditioning duct sys-
tems.
l. Recall elevators to primary or alternate recall floors.
m. Activate emergency lighting control.
n. Activate emergency shutoffs for gas and fuel supplies.
o. Record events in the system memory.
p. Record events by the system printer.
q. Sending Alarm Messages to the Fire Brigade Unit using the Auto Dialer.
3. Supervisory signal initiation shall be by one or more of the following devices

and actions:
a. Valve supervisory switch.

b. Low-air-pressure switch of a dry-pipe sprinkler system.
c. Elevator shunt-trip supervision.
d. Flow supervisory switch.
e. Sprinkler system Tamper switch.
f. Firefighting panels auxiliary contacts.
g. Water Level switches.
4. System trouble signal initiation shall be by one or more of the following

devices and actions:
a. Open circuits, shorts, and grounds in designated circuits.

b. Opening, tampering with, or removing alarm-initiating and supervisory
signal-initiating devices.
c. Loss of primary power at fire-alarm control unit.
d. Ground or a single break in fire-alarm control unit internal circuits.
e. Abnormal AC voltage at fire-alarm control unit.
f. Break in standby battery circuitry.
g. Failure of battery charging.
h. Abnormal position of any switch at fire-alarm control unit or annunciator.
i. Fire-pump power failure, including a dead-phase or phase-reversal condi-
tion.
5. System Trouble and Supervisory Signal Actions: Initiate notification appliance

and annunciate at fire-alarm control panels and repeater panels. Record the
event on system printer.
1. National Fire Protection Association (NFPA):
a. NFPA72: National Fire alarm code

b. NFPA101: Life Safety Code
c. BS5839: British Standard

3. Local safety Standard.
4. Standards of local Authorities having jurisdiction.
5. Under writer Laboratories (UL).

charge.
A TGB: telecommunication grounding busbars
B TMGB: telecommunication main grounding busbar

E AHJ : Authorities having jurisdiction
F LED: Light-Emitting Diode.
G NFPA: National Fire Protection Association.
H BS: British Standard.
I LPCB: Loss Prevention Certification Board
J VDS: Verand der Schadversicherer
K FACP: Fire Alarm Control Panel.
L BMS: Building Management system.
M UL: Underwriter laboratories.
N GUI: Graphic User Interface.
O EPS: Emergency Power Supply.
A MANUFACTURER QUALIFICATIONS: Manufacturing firms of intelligent addressable

fire alarm system shall be regularly engaged in manufacturing of the systems of type,
five (5) years.


supplier/installer.
D TRAINING:

one week.
English and Arabic.
operator.


damage.


following:

washers, etc.
works
softcopy and hardcopy formats. No of copies shall be according to contract
submitted.
10. [All System cables must be approved by system manufacturer. Contractor
12. The submitted BOQ must be mapped to ECG BOQ. i.e. Each item in ECG BOQ
requirements of ECG BOQ item. this shall include all hardware and software

Engineer.
compliance.


component.
components.
the submittal


configuration.

1. Provide calculations to support the size of stand-by batteries for the

emergency power supply.
2. Provide voltage drop calculation of the DC lines to indicate the no. of audible
alarms and visual strobe lights per each circuit.
and abide by all requirements in project documents (specifications, drawings, BOQ,

team.


performance.
system operation with its full capacity, are considered in the contractor scope
of work without any extra fees.
testing
P Close out documents: Required documents shall include but not limited to the
following:
calculations, data sheets… etc. previously submitted in shop drawing stage to
Engineer.
etc.).
and technical data sheets of installed equipment, devices…. etc. Final originals
Contract documents.
including; updated data sheets for installed equipment, operation instructions,
programming procedures Electronic circuits for every device and equipment,
troubleshooting repair guide, and the required spare parts list for 5 years of
operation, along with the circuit diagram. Selected spare parts shall be
provided without any extra cost.
Q EXTRA MATERIALS


requirements.
Agreement).
PART 2 PRODUCTS
2.1 GENERAL
A The intelligent addressable fire alarm system will be composed of the following
items:
1. Main Fire Alarm Control Panel

2. Satellite Fire alarm control panel
3. Repeater Panels
4. Graphical User Interface (GUI)
5. Event printer
6. Automatic telephone dialer
7. Automatic addressable Multi-Sensor detectors
8. Automatic addressable Fixed Heat detectors
9. Conventional Smoke detector
10. Conventional Heat detector
11. Projected beam detector
12. Addressable Manual fire-alarm station (indoor/outdoor)
13. Notification Appliances (Siren & Strobe)
14. Fire Alarm Interface Unit (IFU)
15. Addressable monitor module (indoor/outdoor)
16. Addressable control module (indoor/outdoor)
17. Addressable Zone Monitor Module
18. Signal control module
19. Fire Alarm Cables
read in conjunction with all design package documents (specification, BOQs...etc)


FIRE ALARM SYSTEM Minimum requirements tially comply (indicating
tures/items)
Main Fire Alarm Control Panel [MFACP]
 Intelligent Addressable
 Loops as per drawings [loop must have 20% spare]
 Interface communication cards
 Listed for smoke control, [UL 864] [Or equivalent Standards]
 [Modular] [Microprocessor based] [LED display]
 [RJ45 Ethernet Network interface] [RS 484] [RS323] [FO
communication]
 [UL Listed Backup battery 24 Hour in standby mode and 15
Min in system full alarm mode] [Battery charger] [Battery
monitoring system-provide battery status and alarm].
 I/O points on the panel for hardwired interfaces.
 Not less than 5000 Events in memory
 Grounding kit
 Power supply panels
Satellite Fire Alarm Control Panel [SFACP]
 Operate in a network configuration with the M-FACP

 Shall operate independently if communication fail between
MFACP & Satellite FAPs.
 Exchange data and commands with the M-FACP and other
satellite panels of the system.
 Include all necessary hardware and software required to
function as specified and according to the code require-
ments.
 Central processing unit (CPU) as in the M-FACP
 Communication interfaces
 Display and control unit
 Emergency power supply (EPS) C/W batteries
 Software Operating System including all necessary modules
(communication interfaces, etc.)
Repeater Panel
 Repeater panels shall be connected to the FACP and installed

as indicated on drawings.
 Repeater panels shall display all the status indicated on the
FACP.

 Repeater panels shall include LEDs, LCD and any other re-
quired indicating facility and buttons.
Graphical User Interface (GUI)
 GUI terminal shall be connected directly to the fire alarm

control panel (FACP) located inside the control room.
 GUI terminal hardware and software specifications shall be
according to the system manufacturer requirements.
 UL listed and approved to be used with the fire alarm sys-
tem.
 The building graphics shall be stored floor by floor in a form
of AutoCAD or BMP whatever suits the system software.
 GUI shall Have graphic editing modes for on-site program-
ming of floor plan screens, device icon, functional and navi-
gation buttons.
 GUI terminal shall be provided with minimum 23” LED
Screen.
 GUI terminal shall be provided with operator Log-
in/Logout/Change Password features to access the system.
 FACP shall be interfaced with the GUI terminal so as to if any
alarm initiated, the corresponding layout or map shall be ac-
tivated on the PC screen with initiated device flashing.
Event Printer
 Dot matrix type

 UL listed and approved to be used with the fire alarm sys-
tem.
 Not less than 1000 events stored in memory
 Real time event printing once the event happens
 Hardcopies of records of all system activities including [Un-
scheduled events] [ operator Acknowledgement] [Operator
commands] [all system alarms] [supervisory conditions]
[Fault and trouble conditions] [All system troubles]
 All records must be time stamped
 At least one (1) paper roll should be supplied with printer.
Automatic telephone Dialer
 Message length shall not be less than (50) seconds

 Transmit pre-recorded message to 4 phone numbers
 Message test speaker and a message test switch.
 Battery backup operation
 programmable
 Include Analog terminal adapter [ATA] [Analog to IP ]
Multi-Sensor Detector -Intelligent addressable-microprocessor based
 Integrated Photoelectric Smoke sensor, and (+57°C)

Fixed-Temperature Heat Sensing Elements.
 Integrated detection algorithms.
 Built-in microprocessor.
 Built-in Fault isolation.
 Bicolor (green/red) status LED
 Standard detector base plug-in type with screw terminals
Addressable Multi-Sensor Detector above false ceiling
 Multi-Sensor detectors located above false ceiling, under

raised floor, in floor voids or at any other invisible areas
shall have terminal output to be connected with remote
LED indicator.
 The remote LED indicator shall be located in a visible lo-
cation such as public corridors, passageways to be clearly
viewed by the fire alarm personal.
 The Remote LED flashing shall be latch when the associ-
ated device is in an alarm or trouble mode.
 The lamp in the remote LED should be flush mounted in
a single gang wall plate.
 The remote LED indicator plate should have engraved
red letters indicating “Remote Fire Detectors”
Addressable Multi-Sensor Detector wall mounted
 Wall mounted Multi-Sensor detectors shall be located in

elevator shafts and it should be installed maximum every
three floors.
Fixed Heat Detector-Intelligent addressable-microprocessor based
 Intelligent addressable Fixed Heat Detector (FHD)

 Heat detectors shall be classified as to the temperature
of operation and marked with a color code in accordance
with NFPA72 requirements.
 Fixed-Temperature Type: Actuated by temperature that
exceeds a fixed temperature of 57°C + 5°C.
 Mounting: Twist-lock base interchangeable with smoke-
detector bases.
 Integral Addressable Module: Arranged to communicate
detector status (normal, alarm, or trouble) to fire-alarm
control unit.
 Built in isolator capability.
Conventional Smoke detector
 Photoelectric Conventional smoke sensor.

 Integrated detection algorithms.
 Built-in Fault isolation.
 Bicolor (green/red) status LED
 Standard detector base plug-in type with screw terminals
Conventional Heat detector
 Conventional fixed type heat detectors.

 Fixed-Temperature Type: Actuated by temperature that
exceeds a fixed temperature of 57°C + 5°C.
 Mounting: Twist-lock base interchangeable with smoke-
detector bases.
 The detector shall communicate with the control unit us-
ing an addressable zone monitor module.
Projected Beam Detector:

 Complete with transmitter & receiving unit.
 IR Infrared light beam technology between TX & RX unit.
 Alarm sensitivity: adjustable 25%, 35% and 50% thresh-
old.
 Powered from FACP.
 Alarm & trouble signal via relay contact.
 Detection distance [100mx15m - LxW].
 Monitor continuously changes in sensitivity due to envi-
ronmental effects of dirt, smoke & temperature.
 LED normal status indicator.
 Installation as per manufacturer recommendations.
Addressable Manual Station
 Addressable.
 Double actions
 Tamper resistant
 Reset Key lock
 LED Indicator
 Built-in Fault isolation module.
 Operable part of a manually actuated alarm initiating de-
vice shall be ranging from 1.10m to 1.40 m from the fin-
ished floor as per local fire alarm code.
 Manual fire alarm boxes shall be located within 5ft
(1.5m) of each exit doorway on each floor.
Addressable Manual station - Outdoor
 Same specs as the manual station.

 Minimum IP 65
Strobe light
 Field Configurable 15/30/75/110cd strobe output

 Flash Rate: one flash per second (minimum).

 Lens type: Xenon strobe lights with clear or nominal
white polycarbonate lens
Strobe light - Outdoor
 Same specs as the strobe light.

 Minimum IP 65
Siren
 Multi-tone Electric type with selectable high/low dB out-

put
 Sound-pressure level up to 95 dBA,
 Sound level shall be at least 15 dB above the average
ambient sound level or 5 dB above the maximum sound
level having a duration of at least 60 seconds.
Siren -Outdoor
 Same specs as the siren.

 Sound-pressure level up to 110 dB
 Minimum IP 65
Fire Alarm Interface Unit (IFU)
 Fire Alarm Interface Unit (IFU’s) shall be used in all core

& shell areas.
 Fire Alarm Interface Unit (IFU’s) shall perform all monitor
& control functions between tenant fire alarm system
(Tenant FAS) and landlord fire alarm system (Landlord
FAS).
 Fire alarm interface unit (IFU’s) shall be addressable type
consist of groups of monitor / control modules to per-
form monitoring and control functions between tenant
FAS & landlord FAS.
 The landlord FAS shall be capable of issuing commands &
receive alarms to/from the tenant FAS via the fire alarm
interface unit (IFU’s).
Addressable Monitor Module
 Addressable
 Two (2) state alarm or supervisory signals.
 Built-in Fault isolation module
 LED indicator

Addressable Monitor Module-Outdoor
 Same as monitor module specs.

 Minimum IP 65
Addressable Control Module
 Addressable.
 Interfacing circuits.
Addressable Control Module-Outdoor
 Same as control module specs.

 Minimum IP 65
Addressable Zone Monitor Module
 Addressable zone monitor modules shall be provided to

connect one supervised zone of conventional 2-wire de-
tectors or alarm initiating devices (any N.O. dry contact
device).
 Each Zone monitor module shall connect one supervised
zone with maximum no. of 15 conventional 2-wire detec-
tors per module.
 Device shall be equipped with Indicator LED that shall
flash under normal conditions, indicating that the moni-
tor module is operational and in regular communication
with the control panel.
Fire Fighter Telephone
 Handset shall be enclosed in a cabinet with red powder-

coat finish, break glass and lockable door which allows
access by breaking the glass if the key is not available.
 Unit includes Push-to-talk switch on the telephone hand-
set.
 LED Indication for connection with Master station.
 Durable security types armored cable.
Telephone Control Module
 Support up to two firefighter telephones

 Direct dial entry of address from 01-159
 Normal or up-normal LED indication
 15 to 32 Vdc, 7.5mA maximum with LED on.
 Automatically identify itself to the control panel.
 UL listed & FM approval
Signal Control Module (if strobe and sirens are not addressable)
 Addressable
 Operate audible and visible signal appliances.
Fire alarm cables

 Fire alarm cables Flame retardant - 105ºC –Overall Shielded –
Minimum 1.5 mm2 for loop cables & 2.5 mm2 for DC Circuits.
 Communication cables between control panels according to system
manufacturers requirements [Copper & fiber are accepted] [Commu-
nication module shall be coordinated with cable type]
Note:
Letter from fire alarm system Manufacturer approving used cables
and system calculations must be submitted by the contractor for the
Engineer Approval.
PART 3 INSTALLATION


requirements.

instructions.
requirements
3.2 GROUNDING:





and inspections.




ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. DISABLED ALARM SYSTEM
CAIRO - EGYPT 283101 - 2874 0

CONTENTS
SECTION 283101
EMERGENCY CALL SYSTEM FOR DISABLED PERSONS
Page
1.1 SCOPE 2
PART 2 PRODUCTS 11
2.1 General 11
3.2 Grounding: 14
Disabled Alarm System

Urbanium New Administrative Building (Prj. 2874) Section 283101
Page 1 of 15
SECTION 283101 –EMERGENCY CALL SYSTEM FOR DISABLED PERSONS
PART 1 INTRODUCTION
1.1 SCOPE
Disabled Persons Emergency Call System that shall be installed in the project as
D This section applies to the Disabled Persons Emergency Call System, as indicated on

instructions.

into operation a complete Disabled Persons Emergency Call System as indicated in
the drawings to achieve system requirements indicated in related plans, risers, BOQ,
to-the following:
1. Disabled Alarm Control Panel

2. Floor controller
3. Pendant Pull Cord with two red bangles
4. Wall Mounted Reset Switch
5. Siren with Strobe

Page 2 of 15
complete Disabled Persons Emergency Call System as per specifications and
drawings. Contractor shall develop a comprehensive Disabled Persons Emergency
Call System including, but not limited to the items indicated throughout the design
package including specification , drawings and BOQ

specified herein.

F The Disabled Emergency Call Systems are facilities that shall be used by disabled
persons in emergency cases.
G A Disabled Toilet Emergency Call System shall be used inside all Disabled Toilets.
H Pulling a pull cord by a disabled person shall initiate an alarm led in the main control
panel and a led in the remote alarm indicator located outside the toilet.
I Upon dealing with the emergency case, a reset button inside the toilet can reset the
system to its normal operation.
J Operation of a call initiation station or pendant shall cause a call assurance

indication. The indication shall be audible and visual.
K An emergency call shall only be reset/canceled at the call initiation station or

pendant from which the emergency call was placed.
L The emergency call system shall be electrically supervised so that loss of AC power
will result in an audible and visual trouble indication at the control panel.
M The system shall be equipped with secondary power, or terminals or leads for the
connection of secondary power (batteries).
N The capacity of the secondary power (batteries) shall be sufficient to operate the
system at 10% of its maximum signaling capacity for the time specified in the
manufacturer’s installation instructions.

Page 3 of 15
O The System shall allow for Full Monitoring for Power Supply failure, Backup Battery
and Call Stations Fault.
P With secondary power connected, neither loss nor restoration of the primary voltage
source shall cause the indication of an off-normal condition.
Q There shall be no loss of emergency call signals while a signaling unit is energized by a
secondary power source.
R A trouble signal shall be distinguishable from all emergency call signals and shall be
indicated by operation of a sounding appliance.
S Momentary power failures and subsequent power restorations shall not render the
equipment inoperative for any of its functions.

A [All systems alarms and faults shall be reported to the BMS.

requirements of NFPA 70 "National Electrical Code".
5. UL Compliance: Comply with requirements of UL-2560 “Emergency Call
Systems”.
charge.

Page 4 of 15
1.7 ABBREVIATIONS & DEFINITIONS :
A TGB: telecommunication grounding busbars
B TMGB: telecommunication main grounding busbar

A MANUFACTURER QUALIFICATIONS: Manufacturing firms of Disabled Persons

Emergency Call System shall be regularly engaged in manufacturing of the systems of
type, size and characteristics similar to those required by the Contract for this project
and whose products have been in satisfactory service in similar projects for not less
than five (5) years.

supplier/installer.
installations indicating, location P/N and Quantities of installed items .
D TRAINING:

one week.
Page 5 of 15
English and Arabic.
operator.

damage.



Page 6 of 15
following:
washers, etc.
works
Page 7 of 15
submitted.
specifications document) with project approved vendor list . Any deviations
Engineer.
compliance.


component.
components.

Page 8 of 15
the submittal

configuration.

1. Provide calculations to support the size of the backup batteries for the
emergency power supply.
2. Provide calculation of the DC lines to indicate the no. of audible alarms and
visual strobe lights per each circuit.

Page 9 of 15

team.


performance.
testing
P Close out documents: Required documents shall include but not limited to the
following :
Engineer.
etc.).
Page 10 of 15
Contract documents.
Q EXTRA MATERIALS

requirements.
Agreement).
PART 2 PRODUCTS
2.1 GENERAL
A The Disabled Persons Emergency Call System will be composed of the following
items:
1. Disabled Alarm Control Panel

2. Floor controller
3. Pendant Pull Cord with two red bangles
4. Wall Mounted Reset Switch
5. Siren with Strobe

Page 11 of 15

DISABLED ALARM SYSTEM Minimum requirements tially comply (indicating
tures/items)
Disabled Alarm Control Panel
 Modular Central control unit c/w backup battery, multi-color

LED indicators, Switches for each Call Station / Pull Cord
 Loop connection to call point
 Audible and visual trouble indicator for power failure
 Full monitoring for Power Supply failure, Backup Battery and
Call stations faults.
 Unit shall be UL listed & BS approval
Floor Controller
 Input: 16 alarm zone

 Output: Alarm acknowledge
 2x RS485 bus connection
 Networked together up to 256 zones expandable
Pendant Pull Cord with Two Red Bangles
 Ceiling mounted installed inside the toilet cubic (one meter

beside the toilet bowl)
 Consist of 4m cord with two red, circular bangles
 Visual indicator (LED) for call activation.
 Activate the sounder/strobe alarm and raise an audible and
visual alert at the remote Control Panel
 Unit shall be UL listed & BS approval.
Wall Mount Reset Switch
 Mounted at 1.2 m from F.F.L.

 Illuminates when the call is activated
 Alarm is reset when pressing the reset button
 Unit shall be UL listed & BS approval.

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Siren with Strobe
 Stainless steel plate mounting outside the detection area

 Activated by the control panel and remains active until
alarms have been released
 UL listed & BS approval
 Siren: min. 60 dBA at one meter
 Strobe light: steady, flashing or pulsing every 10 seconds
PART 3 INSTALLATION


requirements.

instructions.
requirements
Page 13 of 15
3.2 GROUNDING:




and inspections.

Page 14 of 15


Page 15 of 15

ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. WATER LEAK DETECTION SYSTEM
CAIRO - EGYPT 283600 – 2874 0

CONTENTS
SECTION 283600
WATER LEAK DETECTION SYSTEM
Page
1.1 SCOPE 2
PART 2 PRODUCTS 11
2.1 General 11
3.2 Grounding: 14
Water Leak Detection System Section 283600

SECTION 283600 – WATER LEAK DETECTION SYSTEM
PART 1 INTRODUCTION
1.1 SCOPE
Water Leak detection system that shall be installed in the project as indicated in
D This section applies to the Water Leak detection system, as indicated on


instructions.

into operation a complete Water Leak detection system as indicated in the drawings
to achieve system requirements indicated in related plans, risers, BOQ, specifications
following:
1. WLD system control panel.

2. Sensor cable.
3. WLD Siren with strobe

complete Water Leak detection system as per specifications and drawings.
Contractor shall develop a comprehensive Water Leak detection system including,
but not limited to the items indicated throughout the design package including
specification , drawings and BOQ

specified herein.

F Leak detection system should be provided to notify building operators in the event of
a water/fuel leak.
G Water leak detection system shall be installed under raised floor of the server room
and under CRAC units or at any other areas as indicated on drawings.
H Fuel leakage detection system shall be installed inside generator rooms of the data
center.
I The Water leak detection system shall detect and report the presence and exact
location of water and other liquids.
J The system shall points the location of the leak when a conductive liquid comes in
contact with the water leak detection sensor cable.
K In the event of a leak the system shall sound and the exact location (distance from
the panel) of the leak shall be shown on the liquid crystal display (LCD).
L The system shall have the capability to eliminate high humidity false alarms that can
occur.
M The system shall continuously monitor the Leak Detection Sensor Cable and the
following trouble signals in the system shall activate local audiovisual alarm together
with visual display of the nature of the trouble in the water leakage detection panel:
1. If the cable is cut

2. If the cable has a bad connection
3. If the continuity is lost
N The system shall be consists of leakage detection control panel and Sensor Cable.
O The contractor is responsible for selecting the sensor cable length and to make sure
that the sensor length shall fit the room dimensions in order to have full coverage
areas.
P The system shall be interfaced with BMS systems to report the alarms and take the
proper actions.


requirements of NFPA 70 "National Electrical Code".
charge.

A MANUFACTURER QUALIFICATIONS: Manufacturing firms of Water leak detection

system shall be regularly engaged in manufacturing of the systems of type, size and
years.

supplier/installer.
D TRAINING:

one week.
English and Arabic.
operator.

damage.



following:
washers, etc.
works
9. Complete room coverage layout showing sensor cable routing and all related
equipment exact locations (i.e. HVAC CRAC units, fuel tanks, generator,…etc.

submitted.
Engineer.
compliance.


component.
components.

the submittal

configuration.


electrical team.



performance.
testing
following :
Engineer.
etc.).
Contract documents.

Q EXTRA MATERIALS

requirements.
Agreement).
PART 2 PRODUCTS
2.1 GENERAL
A The Water leak detection system will be composed of the following items:
1. WLD system control panel.

2. Sensor cable.
3. WLD Siren with strobe
B he above components shall be provided with the appropriate numbers and capacities
to serve the whole project and achieve the design intent. The locations of various
system components are shown on the drawings. Other components and accessories
deemed necessary and essential for system operation and integration which are not
shown on drawings are deemed essential and integral part of the design intent which
should be included in the contractor submitted solution to achieve end to end fully
functional integrated system.

WATER LEAK DETECTION SYSTEM Minimum requirements tially comply (indicating
tures/items)

tures/items)
WLD System Control Panel
 Wall mounted with metal enclosure.

 Programmable Leak Alarm Thresholds.
 LCD Panel
 Interface with Building Management System (Modbus,
RS485, etc.)
 Cable Calibration.
 including event logging and recording facility
 Storing events (not less than 100) [alarms, system faults, su-
pervisory conditions, etc.]
 Built-In Audible Alarm.
 Emergency power supply c/w Batteries.
 Software operating system including all necessary modules
(communication, diagnostics, etc).
 LED Indicators
 Detection response time not Less than 30 seconds
 Detection Accuracy applied to the nearest meter
 System configuration shall be via front panel
 Produce fault signal in case of cable is cut or disconnected
 Produce alarm signal in case of leak condition is detected
Sensor Cable
 Water Sensor Cable detecting water presence or any con-

ducting fluid over its entire length
 Panel shall constantly monitor the sensing cable’s status for
water presence and cable faults
 Sensor cable length shall fit the room dimension c/w all re-
quired fitting and accessories
 Sensor cable shall be pre-terminated segments allowing for
expansion
 Provided with end termination kit connector.
 Sensor cable includes clips, joints and all related accessories.
 Including leader cable (non-Sensing Cables) for connection
with WLD panel at non protected area.
WLD Siren with Strobe
 Stainless steel plate mounting outside the detection area

 Activated by the control panel and remains active until
tures/items)
alarms have been released.
 UL listed & BS approval.
 Siren: min. 60 dBA at one meter.
 Strobe light: steady, flashing or pulsing every 10 seconds.
PART 3 INSTALLATION


requirements.

instructions.
requirements

3.2 GROUNDING:




and inspections.




ISSUED FOR
SHALL BE COMPLETED WITHIN THEIR ENTIRELY. TENDER/QUOTATION
PURCHASE
CONSTRUCTION X

NO. BY BY BY
0 June 2021 E.M 17 ISSUED FOR TENDER
1 June 2021 E.M 17 ISSUED FOR CONSTRUCTION
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. EARTHWORK
CAIRO - EGYPT 312000 – 2874 1

CONTENTS
SECTION 312000
EARTHWORK
Page
PART 1 GENERAL 2

1.2 Summary 2
1.3 Reference Standards 2
1.5 Submittals 3
1.6 Definitions 4
1.8 Use Of Explosives 6
1.9 Contractor's Responsibility 6
PART 2 PRODUCTS 7
2.1 Soil Materials 7

2.2 Warning Tape 9
2.3 Water 10
2.4 Equipment 10
PART 3 EXECUTION 10
3.1 Open-Cut Excavation, General 10

3.2 Excavation For Structures 12
3.3 Approval Of Subgrade Bottom 13
3.4 Footing Subgrade 14
3.5 Backfilling Around Foundations 14
3.6 Soil Replacement Under Foundations And Above Water Level 14
3.8 Auxiliary Works 16
3.9 Tolerance Limits 16
3.10 Surface Finish 16
3.11 Disposal 17
Earthwork Section 312000

Urbanium Office Building (Prj. 2874) Page 1 of 17
SECTION 312000 - EARTHWORK
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including Contract Conditions and
Division 1 Specification Sections, apply to work of this section.
1.2 SUMMARY
A. This section covers:
1. Survey of the site

2. Cleaning and garbing
3. Stock piling and disposal of excavated material
4. All necessary safety measures
5. Testing
6. Excavation and backfilling for building and structures to subgrade elevations.
7. Preparing subgrades for slab-on-grade, walkways, pavement, etc... to final
grade and levels
B. Extent of excavation, backfilling shall be as indicated on the Drawings.
1.3 REFERENCE STANDARDS
A. Earth works including cut, fill and backfilling and grading works shall be performed in
compliance with Drawings, tests and the requirements of the project, and the
specifications of the American Society of Testing and Materials (ASTM) as noted
below:
American Society of Testing and Materials
ASTM No.
ASTM C131 Standard Test Method for Resistance to Degradation of Small Size
Coarse Aggregate by Abrasion and impact in the Los Angeles
Machine.
ASTM C136 Sieve Analysis of Fine and Coarse Aggregates
ASTM C142 Clay Lumps and Friable Particles in Aggregates
ASTM D421 Practice for Dry Preparation of Soil Samples for Particle Size Analysis
and Determination of Soil Constants
ASTM D422 Particle Size Analysis of Soils
ASTM D427 Shrinkage Factors of Soils
ASTM D512 Chloride Ion in Water
ASTM D516 Sulfate Ion in Water
ASTM D638 Tensile Properties of Plastics
ASTM D698 Moisture Density Relation of Soils and Soil Aggregate Mixtures
ASTM D854 Specific Gravity of Soils
ASTM D1293 pH of Water
ASTM D1556 Density of Soil in Place by the Sand-Cone Method
ASTM D1557 Moisture Density Relations of Soils and Soil Aggregate Mixtures Using
10 lb. (4.54 kg) Hammer and 18 in (457 mm) Drop
ASTM D1586 Penetration Test and Split-Barrel Sampling of Soils
ASTM D1883 Standard Test Method for California Bearing Ratio of Laboratory
Compacted Soils
ASTM D2167 Density and Unit Weight of Soil In-Place by the Rubber Balloon
Method
ASTM D2487 Classification of Soils for Engineering Purposes
ASTM D2488 Description and Identification of Soils (Visual-Manual Procedure)
ASTM D2922 Density of Soil and Soil-Aggregate in Place by Nuclear Methods
(Shallow Depth)
ASTM D2940 Graded Aggregate Material for Bases or Sub-bases for Highways or
Airports
ASTM D3776 Standard Test MG7000 for Mass per Unit Area (Weight) of woven
fabric
ASTM D3786 Hydraulic Bursting Strength of Knitted Goods and Nonwoven Fabrics-
Diaphragm Bursting Strength Tester Method
ASTM D4253 Maximum Index Density of Soils Using a Vibratory Table
ASTM D4254 Minimum Index Density of Soils and Calculation of Relative Density
ASTM D4318 Standard Test Method for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM D4491 Standard Test Method for Water Permeability of Geotextiles by
Permittivity
ASTM D4632 Standard Test Method for Grab Breaking Load and Elongation of
Geotextiles
ASTM D4718 Correction of Unit Weight and Water Content for Soils Containing
Oversize Particles
ASTM D5030 Density of Soil and Rock in Place by the Water Replacement Method
in a Test Pit
A. The following sections includes requirements which relate to this section:
1. Division 01 Section: Quality Control

2. Division 02 Section: Geotechnical Investigation and Reporting
3. Division 03 Section: Cast-in-Place Concrete
1.5 SUBMITTALS
A. Submit the following in accordance with Conditions of the Contract and Division-1
B. Product Data for the following:
1. Each type of plastic warning tape

2. Drainage fabric
3. Separation fabric
C. Photographs of existing adjacent structures and site improvements.
D. Certificates: Submit a certificate of control of water.

E. Samples: Submit for verification purposes:
1. 2 kg samples sealed in airtight containers, of each proposed fill and backfill soil
material from on-site or borrow sources
2. 300 mm long of each type of plastic warning tape
3. 300 x 300 mm samples of drainage fabric
F. Quality System: Comply with ISO 9001/9002 Quality System as a minimum.

Incorporate all the standard procedures supplied by the Engineer and the Employer.
G. Detailed design of temporary side slopes and side support system (if any) for
approval.
H. Stock piling of excavated materials for approval.
1.6 DEFINITIONS
A. Borrow soil: Satisfactory soil imported from off-site for use as fill or backfill.
B. Fill: Soil materials used to raise existing grades.
C. Backfill: Soil material or controlled low-strength material used to fill an excavation.

1. For utility trench
2. Initial Backfill: Backfill placed beside and over pipe in a trench, including
haunches to support sides of pipe.
3. Final Backfill: Backfill placed over initial backfill to fill a trench.
D. Rock Fill: Material composed of hard, sound, durable rock with only a small amount
of fine particles used for filling or back filling
E. Sub-base Course: Course placed between the subgrade and base course for hot-mix
asphalt pavement, or course placed between the subgrade and a cement concrete
pavement or a cement concrete or hot-mix asphalt walk.
F. Retain definitions that remain after this Section has been edited. Revise to suit office
or local earthwork practices.
G. Base Course: Course placed between the sub-base course and hot-mix asphalt
paving.
H. Bedding Course: Course placed over the excavated subgrade in a trench before
laying pipe.
I. Revise heading in first paragraph below to read "Capillary Water Barrier" or a similar
title if required.
J. Drainage Course: Course supporting the slab-on-grade that also minimizes upward
capillary flow of pore water.
K. Excavation: Removal of material encountered above subgrade elevations and to lines

and dimensions indicated.
1. Authorized Additional Excavation: Excavation below subgrade elevations or

beyond indicated lines and dimensions as directed by Engineer. Authorized
additional excavation and replacement material will be paid for according to
Contract provisions for unit prices.
2. Bulk Excavation: Excavation more than 3 m in width and more than 9 m in
length.
3. Unauthorized Excavation: Excavation below subgrade elevations or beyond
indicated lines and dimensions without direction by Engineer. Unauthorized
excavation, as well as remedial work directed by Engineer, shall be without
additional compensation.
L. Structures: Buildings, footings, foundations, retaining walls, slabs, tanks, curbs,

mechanical and electrical appurtenances, or other man-made stationary features
constructed above or below the ground surface.
M. Subgrade: Surface or elevation remaining after completing excavation, or top surface

of a fill or backfill immediately below sub-base, drainage fill, or topsoil materials.
N. Utilities: On-site underground pipes, conduits, ducts, and cables, as well as

underground services within buildings.
A. Project Site Information: Excavation shall be unclassified and shall be completed

regardless of the type, nature or condition of material encountered.
B. A geotechnical report has been prepared for this project and is available. The
opinions expressed in this report, the design and drawings are those of the
geotechnical engineer and represent interpretations of the subsoil conditions, tests,
and results of analyses conducted by the geotechnical engineer.
C. The Contractor shall carry out his own site investigations and shall inform and satisfy
himself as to the character, quality and distribution of all material to be excavated,
filled, spoiled and borrowed. The Contractor shall be fully responsible for asserting
necessary information concerning permanent water-table, period of rainfall and all
matters affecting the excavation and foundation work.
D. The contractor is responsible to verify the required different levels before starting
construction works.
E. Before starting any construction works compacting the top surface is required to
assure the quality of compaction.
F. Topographic Survey: Do not assume accuracy of the existing benchmark, and run a
closing survey of the existing project area and take cross-sectional elevations and
levels of the works on the Site and submit the result to the Engineer for approval, as
quantities of excavation, earthwork etc., shall be measured from these levels as
agreed and signed by the Engineer.
G. Locate datum level used to establish benchmarks sufficiently distant so as not to be

affected by movement resulting from excavation operations.

H. Employ a qualified professional engineer or surveyor; establish exact elevations at
fixed points, construct and protect benchmarks during the period of construction.
Such benchmarks shall be checked periodically and whenever required by Engineer.
I. Existing Utilities: Do not interrupt utilities, if any, serving facilities occupied by

Employer or others unless permitted in writing by Engineer and then only after
arranging to provide temporary utility services according to requirements indicated.
1.8 USE OF EXPLOSIVES
A. Blasting and use of explosives is prohibited. Do not bring explosives onto Site or use
in work.
1.9 CONTRACTOR'S RESPONSIBILITY
A. The methods of excavation which the Contractor desires to use shall be at the sole
discretion of the Contractor.
B. The Contractor shall perform all excavation and backfilling as required for all works
under this Contract. Excavations shall be carried out in all materials, by whatever
means necessary and shall be performed accurately to the lines, levels and grades
shown on Drawings.
C. Except where indicated on the Drawings to remain undisturbed, the Contractor shall
remove all unaccepted topsoil, plants, roots, vegetation, rubbish, rock, etc., from
areas lying within limits of structures and from area to receive fill, embankment,
surfacing, road construction, concrete or other constructions.
D. Safety of Excavations: It is the Contractor's responsibility to provide and maintain

safe excavations for all phases of construction. In no case shall any be made in such a
manner to endanger or damage workmen, adjacent utilities, paving or structures.
The Contractor shall be responsible for providing safe construction slopes and he
shall adequately shore and sheet the side of excavations to ensure complete safety
against collapse of soil at these areas.
E. In the event of a fall occurring in any excavation the Contractor shall carry out at his
own expense and to the satisfaction of the Engineer any re-excavation reinstatement
or repairs which may become necessary as the result of such fall. Any voids caused
by a fall shall be filled and consolidated as directed by the Engineer.
F. Protection of Persons and Properties: The Contractor shall erect temporary fencing
or barricade open excavations occurring as part of this work and post with warning
lamps and take all necessary steps to prevent any entry of public to the vicinity of
open excavation. He shall protect structures and utilities from damage caused by
settlement, lateral movement, undermining, washout and other hazards created by
earthwork operations.
G. The Contractor shall restore and repair any damage or defects caused to adjacent
structures, utilities or properties without responsibilities or extra charge to the
Employer.

H. Protection of Utilities and Services: Any cable, pipeline or other services exposed by
Contractor shall be protected and supported by him to prevent damage to the
service. Supports shall be maintained throughout the whole period of the exposure
of services and it shall be the Contractor's responsibility to ensure that, on and after
backfilling or building in, the said services are adequately supported by any
satisfactory means so that no damage shall be caused to them on or after such
backfilling or building in.
PART 2 PRODUCTS
2.1 SOIL MATERIALS
A. General: Provide borrow soil materials when sufficient satisfactory soil materials are
not available from excavations.
B. Topsoil: Natural and cultivated surface-soil layer containing organic matter and sand,
silt and clay particles, friable, pervious, and black or darker shade of brown, gray or
red than underlying subsoil, reasonably free of subsoil, clay lumps, gravel, and other
objects more than (50mm) in diameter, and free of subsoil and weeds, roots, toxic
materials, or other non-soil materials.
C. Engineering/Structural Fill: Fill under foundation of structures and backfill of

excavation for foundations shall be classified as structural fill, Table 1. This backfill
shall be used as well below slab on grades, ramps, and steps. Material for structural
fill shall be in accordance the requirements shown on Part 2 unless otherwise
approved by the Geotechnical Engineer.
D. Structural fill shall be used underneath the structures and under slab on grade.
E. The source of the Engineering fill shall be provided by the Contractor and approved
by the Engineer. The Contractor shall provide samples at specified intervals to
monitor the material, and to the Engineer satisfaction.
F. Engineering fill shall be used underneath the structures, roads, shoulders and paved
areas and under slab on grade as specified in the geotechnical report.
Table 1
Structural Fill Gradation and Criteria
Sieve Designation Percent Passing (by Weight)

50 mm (2”) 100
19 mm (3/4”) 80-100
4.75 mm (No.4) 45-100
0.425 mm (No.40) 15-40
0.075 mm (No.200) 2-10
Liquid limit Not greater than 25%
Plasticity index Not greater than 10%
Free swell Not greater than 0 %
Cu > 4 and 1 < Cc <3

G. Selected Fill: Naturally or artificially graded mixture of natural or crushed gravel,
crushed stone, and natural or graded sand; plasticity index shall not exceed 10%. The
soaked CBR value shall not be less than 15% and the swell shall not exceed 2.0%.
Table 2
Selected Fill
Sieve Designation Percent Passing (by Weight)

100 mm (4") 100
75 mm (3") 90-100
37.5 mm (1.5") 70-100
10 mm (3/8") 60-100
4.75 mm (No.4) 40-85
0.425 mm (No.40) 8-45
0.075 mm (No.200) 0-15
Liquid Limit Not greater than 40%
Plasticity index Not greater than 10%
CBR (Soaked) Greater than 15%
Swell Not greater than 2%
H. Common Fill: Areas of using common fill are as follows:
1. For depth from 3.0 m to 10.0 m (under buildings area) with max. Fines
percentage 20% and min. compaction percentage 85% (as stated in table 3).
2. For depth from 2.0 m to 10.0 m (under roads and parking area) with max. Fines
percentage 25% and min. compaction percentage 85%.
3. Landscape area and non-loaded area (non-structural fill) with max. Fines
percentage 25%, min. compaction percentage 85% and the maximum
thickness for each layer is 700 mm.
I. Maximum dry density and optimum moisture content shall be determined based on
Modified Proctor Test according to ASTM D 1557.
J. Backfilling material uses under buildings specifications and criteria are stated in the
following table:
Table 3
Backfill specifications and criteria under buildings
Depth of Back- Compaction

Max. Grain Maximum
filling under Material Layer’s Compaction percent
Size Fines
Foundation Level Type Thickness (%)
(mm) Percent (%)
(m) (mm)
Structural
0 - 1.5 m 250 50 10 95
Fill
1.5 - 3.0 m Selected Fill 300 100 15 95
3.0 - 10.0 m Common Fill 500 250 20 90
K. Backfilling material uses under roads and parking areas specifications and criteria are
stated in the following table:
Table 4
Backfill specifications and criteria under roads and parking areas
Depth of Back- Compaction

Max. Grain Maximum
filling under Material Layer’s Compaction percent
Size Fines
Foundation Level Type Thickness (%)
(mm) Percent (%)
(m) (mm)
Structural
0 - 1.0 m 250 50 10 95
Fill
1.0 - 2.0 m Selected Fill 350 100 15 95
2.0 - 10.0 m Common Fill 600 250 25 90
L. Backfilling material uses under roads and parking areas specifications and criteria are
stated in the following table:
M. Bedding for Underground Utility Installation: Bedding shall be granular, well graded,
with all material passing 12.5 mm (1/2 inch) mesh screen and at least 90 percent
retained on 75 µm (No. 200) sieve as determined in accordance with ASTM D 422.
N. Trench Backfill (Within the Pipe Zone): Trench backfill shall contain no rocks or
stones larger than 25 mm in the greatest dimension and shall be free of vegetation,
trash, chunks of highly plastic clay, or other unsatisfactory- material. Trench backfill
placed under roadways or structures shall meet the requirements of engineering fill.
O. Sub-base Material: Naturally, or artificially graded mixture of natural or crushed

gravel, crushed stone, and natural or crushed sand; ASTM D 2940; with at least 90
percent passing a 37.5-mm sieve and not more than 10 percent passing a 0.075-mm
sieve.
P. Base Course: Naturally or artificially graded mixture of natural or crushed gravel,

crushed stone, and natural or crushed sand; ASTM D 2940; with at least 95 percent
passing a 37.5-mm sieve and not more than 8 percent passing a 0.075-mm sieve.
Q. Drainage Course: Narrowly graded mixture of crushed stone, or crushed, or

uncrushed gravel, ASTM D 448; coarse-aggregate grading Size 57; with 100 percent
passing a 37.5-mm sieve and 0 to 5 percent passing a 2.36-mm sieve.
R. Sand: ASTM C 33; fine aggregate, natural, or manufactured sand.
2.2 WARNING TAPE
A. Acid- and alkali-resistant polyethylene film warning tape for marking and identifying
underground utilities 150 mm wide and 4 mils thick, continuously inscribed with a
description of the utility; colored as follows:

1. Red: Electric
2. Yellow: Gas, oil, steam and dangerous materials
3. Orange: Telephone and other communications
4. Blue: Water systems
5. Green: Sewer system
2.3 WATER
A. Water used for soil compaction shall be clean and free from unusual proportions of
dissolved salt, organic matters and industrial contamination oils, acids or other
deleterious matter.
B. Water shall not contain chemical salts including sulfates (SO3) and chlorides (Cl) in a
percentage that shall increase the overall salts percentage for filling materials more
than 0.35%.
C. For the water used in compaction process, water sample from wells and/or any
source shall be tested to satisfy the previous limits.
2.4 EQUIPMENT
A. Use types of equipment that are most suitable for the work and of numbers, sizes
and capacities that can perform earthwork as specified within the time schedule.
Equipment for earthwork shall be operated in strict accordance to manufacturer's
instructions and recommendations and shall be always maintained by the Contractor
in such condition that they shall deliver manufacturer's rated capacities.
PART 3 EXECUTION
A. Should the Contractor through negligence or other fault excavate or fill beyond the
designated lines, he shall replace/remove such excavation/fill in an approved manner
and condition at his own expense with satisfactory soil materials and thoroughly
compact to a density equal to adjacent original ground.
B. Do not neglect to check for underground services, which may not initially appear to
be of interest. Protect utilities, structures, improvements, pavement from damage
caused by settlement due to lateral movement created by earthwork operations.
C. No compensation shall be paid to the Contractor in respect to excavation or

backfilling for the extra width.
3.1 OPEN-CUT EXCAVATION, GENERAL
A. Excavation shall be performed as indicated on Drawings and in the Specifications to

the lines, grades and elevations shown or as directed by the Engineer.
B. Survey points, benchmarks, boundary stones and the like shall be removed only with
the engineer’s written consent.
C. Removed boundary stones and marking shall be stored according to the engineer
instructions.
D. Extra temporary benchmarks to be provided by the Contractor shall be furnished

with a plate, approximately 25x25 cm in size. With the benchmark inscription

painted in black letters on a light background with clearly legible weatherproof oil
paint.
E. For all fill and cut over 1 m in height, sturdy stakes shall be placed at any changes of
direction of the ground but in all cases at intervals not greater than 30 m as directed
by the engineer.
F. Permanent slope (if any) to be kept in the sand it shall be stabilized by one of the
following means:
1. Mass concrete blinding

2. Cement/sand mixture
3. Bituminous/cement mixture.
G. The quantity, type and capacity of the equipment provided, the work method
envisaged transportation and distribution of the excavated materials, location of
stock-piles, main storage areas as well as the approximate number of laborers, etc.
and the working schedule and any amendment to it during the construction period
shall require the engineer’s period approved.
H. Bottom and slopes of open-cut elevations on which concrete is to be placed shall be

finished exactly according to the established levels and slopes. Stability of slopes are
to be checked to achieve an acceptable factor of safety, a berm of width not less than
2.0m is to be performed for each 4.0m excavation height.
If no side slope stability studies are available, the contractor shall follow the following
side slopes according to the site soil type:
1. Clayey soil: 1Hal: 1 Val

2. Silty soil: 3Hal: 2 Val
3. Sandy soils: 1Hal: 1 Val
4. Rock: 1Hal: 6 Val
I. Regardless of the methods of excavation adopted, the basis of payment shall be as

assumed in Section 012700 “Measurement and Payment”.
J. Excavation shall consist of removal of all earth, rocks, boulders, remains of

buildings, services not to be used and all material encountered within the limits
indicated to subgrade elevations indicated on Drawings and subsequent stock piling
of materials needed for backfilling or disposal of material determined unsuitable.
K. Excavation shall be unclassified and shall be completed regardless of the type of

material and obstruction encountered together with soil, boulders and other
materials.
L. The Contractor shall make his own estimate of the kind and extent of the various
materials and presence or absence of water which shall be encountered in the
excavation.
M. The final 150 mm depth of all excavations shall be taken out manually or otherwise if
accepted by the Engineer and the bottom levelled and rammed immediately prior to
placing structures.

N. Footings, foundations and pipes shall rest on firm undisturbed soil free from loose
materials.
O. Stockpile soil materials suitable for backfill at sufficient distance away from edge of
excavation and neatly pile in stock piles in a manner that shall not overload or cause
collapse of excavation sides. All unsuitable and surplus excavated materials shall be
immediately removed from site, loaded and transported to dumps approved by local
authorities.
P. Extend excavations a sufficient distance from structures for placing and removing
concrete formwork, for installing services and other construction, for inspection.
Q. Excavate to indicated elevations and dimensions within a tolerance of ± 25 mm.
R. No back-throwing whatever shall be allowed and all materials shall be brought to the
surface and formed in heaps clear of excavation.
S. Excavation in rock, if any, rock layer should be classified according to the

geotechnical consultant, field and lab tests and confirmed by the geotechnical
engineer. The excavation on rock layer (if any) will measured with rate only.
T. Over Excavation: If somewhere and for any reason excavations are executed beyond
the established lines and without the engineer’s previous approval, the Contractor
shall backfill with lean concrete or other approved materials, the volume
corresponding to the over excavation.
U. Drainage of Excavated Areas: Grading in the vicinity of excavations shall be controlled

to prevent surface water from flowing into excavated areas.
V. Protect subgrades from softening and damage by rain or water accumulation.
W. The excavation shall at all times be well drained, kept free from storm water,
percolating water or subsoil water.
X. The Contractor shall make good at his own expense any damage that may result from
his failure to keep the excavation free from water.
3.2 EXCAVATION FOR STRUCTURES
A. Excavation Limits for Structures: Banks shall be either shored or sloped at a safe
angle according to conditions and to the approval of the Engineer. If necessary
extend a reasonable sufficient distance from footing and foundations to permit
placing and removal of concrete form work, shoring, installation of services and other
constructions, for performing all works in the excavation and for inspection. No
compensation shall be paid to the Contractor in respect to excavation or backfilling of
extended distances.
B. If any part of an excavated area is in error or excavated wider than required, the
excess excavated distance shall be backfilled as directed by the Engineer and
compacted at the Contractor's charge.
C. Excavation for underground: tanks, basins and mechanical or electrical utility

structures. Do not disturb bottom of excavations intended for bearing surface.

3.3 APPROVAL OF SUBGRADE BOTTOM
A. When excavation has reached required subgrade elevations, the Engineer shall
inspect soil materials at these elevations for suitability as a foundation level for the
related construction, and he may instruct the Contractor to test the bearing capacity
of the soil at this level. Should the bottoms of excavation be found to be unsuitable
as bearing surfaces as a result of such tests, the Engineer may decide to continue
excavation until suitable bearing materials are encountered and replace with
compacted backfill. Additional excavation and replacement material shall be paid for,
according to Contract.
B. Excavated materials shall not be piled up along sides of excavations in a manner that
will overload or cause collapse of excavation sides.
C. Sub-soil from the excavation shall be selected for suitability for backfilling and
compaction, shall be free from any organic materials and shall not have big lumps. It
shall be placed directly in its final position or stacked on site as directed by the
Engineer in the vicinity of the work and those unsuitable for fill shall be removed
from site to a tip provided by the Contractor. All other filling materials shall be
imported.
D. Cleaning, grubling and removal of trash and debris from excavation shall be done
before backfilling works.
E. Contractor shall make corrections and adjustments in methods or moisture content

in order to achieve the correct fill density.
F. Compaction areas shall be kept separate and no layer shall be covered by another
until the proper density is obtained.
G. Roads' banks, if any, shall be sloped at a safe angle of repose.
H. Materials shall be as specified in Part 2 of this section and compaction requirements

shall be based on relative density.
I. The soil used in backfilling shall be mixed with sufficient water to provide a moisture
content within a range of 2% from the optimum value. The mixing process shall be
completed out of backfill area then soil shall be spread in loose lifts and compacted
at designated locations. The moisture content shall be uniform throughout the
compacted layer. If the field quality testing as specified in Clause 3.9 revealed
moisture content out of the previously specified range, the soil shall be removed,
remixed and compacted again.
J. The Engineer, at his own discretion, may allow greater lift thickness not exceeding
350 mm thick if proper density and uniformity is obtained. Effective spreading
equipment shall be used on each lift to obtain uniform thickness prior to compacting.
As the compaction of each layer progresses, continuous levelling and manipulating
shall be required to assure uniform density. Water shall be added in order to obtain
the correct water content and the required density on stocked soil outside the
excavation. Construction equipment shall be routed uniformly over the entire
surface both in width and longitudinal extent of each layer before the next lift is
started. At the start of the work a field test shall be performed in the Site over an
adequate area not less than 100 m2 to determine the allowable thickness of layers

that can be compacted to the required density by means of the compaction
equipment provided by the Contractor.
K. Pipes and reinforced concrete foundation members such as tie-beams laid on natural
ground shall be protected with a minimum of 1000 mm of tamped fill over the top
surface or according to Drawings before heavy equipment is allowed to pass over.
L. Backfill excavations shall start as promptly as work permits, but not until completion
of the following:
M. Pipes and reinforced concrete foundation members such as tie beams laid on natural
ground shall be protected with a minimum of 1000 mm of tamped fill over the top
surface or according to Drawings before heavy equipment are allowed to pass over.
N. Acceptance of layers below finish grade including, where applicable, damp-proofing,

waterproofing and perimeter insulation.
O. Inspection, testing, approval and recording locations of underground utilities have

been performed and recorded. Do not backfill trenches until tests and inspections
have been made and backfilling is authorized by the Engineer. Use care in backfilling
to avoid damage or displacement of pipe systems.
P. Removal of concrete formwork.
Q. Removal of temporary shoring and bracing, backfilling of voids with satisfactory

materials. Cut off temporary sheeting, piling driven below bottom of structures and
remove in a manner to prevent settlement of the structure or utilities or leave in
place if required. External surfaces of wood sheeting instructed to be left in place
shall be painted with suitable protective material.
R. After installation of pipes and cables according to specifications and all related tests
are performed and approved by Engineer.
S. Removal of trash and debris from excavation.
3.4 FOOTING SUBGRADE
A. Unless otherwise indicated on Drawings, the subgrade under footings and tie-beams
shall be prepared in the following sequence:
1. Excavate under footing and tie-beams down to the required depth from
existing ground surface.
2. Clean bottom of excavation from the loose surface soil skin and compact the
soil using suitable compaction equipment.
3.5 BACKFILLING AROUND FOUNDATIONS
A. Use selected fill materials as specified in Clause 2.1 and compact mechanically or by
manual tamping to 90% of maximum dry density according to ASTM D 1556 at
optimum moisture content during excavation.
3.6 SOIL REPLACEMENT UNDER FOUNDATIONS AND ABOVE WATER LEVEL

A. Use Engineering/structural fill materials as specified in Clause 2.1, Percentage of fine
materials passing ASTM Sieve No. 200 must not exceed 10, and the percentage of
sulphates (SO3) and chlorides (Cl), shall not exceed 0.35%.
B. Percentage of absorbed water by weight shall be 10% maximum. Percentage of

dissolution in water of coarse and fine aggregates shall be 5% maximum.
C. Compaction requirement shall be based on Relative Density Compaction
Replacement and shall be executed in loose lift (250 mm thick) uniformly spread,
compacted mechanically or by manual tamping, either equipment or vibratory
equipment according to available space, replacement shall be compacted to a
minimum of 95% of maximum dry density.
3.7 FIELD QUALITY CONTROL:
A. Allow testing agency to inspect and test each subgrade and each fill layer.
B. Compaction and field density tests of in-place soil or the fill shall be made at each
location directed by the Engineer at the rate of one (1) test every 250 m2 for each
compacted layer according to ASTM D1556.
C. One plate loading test/1000 m2, with minimum of two tests for each plot, shall be
carried out at foundation level of natural granular soil or the top of the replacement
layer (if existing), or as directed by the Engineer.
In case of the existence of replacement soil with thickness equal to or bigger than
1.50 m, then the same number of tests shall be carried out at the middle of the layer
The test shall be carried out dry and soaked to check the soil collapsibility as per the
Egyptian code and shall satisfy the following:
1. The steel plate diameter at least 450 mm.
2. The stress of the test should be not less than three times the net allowable
bearing capacity at the foundation level.
3. The submergence is to occur at stress equals the net allowable bearing
capacity at the foundation level.
4. The value of deformation modulus, Es should be not less than 500 Kg/cm2
D. Field density tests shall be performed in accordance with AASHTO T-191 (sand cone
method). The Contractor shall perform the following tests at locations as directed by
the Engineer:
1. Laboratory test for Maximum Dry Density (MDD), Optimum moisture content,
for each layer.
2. Field density and California Bearing Ratio (CBR), for each layer as required by
the Engineer.
3. The areas shall be rejected if the resulting test results do not satisfy specified
requirements.
4. The Contractor shall be responsible for making good all settlement of filling
that may occur at/to the end of the Defect Liability Period.

3.8 AUXILIARY WORKS
A. Unless otherwise specified, all and any kind of works, materials, services, safety
measures, etc. as well as, and if so requested by the Engineer, all tests and samples
required for the completion of the work shall be for the responsibility of the
Contractor. The auxiliary works comprises, but not limited to the following:
1. Removing and storing of boundary stones, bench marks, etc., protection of

surveying points/designations by means of boards, burvey and protection of all
secondary survey points, profiles, etc.
2. Difficulties to be overcome where excavation may have to be carried out in
layers.
3. Keeping off or diversion of water if any, including any pump required, difficult
work caused by water, etc.
4. Removal of any groyne, buried pipes, fascines and the like that might interfere
with excavation profiles, irrespective of whether or not such structures are
specified.
5. Difficulties resulting from the specification relating to filling, eliminating
unsuitable material from filling and if necessary, mixing of different soil
materials.
6. Transport of excavated materials to fill or deposit, placing and spreading in
layers according to conditions and drawings and careful compaction.
7. Difficulties in transport due to existing ground condition.
8. Sorting of excavated materials which if necessary, are to be used for special
purposes.
9. Providing, maintaining and later removing access way-maintaining existing
ways and roads providing, placing, maintaining and later removing, conveying
and dumping materials and/or equipment that might be required.
3.9 TOLERANCE LIMITS
A. The tolerance limits for the permanent finished earthworks will be as follows:
1. Horizontal dimensions will be within +75 mm and –75 mm of the true

dimensions shown on the approved drawings.
2. For slopes to embankments or cutting the horizontal deviation between the
top and the bottom of the slope will be within +5% and –5% of the true
horizontal component of the slope shown or calculated from the approved
drawings.
3. Formation levels shall be within 0 mm and –25 mm of the true levels shown on
drawings.
4. Other earth work levels be within +50 and –50 mm of the true levels shown on
the approved drawings.
3.10 SURFACE FINISH
A. The top surface area shall be of dense and level without any protruding rock
fragments in excess of 50 mm, recesses of soft spots to the satisfaction of the
engineer.

3.11 DISPOSAL
A. Remove, only by night, surplus satisfactory soil and waste material including
unsatisfactory soil, trash, debris, and legally dispose of it off to the public disposal
areas.


ISSUED FOR
PAGES BECOME PART OF THE ORIGINAL SPECIFICATION AND SHALL BE REVIEW/COMMENTS X
PURCHASE X
CONSTRUCTION
X
NO. BY BY BY
0 March 2022 A.S. 10 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. AGGREGATE BASE COURSE
CAIRO - EGYPT 321123 – 2874 0

CONTENT
SECTION 321123
AGGREGATE BASE COURSE
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Reference Standard 2
1.4 Submittals 3
1.5 Quality Control 3
PART 2 PRODUCTS 4
2.1 Materials 4
2.2 Equipment 5
2.3 Operation 7
PART 3 EXECUTION 7
3.1 Preparation Of Subgrade 7
3.2 Application Of Base Course 8
3.3 Protection And Maintenance 10
Asphalt Paving -Aggregate Base Course Section 321123

SECTION 321123 –AGGREGATE BASE COURSE
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including General Conditions,

work of this section.
1.2 SUMMARY
A. This section covers the work of a crushed aggregate base layer (course) as required
by the Contract.
1. The base course shall consist of placing and compacting crushed aggregates
on a prepared subgrade in accordance with the technical specifications and in
conformity with the lines, grades, thickness and typical cross sections shown
on Drawings.
2. Extent of base layer (course) work is shown on Drawings.
B. Related Sections
1. Division 31 Section “ Earthwork.”
1.3 REFERENCE STANDARD
A. Works shall be performed in strict accordance with the stipulations of the Egyptian
standard specifications (ES), the specifications of the American Association of State
Highway and Transportation Officials (AASHTO),the American Society for Testing and
Materials (ASTM), or other equivalent standards and sound practice..
Test Name AASHTO ASTM
Sampling of Aggregate T2 D 75
Sieve analysis of coarse and fine aggregate T 27 C 136
Sieve analysis of materials finer than (passing through) sieve T 11 C 117

no. 200 (0.075 mm)
Bulk density and Voids in aggregate T 19 C 29
Fine aggregate Specific Gravity and Absorption T 84 C 128

Coarse aggregate Specific Gravity and Absorption T 85 C 127
Particular size analysis by Hydrometer T 88 D 422
Liquid Limit T 89 D 4318
Plastic Limit (Plasticity Index) T 90 D 4318
Abrasion of aggregate (Los Angeles test) T 96 C 131
Sulfate Soundness of Aggregates T 104 C 88
Sand Equivalent Test T 176 D 2419
Moisture – Density (modified Proctor method) T 180 D 1557
Sand cone –in place- Density T 191 D 1556
California Bearing Ratio T 193 D 1883
B. In the event of conflict between various codes and standards, the most stringent
conditions shall apply.
1.4 SUBMITTALS
A. Equipment list and manufacturer's product data
B. Samples of all materials
C. Test reports and materials certificates as specified hereinafter
1.5 QUALITY CONTROL
A. Installer Qualifications: Engage an experienced installer who has completed a base

course similar in material, design and extent to that indicated for the project.
B. Weather Limitations: Construct base course only when atmospheric temperature is

above 4C and when subgrade is dry.
C. Testing: Materials and installed work may require testing or retesting at any time
during the progress of the works. Tests, including retesting of rejected materials or
installed work, shall be done at the Contractor's expense.
D. All sampling and testing shall be performed by site testing laboratory or an approved
independent laboratory according to “Quality Control”.
E. The following tests should be carried out unless otherwise directed by the Engineer
and at frequencies laid down by the Engineer.

Allowable Limits
Test Name Min. Max.
Liquid Limit - 25%
Plastic Limit (Plasticity Index) - 6%
Abrasion of aggregate (Los Angeles test) - 50%
Sulfate Soundness of Aggregates - 12%
Sand Equivalent Test - 45%
Sand cone –in place- Density 95% -
California Bearing Ratio 80% -
F. Minimum test requirement for aggregate base course: One sample every 1,000 m3
or part thereof as directed by the engineer shall be tested for grading plasticity
index, sand equivalent, maximum dry density, C.B.R. and loss by abrasion. Three in-
situ density tests shall be made per unit (900m2) of aggregate base course laid or as
directed by the engineer.
G. Grade Control: Establish and maintain required lines and elevations.
A. Traffic Control: Maintain access for vehicular and pedestrian traffic as required for
other construction activities.
B. Utilize flagmen, barricades, warning signs and warning lights as required.
PART 2 PRODUCTS
2.1 MATERIALS
A. General: Use locally available materials and gradations which exhibit a satisfactory
record of previous installations and which shall after addition of water and
compaction form a uniform and homogeneous section conforming with this
specification.
B. Borrow pits and quarries shall be cleared and grubbed in accordance with the
requirements and approved before crushing operations started.
C. Base Course Granular: Base course aggregate shall consist of well graded coarse,
fine aggregates and filler from clean crushed rock or crushed aggregates stone.
D. Crushed Aggregate: Crushed aggregate shall consist of hard, durable particles or

fragments of stone, crushed to the required size well graded and a filler from same
crushed material.

E. Particle size analysis and sieve analysis of aggregates shall be carried out in
accordance with AASHTO T 27 and T 88.
TABLE 1
GRADING FOR BASE COURSE AGGREGATE
(PERCENTAGE BY WEIGHT)
AASHTO T 88 - 57
Percentage Passing
by Weight (%)
Sieve Size Max. Size (mm)
(mm) 50.8 38.1 25.4
50.8 (2") 100 - -

38.1 (1 1/2") 70 - 100 100 -
25.4 (1") 55 - 85 70 - 100 100
19.0 (3/4") 50 - 80 60 - 90 70 - 100
9.51 (3/8") 40 - 70 45 - 75 50 - 80
4.76 (No. 4) 30 - 60 30 - 60 35 - 65
2.00 (No.10) 20 - 50 20 - 50 25 - 50
0.425 (No. 40) 10 - 30 10 - 30 15 - 30
0.074 (No. 200) 5 - 15 5 - 15 5 - 15
F. The fraction passing the No. 200 sieve shall be not more than one half the fraction
passing the No. 40 sieve.
G. The fraction passing the No. 40 sieve shall have a liquid limit not exceeding 25 and a
plasticity index not exceeding 6.
H. The mixture shall have a soaked California Bearing Ratio CBR of not less than 80%
(with zero swelling).
I. Blending Materials: If fine aggregate or filler in addition to that naturally present in

the base course material, is necessary in order to meet the grading requirements, or
for satisfactory bonding of the material, it shall be uniformly blended with the base
course material at the screening and crushing plant or on the road. The material for
such purpose shall be obtained from sources approved by the Engineer and shall be
free from hard lumps.
2.2 EQUIPMENT
A. The Contractor shall use types of earth moving compaction equipment that are most
suitable for the work and of numbers, sizes and capacities that can perform the work
of the base course as determined in the time schedule and they shall include:

Tamping, smooth-wheel steel roller, pneumatic-tired rollers etc., and watering
equipment conforming to the following respective requirements:
B. Tamping Rollers: A tamping roller unit shall consist of two watertight metal drums
mounted in frames in such manner as to be fully oscillating, together with a tractor
having sufficient weight and power under actual working conditions to pull the roller
drums at a minimum speed of 5 km/hour.
C. The drums shall be not less than 1.00 m in diameter and not less than 1.00 m in
length, measured at the drum's surface and shall be studded with tamping feet
projecting not less than 18 cm from the face of the drums. The distance between
circumferential rows of tamper feet shall be such that the diagonal distance from
any foot to the nearest foot in each adjacent row shall be not more than 30 cm,
measured center-to-center of feet at the surface of the drums. The cross sectional
area of the face of each tamper foot, measured perpendicular to the axis of the stud,
shall be not less than 30 cm2 not more than 55 cm2.
D. The weight of the tamping-roller unit shall be such as to exert a minimum pressure
of 18 kg/ cm2 on the ground area in contact with the tamping feet and the roller
shall be so designed that the weight may be increased to exert a pressure up to 36
kg/ cm2 on the ground area in contact with the tamping feet. The ground pressure
shall be determined by dividing the total weight of the roller unit, not including the
weight of the tractor, by the total cross sectional area of the tamping feet in one row
of tamping feet parallel to the axis of the roller.
E. Smooth-wheel Static Power Rollers: Smooth-wheel static power rollers shall be of

the 2 or 3 wheel type weighing between 8 and 12 tons and shall provide
compression under the rear wheels of not less than 30 kg per linear cm of width.
F. Maximum speed of these rollers under working conditions shall not exceed 5
km/hour.
G. Smooth-wheel Vibrating Power Rollers: Smooth-wheel vibrating power rollers shall

be of the one or 2-wheel type weighing not less than 3.5 tons and shall provide
compression under wheels of not less than 20 kg per linear cm width.
H. Pneumatic-tyred Rollers: Pneumatic-tyred rollers shall be of the double-axle type

equipped with not less than 7 pneumatic tyres of equal size and type. The spacing
between the sides of adjacent tyres shall not exceed 12 cm, and the rear tyres shall
be staggered in relation to the front tyres.
I. The rolling width of the unit shall be not less than 1.50 m exclusive of the power
unit. The roller shall be so constructed that the contact pressure is adjustable
between 3 and 8 kg/cm2, and uniformly distributed on all of the tires; the tyres shall
be inflated to maintain the air pressure in the several tires within a total tolerance of
1 kg/cm2. The roller shall be so constructed that the total weight of the roller can be
varied to produce an operating weight of between 500 and 2000 kg per tyre, the
actual operating weight of the rollers shall be as ordered by the Engineer.
J. Each pneumatic-tyred roller shall be drawn by equipment having sufficient power

and sufficient weight under normal working conditions to pull the roller at a

minimum speed of 10 km/hour or may be self-propelled to obtain the same
minimum speed.
K. Water Sprayer: Shall be truck mounted, equipped with a pump, with a separate
power unit including a spray bar.
L. The design of the spraying equipment shall be such as water shall be applied and
added to soils at uniform and controlled rated to provide the optimum, moisture
content.
2.3 OPERATION
A. The particular type of roller to be used, as described above shall be designated by

the Engineer to suit the type of material used. In lieu of the rolling equipment
specified above, the Contractor upon written permission from the Engineer, may
operate other compacting equipment that will produce equivalent relative
compaction in the same period of time as the equipment specified herein. If the
substituted compaction equipment fails to produce the desired compaction within
the same period of time as would be expected of the equipment specified herein, its
use shall be discontinued.
PART 3 EXECUTION
3.1 PREPARATION OF SUBGRADE
A. The work shall be performed after the earthwork and sub-grade have been
substantially completed and tested.
B. Immediately before placing base course, subgrade shall be rolled with pneumatic
tyred roller of sufficient weight or heavy smooth wheel roller, to satisfy the
adequate levels shown on Drawings and to detect soft spots.
C. For vehicle areas compact with a roller weighing not less than 8 to 10 tons. For
pedestrian areas compact with a roller weighing not less than 2.5 tons.
D. After the subgrade has been constructed, prepared and substantially completed, and
if after compaction any soft spots are found the full width shall be conditioned by
removing any soft or other unstable material that was not compacted properly or
serve the intended purpose. The resulting areas and all other low sections, holes, or
depressions shall be brought to grade with suitable selected material.
E. Compaction soil test shall be made to determine the maximum dry density and
optimum moisture content of soil.
F. Relative compaction of subgrade shall be 95% according to the modified AASHTO

Designation T 180.

3.2 APPLICATION OF BASE COURSE
A. Contractor shall make the survey required for the reference grade, he shall erect a
reference straight line parallel to the centerline of the road, and operate the
compacting equipment to conform the straight line.
B. Elevation control point stakes for the crushed aggregates course shall be set at
maximum spacing of 50 m.
C. Sufficient uniform material mixture shall be spread on the road surface by a motor
grader and well mixed with water with the specified equipment to reach the
maximum density after compaction and so that the surface of the compaction is just
above the specified grade.
D. Placing: The wet granular base material shall be spread in layers on the prepared
subgrade and compacted to grade and cross section shown on the Drawings. When
more than one layer is required, each layer shall be shaped and compacted before
the succeeding layer is placed.
E. The placing of material shall begin at the point designated by the Engineer. Placing
shall be from spreader boxes or from vehicles especially equipped to distribute the
material in a uniform layer of windrow on the existing surface for immediate
spreading by a motor grader.
F. The layer or windrow shall be of such size that when spread and compacted, making
allowance for any blending material that is to be added on the road, the layer shall
have the required thickness of 150 mm after compaction.
G. Slope base course to the required crown elevations and cross slope grade.
H. When hauling is done over previously placed material, hauling equipment shall be
routed as uniformly as possible over the entire area of previously constructed layers.
I. Adding Blending Material: When additional fine aggregate or filler is required and it
is to be blended with the material on the road, the blending material shall be
uniformly placed with spreader boxes or other approved devices.
J. Mixing and Spreading: After layer of base course material has been placed and
blending material added when required, it shall be thoroughly mixed to its full depth
by means of power graders, travelling mixers, or other mixing equipment.
K. During the mixing, water shall be added in the amount necessary to provide the
optimum moisture content for compacting as specified in Item 3.2.M. When
uniformly mixed, the mixture shall be graded smoothly to a uniform thickness, to the
cross section shown on the Drawings.
L. The Contractor shall so schedule his operations as to assure completion of grading

within 48 hours after processing.
M. Compaction: Immediately following the spreading and water addition compact with
a pneumatic-tire roller and for the final grading and smoothing, the layer shall be

compacted to the full width by means of smooth wheel power rollers meeting the
requirements of the Technical Specifications. Each 100 square meters, compacted
material placed shall receive at least 1 hour of continuous rolling.
N. Rolling shall progress gradually from the sides to the center parallel with the
centerline of the road, and shall continue until the entire surface has been rolled.
O. Any irregularities or depressions shall be corrected by loosening the material at

these places and adding or removing material until the surface is smooth and
uniform. Along curbs, headers, and walls, and at all places not accessible to the
roller, the granular base material shall be tamped thoroughly with mechanical
tampers. The material shall be both bladed and rolled until a smooth, even surface
has been obtained.
P. The amount of rolling and tamping as required above is estimated as the minimum
necessary for adequate compaction. During the progress of the work, the Engineer
may make density tests in accordance with AASHTO T-147, modified to include only
materials passing a 19 mm sieve, and if the density is less than 100 percent of the
maximum density as determined by AASHTO T 180 Method C, the Contractor shall
perform additional rolling tamping as may be necessary to obtain that density.
Other types of field density tests may be used for control purposes after density
value corresponding to those obtained by AASHTO T 147 have been established.
Q. The Engineer may permit compaction with types of equipment other than those
specified above, provided he determines that use of the alternative equipment will
consistently produce densities of not less than 100 percent according to the
modified AASHTO Designation T180.
R. California Bearing Ratio (CBR) shall not be less than 80%, (with zero swelling)
according to AASHTO Designation T 193.
S. Thickness Requirements: The thickness of the completed base shall not vary more
than 20.0 mm from the thickness shown on the Drawings for roads and parking
areas.
T. Immediately after final compaction of the base, the thickness shall be measured at
one or more points in each 150 m length of base. Measurements shall be made by
means of test holes or other approved methods. The points for measurement shall
be selected by the Engineer at random locations within each 150 m section in such a
manner as to avoid any regular pattern. Various points on the cross section shall be
covered. Whenever a measurement indicates a variation from the thickness shown
on the Drawings of more than the allowable tolerance, additional measurement shall
be taken at intervals of approximately 50 m length. Any area not within the
allowable tolerance shall be corrected by removal or adding base course material as
necessary and shaping and compacting as specified.
U. The cutting of test holes and refilling with materials properly compacted shall be
done by the Contractor under the Engineer's supervision.
V. The levelling of the finished course shall be performed by the Contractor in a grid as
indicated by the Engineer. The Contractor shall submit all levels in due time to the

Engineer for checking and approval. Any deviation of the finished elevations from
the design elevations outside the tolerances, shall be corrected by the Contractor by
scarifying, removing and/or adding materials, sprinkling, rolling, reshaping, and
finishing in accordance with this specification.
W. Surface Requirements: Surface at completion of compaction shall be well closed,

free from movement under compaction equipment and free from ridges, crack or
loose materials. Base course shall be tested for straightness of the surface.
X. When tested by a crown template, conforming to the typical cross section shown on
the Drawings and a 3 m straight edge applied at right angles and parallel,
respectively, to the centerline of the road, the variation of the surface from each
testing edge between any two contacts with the surface shall at no point exceed the
requirements of Sub Clause 3.2.5.
3.3 PROTECTION AND MAINTENANCE
A. Protection: Work on the base course shall not be carried out when the subgrade is
too wet.
B. Hauling equipment may be routed over completed portions of the base course,
provided no damage results and provided that such equipment is routed over the
full width of the base course to avoid rutting or uneven compaction.
C. The Engineer shall have full and specific authority to stop all hauling over completed
or partially completed base course when, in his opinion, such hauling is causing
damage.
D. Any damage resulting to the base course from routing equipment over the base
course shall be repaired by the Contractor at his own expense.
E. Maintenance: Following the completion of the base course the Contractor shall
perform all maintenance work necessary to keep the base course in a condition
satisfactory for priming. The base course shall be properly drained at all times.
F. The road base shall be maintained in condition satisfactory to receive any

subsequent base or surfacing material.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
0 March 2022 A.A. 8 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. UNIT PAVING
CAIRO - EGYPT 321400 - 2874 0

CONTENT
SECTION 321400
UNIT PAVING
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
PART 2 PRODUCTS 3
2.1 Concrete Pavers 3
2.2 Accessories 4
2.3 Aggregate Setting-Bed Materials 4
2.4 Mortar Setting-Bed Materials 4
2.5 Mortar Mixes 5
PART 3 EXECUTION 5
3.1 Examination 5
3.2 Preparation 5
3.3 Installation, General 6
3.4 Ungrouted Mortarless Concrete Paver Applications 6
3.5 Mortar Setting-Bed Applications 7
3.6 Repair, Pointing, Cleaning, And Protection 8
Unit Paving Section 321400

SECTION 321400 - UNIT PAVING
PART 1 GENERAL
1.2 SUMMARY
A. This Section includes the following:
1. Ungrouted mortar less concrete interlocking unit pavers.

2. Aggregate setting-bed materials.
1.3 SUBMITTALS
A. Product Data: For materials other than water and aggregates.
B. Samples for Initial Selection: For the following:
1. Each type of unit paver indicated.

2. Exposed edge restraints involving color selection.
3. Precast concrete curbs.
C. Samples for Verification:
1. Full-size units of each type of unit paver indicated. Assemble not less than five
Samples of each type of unit on suitable backing.
2. Joint materials.
D. Shop Drawings: Show details of installation of pre-cast concrete interlocking paving

and edge restraint, including dimensions and profiles of concrete units; arrangement
and details of jointing; and details showing relationship with, attachment to, and re-
ception of related work.
A. Source Limitations: Obtain each type of unit paver, joint material, and setting mate-
rial from one source with resources to provide materials and products of consistent
quality in appearance and physical properties.
B. Fabricators Qualifications: Engage firms experienced in producing precast concrete

units paving similar to that indicated for this Project and with a record of successful
in-service performance for at least five years, as well as sufficient production capaci-
ty to produce required units without delaying the Work.

C. Mock-ups: Build mockups to verify selections made under sample submittals and to
demonstrate aesthetic effects and set quality standards for materials and execution.
1. Approved mockups may become part of the completed Work if undisturbed at

time of Substantial Completion.
A. Store pavers on elevated platforms in a dry location. If units are not stored in an en-
closed location, cover tops and sides of stacks with waterproof sheeting, securely
tied.
B. Store cementitious materials on elevated platforms, under cover, and in a dry loca-
tion. Do not use cementitious materials that have become damp.
C. Store aggregates where grading and other required characteristics can be maintained
and contamination avoided.
D. Store liquids in tightly closed containers protected from freezing.
PART 2 PRODUCTS
2.1 CONCRETE PAVERS
A. Concrete Pavers: Solid interlocking paving units complying with ES 269, made from
normal-weight aggregates.
1. Size: As indicated on Drawings.

2. Thickness: 60 mm for light traffic.
a. Extent of each type to be as indicated on Drawings.
3. Shape: As indicated on Drawings.

4. Pattern: As indicated on Drawings.
B. Color: As selected by Engineer from manufacturer's full range.
C. Finish: As selected by Engineer from manufacturer's full range.
D. Pigments: Comply with BS EN 12878.
E. Compressive Strength:
1. For Rough finish:
a. 350 N/mm2 for unit paver of thickness 60 mm.
2. Pigments: Pigments supplied in powder form shall conform to BS 1014: 1975.

Where pigments are used in the preparation of suspensions or slurries the
pigments shall conform to BS 1014:1975.

a. EU origin.
2.2 ACCESSORIES
A. Precast Concrete Curbs: Made from normal-weight with a compressive strength not
less than 34 MPa and water absorption not more than 5 percent, in shapes and sizes
indicated.
B. Compressible Foam Filler: Preformed strips complying with ASTM D 1056, Grade 2A1.
2.3 AGGREGATE SETTING-BED MATERIALS
A. Graded Aggregate for Subbase:
1. Light Duty Applications: Sound crushed stone or gravel complying with

ASTM D 448 for Size No. 57
2. Heavy Duty Applications: ASTM D 2940, subbase material.
B. Graded Aggregate for Base:
1. Light Duty Applications: Sound crushed stone or gravel complying with

ASTM D 448 for Size No. 8
2. Heavy Duty Applications: ASTM D 2940, base material.
C. Sand for Leveling Course: Shall be fine, sharp, clean masonry sand complying with
E.S. No. 1108 passing Sieve No. 16 and no more than 10% shall pass Sieve No. 200
and containing not more than 3% silt plus clay by weight.
D. Sand for Joints: ASTM C 144 except use aggregate graded with 100 percent passing
the No. 8 sieve and 95 percent, the No. 16 sieve.
E. Geotextile: Woven or nonwoven geotextile manufactured from polyester or

polypropylene fibers, with a permeability rating 10 times greater than that of soil on
which paving is founded and an apparent opening size small enough to prevent
passage of fines from leveling course into graded aggregate of base course below.
2.4 MORTAR SETTING-BED MATERIALS
A. Portland cement: E.S.S 4756.
B. Hydrated Lime: Do not add lime to the mix. Use of approved liquid-type mortar ad-
mixtures that replaces performance of lime is permitted.
C. Sand: E.S.S. 1108.
D. Latex Additive: Styrene-butadiene-rubber water emulsion serving as replacement for

part or all of gauging water, of type specifically recommended by manufacturer for
use with job-mixed Portland cement and aggregate, and not containing a retarder.
E. Water: Potable.

2.5 MORTAR MIXES
A. General: Comply with referenced standards and with manufacturers' written instruc-
tions for mix proportions, mixing equipment, mixer speeds, mixing containers, mixing
times, and other procedures needed to produce setting-bed and joint materials of
uniform quality and with optimum performance characteristics. Discard mortars if it
have reached its initial set before being used.
B. Mortar mixture shall be composed of 300 kg cement to 1 m3 of sand. Combine and

thoroughly mix cementitious materials, water and fine aggregates in a mechanical
batch mixer, comply with standards as applicable, for mixing time and water content
unless otherwise indicated.
C. Mortar for pointing shall be composed of 400 kg cement to 1 m3 sand. Combine and
thoroughly mix cementitious materials, water and fine aggregates in a mechanical
batch mixer, comply with standards as applicable, for mixing time and water content
unless otherwise indicated
D. Cement-Paste Bond Coat: Mix bond coat to a consistency similar to that of thick
cream and consisting of either neat cement and water or cement, sand, and water.
1. For latex-modified Portland cement setting-bed mortar, substitute latex ad-

mixture for part or all of water per directions of latex-additive manufacturer.
PART 3 EXECUTION
3.1 EXAMINATION
A. Examine areas indicated to receive paving, with Installer present, for compliance
with requirements for installation tolerances and other conditions affecting perfor-
mance.
1. Proceed with installation only after unsatisfactory conditions have been cor-
rected.
2. Where pavers are to be installed over waterproofing, examine waterproofing
installation, with waterproofing Installer present, for protection from paving
operations. Examine areas where waterproofing system is turned up or
flashed against vertical surfaces and horizontal waterproofing. Proceed with
installation only after protection is in place.
3.2 PREPARATION
A. Remove substances from substrates that could impair mortar bond, including curing
and sealing compounds, form oil, and laitance.
B. Clean concrete substrates to remove dirt, dust, debris, and loose particles.
C. Proof-roll prepared subgrade according to requirements in Division 31 Section "Earth

Moving" to identify soft pockets and areas of excess yielding. Proceed with unit pav-

er installation only after deficient subgrades have been corrected and are ready to
receive subbase and base course for unit pavers.
3.3 INSTALLATION, GENERAL
A. Do not use unit pavers with chips, cracks, voids, discolorations, and other defects
that might be visible or cause staining in finished work.
B. Mix pavers from several pallets or cubes, as they are placed, to produce uniform
blend of colors and textures.
C. Cut unit pavers with motor-driven masonry saw or block splitter equipment to pro-
vide clean, sharp, unchipped edges. Cut units to provide pattern indicated and to fit
adjoining work neatly. Use full units without cutting where possible. Hammer cut-
ting is not acceptable.
D. Tolerances: Do not exceed 3 mm in 600 mm and 6 mm in 3 m from level, or indicated

slope, for finished surface of paving.
E. Pavers over Waterproofing: Exercise care in placing pavers and setting materials
over waterproofing so protection materials are not displaced and waterproofing is
not punctured or otherwise damaged. Carefully replace protection materials that
become displaced and arrange for repair of damaged waterproofing before covering
with paving.
F. Expansion and Control Joints: Provide for sealant-filled joints at locations and of
widths indicated on approved shop drawings. Provide joint filler as backing for seal-
ant-filled joints where indicated. Install joint filler before setting pavers. Sealant ma-
terials and installation are specified in Division 7 Section "Joint Sealants."
G. Expansion and Control Joints: Provide joint filler at locations and of widths indicated.
Install joint filler before setting pavers. Make top of joint filler flush with top of pav-
ers.
H. Provide steps made of pavers as indicated. Install paver steps before installing adja-
cent pavers.
1. Where pavers set in mortar bed are indicated for steps constructed adjacent
to pavers set in aggregate setting bed, install steps and allow mortar to cure
before placing aggregate setting bed and remainder of pavers. Cut off mortar
bed at a steep angle so it will not interfere with aggregate setting bed.
3.4 UNGROUTED MORTARLESS CONCRETE PAVER APPLICATIONS
A. Compact soil subgrade uniformly to at least 95 percent of ASTM D 1557 laboratory

density.
B. Place aggregate subbase and base over compacted subgrade. Provide compacted
thickness indicated. Compact subbase and base to 100 percent of ASTM D 1557
maximum laboratory density and screed to depth required to allow setting of pavers.

C. Place separation geotextile over compacted base course, overlapping ends and edges
at least 300 mm.
D. Place aggregate subbase and base, compact to 100 percent of ASTM D 1557 maxi-
mum laboratory density, and screed to depth indicated.
E. Place drainage geotextile over compacted base course, overlapping ends and edges
at least 300 mm.
F. Place leveling course and screed to a thickness of 25 to 38 mm, unless otherwise in-
dicted, taking care that moisture content remains constant and density is loose and
constant until pavers are set and compacted.
G. Treat leveling base with soil sterilizer to prohibit growth of grass and weeds.
H. Set pavers with a minimum joint width of 1.5 mm and a maximum of 3.0 mm being
careful not to disturb leveling base. If pavers have spacer bars, then place pavers
hand tight against spacer bars. Use string lines to keep straight lines. Select units
from 4 or more cubes to blend color and texture variations. Fill gaps between units
that exceed 5.0 mm with pieces cut to fit from full-size unit pavers.
1. When installation is performed with mechanical equipment, use only unit pav-
ers with spacer bars on sides of each unit.
I. Spread dry sand and fill joints immediately after vibrating pavers into leveling course.
Vibrate pavers and add sand until joints are completely filled, then remove excess
sand. Leave a slight surplus of sand on the surface for joint filling.
J. Do not allow traffic on installed concrete pavers until sand has been vibrated into
joints.
K. Repeat joint filling process 30 days later.
3.5 MORTAR SETTING-BED APPLICATIONS
A. Saturate concrete subbase with clean water several hours before placing setting bed.
Remove surface water about one hour before placing setting bed.
B. Apply cement-paste bond coat over surface of concrete subbase about 15 minutes
before placing setting bed. Limit area of bond coat to avoid its drying out before
placing setting bed. Do not exceed 1.5-mm thickness for bond coat.
C. Apply mortar bed over bond coat immediately after applying bond coat. Spread and
screed setting bed to uniform thickness at subgrade elevations required for accurate
setting of pavers to finished grades indicated.
D. Mix and place only that amount of mortar bed that can be covered with curbs before
initial set. Cut back, bevel edge, remove, and discard setting-bed material that has
reached initial set before placing curbs.
E. Place curbs before initial set of cement occurs. Immediately before placing curbs on

setting bed, apply uniform 1.5-mm thick, slurry bond coat to bed or to back of each
curb with a flat trowel.
F. Tamp or beat curbs with a wooden block or rubber mallet to obtain full contact with
setting bed and to bring finished surfaces within indicated tolerances. Set each unit
in a single operation before initial set of mortar; do not return to areas already set
and disturb units for purposes of realigning finished surfaces or adjusting joints.
G. Spaced Joint Widths: Unless otherwise indicated on Drawings. Provide 15 mm nomi-

nal joint width with variations not exceeding plus or minus 1.5 mm.
3.6 REPAIR, POINTING, CLEANING, AND PROTECTION
A. Remove and replace unit pavers that are loose, chipped, broken, stained, or other-
wise damaged or if units do not match adjoining units as intended. Provide new
units to match adjoining units and install in same manner as original units, with same
joint treatment to eliminate evidence of replacement.
B. Pointing: During tooling of joints, enlarge voids or holes and completely fill with
mortar. Point up joints at sealant joints to provide a neat, uniform appearance,
properly prepared for sealant application.
C. Cleaning: Remove excess from exposed paver surfaces; wash and scrub clean.


ISSUED FOR
PURCHASE
CONSTRUCTION
X
NO. BY BY BY x
X
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. CONCRETE CURBS
CAIRO - EGYPT 321613 - 2874 0

CONTENT
SECTION 321613.26
CONCRETE CURB
Page
PART 1 - GENERAL 2
1.2 Summary 2
1.3 Submittals 2
PART 2 - PRODUCTS 3
2.1 Materials, General 3
2.2 Precast Concrete Curbs 3
2.3 Mortar And Grout Mixtures 3
2.4 Mortar Mixing And Pointing 3
2.5 Cast-In-Place Concrete Curbs 3
2.6 Joints 4
3.1 Examination 4
3.2 Preparation Of Ground Surface 4
3.3 Laying Precast Curbs 4
3.4 Cleaning 4
3.5 Tolerances 5
Concrete Curbs and Gutter Section 321613

SECTION 321613 - CONCRETE CURBS AND GUTTER
PART 1 - GENERAL
A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.
B. Related Sections:
1. Division 31 Section "Earthwork" for sub-grade preparation, grading, and sub-

base course
2. Division 03 Section "Cast-in-Place Concrete"
1.2 SUMMARY
A. This section covers the contractor works as required for the followings:
1. Pre-Cast Concrete Curbs

2. Cast-in Place Curb and Gutter
1.3 SUBMITTALS
A. Materials specifications and manufacturer’s data sheet
B. Representative samples of all materials to be used in the work in full size units of each
type.
C. Shop drawings showing patterns, colors and full range of variations expected
A. Reference Standards: Works shall be performed in strict accordance with the stipulations of
the Egyptian Standard Specifications (ES) last edition, the American Society of testing and
materials (ASTM) and the American Association of State Highway and Transportation Officials
(AASHTO).
1. E.S. No.
a. 373 Portland Cement (Ordinary and Rapid Hardening)

b. 1109 Concrete Aggregates from Natural Sources
c. 1289 Concrete Curbs
2. AASHTO No.
a. M 33 Specifications for Joint filler
3. ASTM No.

a. C33 Concrete Aggregates
b. C39 Compressed strengths of cylindrical concrete specimens.
c. C150 Portland cement
A. Store Road Curbs in a clean, dry and protected location.
PART 2 - PRODUCTS
2.1 MATERIALS, GENERAL
A. Materials for concrete shall be in accordance with Division 3 Section “Cast-In-Place

Concrete”.
B. Materials for mortar shall be ordinary Portland cement to ASTM C150 and aggregates
to ASTM C 144.
2.2 PRECAST CONCRETE CURBS
A. The curbs shall not present defects such as cracks, distortion or stripping with the di-
mensions, section size, length and shape shown on the drawings with fair and smooth
finishing.
B. Compressive strength of concrete after 28 days shall not be less than 210kg/cm2.
2.3 MORTAR AND GROUT MIXTURES
A. Provide natural color Portland cement in combination with sand and filler materials to
produce joints. Mortar and Grouting shall be 400 kg cement to 1 m3 sand.
B. Grading of aggregates shall be as follows:
1. For joints narrower than 6 mm use aggregate graded with 100% passing the No.
8 sieve and 95% the No. 16 sieve.
2. For pointing mortar use aggregate graded with 100% passing the No.16 sieve.
2.4 MORTAR MIXING AND POINTING
A. Combine and thoroughly mix the cementations materials, water and aggregates in a
mechanical batch mixer as applicable for mixing time and water content.
B. The thickness of the joint between two (2) units of curbs shall be fixed to 5 mm in no
case it shall exceed 10 mm. The joints shall be flat and smoothed with the trowel.
2.5 CAST-IN-PLACE CONCRETE CURBS
A. Forms: Forms shall be made to the required shape according to Drawings, of metal hav-
ing a thickness of not less than 4 mm and shall be furnished in sections of not less than
3.0 m in length.

B. Concrete: Shall be plain concrete complying with Division 3 Section “Cast-In-Place Con-
crete”.
2.6 JOINTS
A. Joints should be constructed with the dimensions and in the places shown in the details
drawings.
B. If the joints are made to be separate from the concrete pavement, or connected with
an elastic binder or wearing surfaces, a metallic mould could be put in the joint’s loca-
tion after the curb has been completely spread with a depth not less than 30mm
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine exposed sub-grades and sub-base surfaces for compliance with requirements
for dimensional, grading, and elevation tolerances.
3.2 PREPARATION OF GROUND SURFACE
A. Soil shall be manually or mechanically compacted uniformly to the sufficient density

(95% relative density).
B. Following, an appropriate sand base in thickness indicated shall be spread and com-
pacted to 95% relative density by tamping with plate vibrator and screed to depth re-
quired to allow setting of pavers units.
3.3 LAYING PRECAST CURBS
A. Curbs shall be bed in plain concrete Type C as per Division 3 Section “Cast-In-Place Con-
crete” hunched half way up back. Joint with mortar as specified herein before as the
work proceeds neatly flush pointed. Lay curbs to lines shown on Drawings with top sur-
face flush and level. Form curves with straight pieces with angling the joints.
B. Laying The cast-in-place concrete Curbs
C. The curbs should be constructed to be one piece with the concrete pavement, the con-
crete should be poured and compacted then shaped with a steel tool according to the
cross-section shown in the details drawings.
3.4 CLEANING
A. After grouting has sufficiently set or hardened, curb surface shall be cleaned and traces
of cement or dust accumulations and foreign matter shall be completely removed.
B. Repair or remove and replace curbs which may damage during paving works on the
contractor responsibilities.

3.5 TOLERANCES
A. The finished work shall be true to line grade and levels within 5mm and shall present a
smooth appearance free from kinks and distortions visible to the eye.


ISSUED FOR
PAGES BECOME PART OF THE ORIGINAL SPECIFICATION AND SHALL BE REVIEW/COMMENTS X
PURCHASE
CONSTRUCTION

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. PAINTED ROADWAY MARKING
CAIRO - EGYPT 321723 - 2874 0

CONTENT
SECTION 321723
PAINTED PAVEMENT MARKINGS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
PART 2 PRODUCTS 3
2.1 Paints 3
2.2 Glass Beads (Ballotini) 4
2.3 Paint Equipment 4
PART 3 EXECUTION 5
3.1 General 5
3.2 Application 5
3.3 Cleaning 5
Painted Pavements Markings Section 321723

SECTION 321723.13 – PAINTED PAVEMENT MARKING
PART 1 GENERAL

1.2 SUMMARY
A. This section covers the Roadway Marking Paint works as required by the contract
for:
1. Marking of the centerline, edge line& Lanes separators, Stop line, etc.
2. Parking bays.
3. Pedestrian Crossings.
4. Ground marking shapes (Traffic Arrows, Give way, etc.).
5. Chevrons at merging or diverging of roads.
B. Extent and location of the roadway marking paint is shown on Drawings.
C. Related Sections:
1. Division 3 Section “Cast-in-place Concrete”
1.3 SUBMITTALS
A. Materials specifications and manufacturer's data
B. Representative samples of all materials to be used in the work for each color,
texture
C. Shop drawings showing patterns, colors and full range of variations expected

Works shall be performed in strict accordance with the stipulations
of the Egyptian standard specifications (ES) last edition, the
specifications of the roads and bridges authority (RBA), and the
American association of state highway and transportation officials
(AASHTO).

AASHTO No.
247 Glass Beads Use in Traffic Paint

248 Ready Mixed White and Yellow Traffic Paint
E.S. No.
794 White Paint for Traffic Use
A. In the event of conflict between various codes and standards, the most stringent
conditions shall apply.
A. Tests: Use standard test with manufacturer to determine if painting materials will
obtain optimum adhesion with asphalt, and shall be nonstinging to asphalt paving
surface or materials constituting the paving. Schedule for sufficient time for testing
and analysis of results to prevent delaying the work.
B. Mock-up: Prior to proceed with the roadway marking work, construct mock-ups for
each form and pattern required to demonstrate aesthetic effects as well as qualities
of materials and execution. Paint mock-ups using material indicated for final unit of
work including same base construction special features as indicated.
A. Deliver pavement marking materials to project site in original package with seals
unbroken and bearing manufacturer's labels containing brand name, type of
materials and date of manufacture.
B. Containers shall be made of a material which does not contaminate the contents,
and shall protect the contents from contamination.
C. Store pavement marking materials in a clean, dry, protected location and within
temperature range required by manufacturer. Protect stored materials from direct
sunlight.
PART 2 PRODUCTS
2.1 PAINTS
A. Thermoplastic Paint: Shall be thermoplastic sprayable or hand-applied consisting of:

1. Light colored aggregates of white silica sand, crushed calcite, quartz, etc., with
a luminance of not less than 50% when compared with magnesium carbonate.
2. Pigments shall be titanium bioxide and shall not be less than 10% of weight of
the mix.
3. Extender shall be whiting. The components shall be bound to the pigments
with hard- wearing resins, and the total content of pigment and extender shall
be 18-22%.
B. The components shall be plasticized with oil as necessary in approximately the

following proportions by weight:
1. Aggregate 40 parts
2. Ballotini 20 parts
3. Pigment and Extender 20 parts
4. Binder 20 parts
C. The grading of the various ingredients shall be such that the final product when in a
molten state can be sprayed on the road surface at approximately 1.5 mm thickness.
D. Alkyd-resin type, ready mixed complying with AASHTO M-248 Type N Factory mixed
quick drying and non-bleeding.
E. A minimum drying time of 1/2 an hour is allowable.
F. Latex, water-base emulsion, ready-mix. The minimum drying time of 2 hours shall
be allowed.
G. Paint Color: White or yellow as required by Engineer.
H. Colored lines shall remain free from discoloration by normal traffic.
2.2 GLASS BEADS (BALLOTINI)
A. Where specifying reflective feature add glass beads (sphere) to the paint.
B. Glass beads incorporated in the mixture shall be in accordance with AASHTO M

247,it shall be transparent glass, reasonably spherical and free from flaws.
C. The ballotini sprayed on the surface of the line shall conform to the same limits of
color and roundness. Consumption shall be up to 6 kg per 10 liters of paint.
2.3 PAINT EQUIPMENT
A. The mechanical marker shall be an approved mobile atomizing spray type marking
machine for the application of the required paint, either hand-propelled or machine-
propelled, capable of applying paint in single, double and dashed lines.

PART 3 EXECUTION
3.1 GENERAL
A. Allow paving to cure for 30 days before starting pavement marking paint.
3.2 APPLICATION
A. Do not apply pavement marking paint until layout, colors and placement have been
verified with Engineer.
B. Proceed with pavement marking only on dry, clean surfaces, entirely free from dirt,
mud, grease, oil, etc., and at a minimum ambient or surface temperature of 10 C
and not exceeding 35C for oil based materials.
C. Sweep broom, blow and clean surface to eliminate loose materials and dust.
D. Sand blasting or high pressure water shall be used to remove curing compound, or
old paint.
E. Apply paint with an approved mechanical pressure spray unit equipment to produce
uniform straight edges with the general alignment of the carriage way.
F. Paint shall be applied uniformly in continuous or intermittent lines at the rate

required.
G. The finished lines shall be free from "raggednesses" on sides and ends.
H. Apply in 2 coats at manufacturer recommended rates to provide a minimum net dry

film thickness of 0.4 mm.
I. In addition to the ballotini included in the mix, an additional quantity of glass beads
shall be sprayed on the wet spray plastic line at the time of application. The rate of
application shall be about 0.5 kg/m2. The upper surfaces of the lines shall be level,
uniform and free from streaks.
J. The thermoplastic must possess excellent wear-resistant properties, the loss in

weight after 200 revolutions shall not exceed 0.5 gm.
3.3 CLEANING
A. All marking paint shall be protected from damage until the paint is dry. Paint shall
be protected from all traffic, vehicle and pedestrian. All paints shall be maintained to
the Engineer's satisfaction.
END OF SECTION 32 17 23


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
0 March 2022 I.K. 72 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. WATER SUPPLY, IRRIGATION MAIN
CAIRO - EGYPT AND FIREFIGHTING NETWORKS 331000 - 2874 0

CONTENTS
SECTION 331000
WATER SUPPLY, IRRIGATION MAIN AND FIREFIGHTING NETWORKS
PAGE
PART 1 GENERAL 2
1.2 Description Of Work 2
1.4 Submittals 5
1.7 Delivery, Handling And Storage 11
PART 2 PRODUCTS 14
2.1 Warning Tapes 14
2.2 Geo-Textile 15
2.3 Pipes, Fittings And Accessories 16
2.4 Valve Features, General 23
2.5 Irrigation Equipment And Accessories 40
PART 3 EXECUTION 45
3.1 General 45
3.2 Pipes 46
Water Supply, Irrigation Main and Firefighting Networks Section 331000

SECTION 331000 – WATER SUPPLY, IRRIGATION MAIN AND FIREFIGHTING NETWORKS
PART 1 GENERAL
A Drawings and general provisions of the Contract, including General and Supplemen-
1.2 DESCRIPTION OF WORK
A This section covers water pressure pipes, valves as indicated on the drawings and
specified here in addition to all types of Potable water structure such as valve cham-
bers as required by the Contract. Extent of these structures is indicated on Drawings.
B This section covers fire pressure pipes, valves as indicated on the drawings and speci-
fied here in after in addition to all types of Fire water structure such as valve cham-
bers as required by the Contract. Extent of these structures is indicated on Drawings.
C This section covers Irrigation pressure pipes, valves as indicated on the drawings and
specified here in after in addition to all types of irrigation water equipment’s and
structure such as valve chambers as required by the Contract. Extent of these struc-
tures is indicated on Drawings.
D The Contractor shall provide equipment, materials, transportation, storing, safety

tools and labor required for proper construction of the water networks.
A The work shall be performed in strict accordance with the stipulations of the British
Standard Specifications (BS), American Standards (ASTM) as noted herein below or
other equivalent approved Standards and Sound Practice.
B British Standard Specifications ( BS No.)
1. BS EN 545 Ductile iron pipes, fittings, accessories and their

joints for water pipelines. Requirements and test
methods
2. BS 4772 Specification for ductile iron pipes and fittings
3. BS 3416 Specification for bitumen based coatings for cold

application suitable for use in contact with potable
water
4. BS 2494 Specification for elastomeric seals for joints in
pipe-work and pipelines.
5. BS 6076 Specification for tubular polyethylene film for use
as protective sleeving for buried iron pipes and
fittings.
6. BS EN 1092 Flanges and their joints. Circular flanges for pipes,
valves, fittings and accessories, PN designated
7. BS EN 1514 Flanges and their joints. Dimension of gaskets for
PN-designated flanges.
8. BS EN 12201 Plastic piping systems for water supply - polyeth-

ylene
9. BS EN 13244 Specification for Polyethylene Pipes (Type 50) in
Metric Diameters for General Purposes
10. BS 5955-8 Plastics pipework (thermoplastics materials). Spec-
ification for the installation of thermoplastic pipes
and associated fittings for use in domestic hot and
cold services and heating systems in buildings
C International Organization for Standardization (ISO No.)
1. ISO 4427 Polyethylene (PE) pipes for water supply – specifi-

cations
2. ISO 161-1 Thermoplastic pipes for conveyance of fluids –
nominal outside diameter and nominal pressure-
part 1: Metric series
3. ISO 1167-1to 4 Thermoplastic pipes, fittings and assemblies for
the conveyance of fluids
4. ISO 3126 Plastic pipes – Measurement of dimensions
5. ISO 4065 Thermoplastic pipes – Universal wall thickness ta-
ble
6. ISO 6964 Polyolefin pipes and fittings – Determination of
carbon black content by calcination and pyrolysis –
Test method and basic specification.
7. ISO 9080 Thermoplastic pipes for the transport of fluids –
Method of extrapolation of hydrostatic stress rup-
ture data to determine the long-term hydrostatic
strength of thermoplastic pipe materials.
8. ISO 11922-1 Thermoplastic pipes for the conveyance of fluids –
Dimensions and tolerances Part: 1: Metric series.
9. ISO 12162 Thermoplastic materials for pipes and fittings for
pressure applications – Classification and designa-
tion – overall service (design) coefficient.
10. ISO 13761 Plastic pipes and fittings – pressure reduction fac-
tors for polyethylene pipeline systems for use at
temperatures above 200 C.
11. ISO 7005 – 3 Metallic flanges – Part 3, Copper alloy and compo-
site flanges
12. ISO 974 Determination of the brittleness temperature by
impact
13. ISO 2505 Thermoplastics pipes - Longitudinal reversion
14. ISO 6259 Determination of tensile properties
15. ISO 1133 Determination of the melt mass-flow rate (MFR)
and the melt volume-flow
16. ISO 877 Methods of exposure to direct weathering
17. ISO 2531/EN Ductile iron pipes, fittings, accessories and their
545 joints for water or gas applications.
18. ISO 4179 Ductile iron pipes and fittings for pressure and
non-pressure pipeline – Centrifugal cement mortar
lining
19. ISO 4587 Adhesives – Determination of tensile lap-shear
strength of rigid-to-rigid bonded assemblies.
20. ISO 4633 Rubber seals – Joint rings for water supply, drain-
age and sewerage pipeline – Specification for ma-
terials.
20. ISO 16134 Earthquake and subsidence resistant design of
ductile Iron pipes
21. ISO 6506-1 Metallic materials – Hardness testing – Brinell test
– Part 1: Test method.
22. ISO 6708 Pipe works components – Definition and selection
of DN (nominal size).
23. ISO 7005-2 Metallic flanges – Part 2: Cast iron flanges.
24. ISO 7268 Pipe components – Definition of nominal pressure.
25.. ISO 7483 Dimensions of gaskets for use with flanges to ISO
7005.
26. ISO 8179-1 Ductile iron pipes – External coating – Part 1: Me-
tallic zinc with finishing layer.
27. ISO 8179-2 Ductile iron pipes – External coating – Part 2: Zinc
rich paint with finishing layer.
28. ISO 8180 Ductile iron pipes – Polyethylene sleeving for site
application.
29. ISO 8501-1 Preparation of Steel Substrates.
30. ISO 9001:2000 Quality Management System
31. ISO 10804 Restrained joint systems for ductile iron pipelines
– Part 1: Design rules and type testing.
32. ISO 8503-1 Preparation of steel substrates before application
of paints and related products.
D American Society for Testing and Materials & American Water Works Association
(ASTM & AWWA No.)
1. AWWA C651 Disinfecting Water Mains

2. ANSI/AWWA Cement mortar Lining for Ductile Iron Pipe and
C104/A21.4 Fittings for Water
3. ANSI/AWWA Polyethylene Encasement for Ductile Iron Pipe

C105/A21.5 Systems
4. ANSI/AWWA Ductile Iron and Gray Iron Fittings, 3in. through
C110/A21.10 48in. for Water and Other Liquids
5. ANSI/AWWA Rubber Gasket Joints for Ductile Iron Pressure Pipe
C111/A21.11 and Fittings
6. ANSI/AWWA Flanged Ductile Iron Pipe with Ductile Iron or Gray
C115/A21.15 Iron Threaded Flanges
7. ANSI/AWWA Thickness Design of Ductile Iron Pipe
C150/A21.50
8. ANSI/AWWA Ductile Iron Pipe, Centrifugally Cast for Water
C151/A21.51
9. ANSI/AWWA Ductile Iron Compact Fittings, 3”24” and 54”64”
C153/A21.53 for Water Service
10. ANSI/AWWA Installation of Ductile Iron Water Mains and their
C600 Appurtenances
11. ANSI/AWWA Grooved and Shouldered Joints
C606
12. ANSI/AWS Guide for Welding Iron Castings
D11.2
13. AWWA C901 Polyethylene (PE) pressure Pipe & Tubing, ½ inch
through 3 inch for water
14. AWWA C906 Polyethylene (PE) pressure Pipe & Fittings, 4 inch
through 63 inch for water
15. ASTM D2321 Standard Practice for Underground Installation of
Thermoplastics Pipe for Sewers and Other Gravity
Flow Applications.
16. ASTM F894 Specification for Polyethylene (PE) Large Diameter
Profile Wall Sewer and Drain Pipe.
17. ASTM D3035 Standard Spec for PE Pipe (DR-PR) Based on Con-
trolled Outside Diameter
18. ASTM D3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
19. ASTM D3350 Standard Specification for PE Pipe & Fittings Mate-
rials
20. ASTM D1238 Melt Flow Index
20. ASTM D1505 Density of Plastics
21. ASTM D2837 Hydrostatic Design Basis
1.4 SUBMITTALS
A Submit the following in accordance with Conditions of the Contract and Division-1
1. Pipes
a. Material technical specifications list and manufacturer’s data of the

pipes include its jointing material, method, fittings/ accessories, bedding
material.
b. Original catalogue
c. Material Certificates of compliance.
d. Materials Sample.
e. Method statement of pipelines construction.
f. Shop drawings.
g. Record drawings.
h. Maintenance data.
i. Certificates of origin.
2. Valves
a. Material technical specifications list and manufacturer’s data of each

type of valve, hydrants, surface box, etc..
b. Original catalogue
c. Representative samples of the above mentioned items.
d. Material Certificates of compliance.
e. Method statement of construction.
f. Shop drawings.
g. Record drawings.
h. Certificates of origin.
i. Installation procedures for fixing, supporting, and anchoring valves
j. Test procedures for adjusting and testing valve assemblies.
k. Operations and Maintenance Manuals:
1) The Contractor shall submit five copies of complete operation and

maintenance manuals for valves written in English. Required opera-
tion and maintenance data shall include, but not limited to
2) Complete, detailed written operating instructions for each product
or piece of equipment. Manuals must be specific to the products
supplied herein and the application and operating conditions in Qa-
tar. General manuals will not be accepted
3) Complete, detailed preventative maintenance instructions
4) A complete inventory of all parts and components
5) Recommended spare parts lists and sources of supply for the parts
6) All safety instructions relating to operation and maintenance proce-
dures
7) Name, address and phone number of manufacturer, manufacturer’s
authorized service representative
8) Troubleshooting instructions.
3. Valve Chambers
a. Detailed design and calculations for different types of valve chambers.

b. Shop drawings for all types of cast-in-situ concrete structures and cham-
bers
c. Materials list, original catalogue, certificate of origin and manufacturer's
data sheet of the ductile iron frames, covers, steps, ladders, grout, wa-
terproofing of the valve chamber.
d. Representative samples of the ductile iron frames, covers, ladders and
steps.
e. Method statement of the chamber construction.
f. Shop drawings of the ductile iron frames and covers installation.
g. Shop drawings of the chambers steps/ladders installation.
h. Record drawings of chambers.
i. Certificates of origin.
4. Certifications:
a. Upon request the CONTRACTOR shall furnish a certified affidavit of

compliance for all pipe and other products or materials furnished under
this Section, as specified in the referenced standards and as specified in
Quality Assurance.
b. Sample Costs: All expenses incurred in making samples for certification
of specified tests shall be borne by the MANUFACTURER

1.5 QUALITY CONTROL
A Testing
1. Testing Laboratory Services
a. All tests which require the services of a laboratory to determine compli-

ance with the commercial testing laboratory acceptable to the Engineer.
The laboratory shall be staffed with experienced technicians, properly
equipped, and fully qualified to perform the tests in accordance with the
specified standards.
2. Preliminary Testing Services.
a. Unless otherwise specified, the Contractor shall be responsible for all

testing laboratory services in connection with concrete materials and
mix designs, the design of asphalt mixtures, gradation tests for embed-
ment, fill, backfill materials, and all other tests and engineering data re-
quired for the Engineer's review of materials and equipment proposed
to be used in the Work. The Contractor shall obtain the Engineer's ac-
ceptance of the testing laboratory before having services performed,
and shall pay all costs for services.
3. Quality Control Testing Services.
a. Quality control tests shall be performed in the field or laboratory on

concrete, asphalt mixtures, moisture-density (Proctor) and relative den-
sity tests on embedment, fill, and backfill materials, in-place field density
tests on embedment’s and fills, and other materials and equipment, dur-
ing and after their incorporation in the Work. Field sampling and testing
will be performed by the Contractor, in the general manner indicated in
the specifications, with minimum interference with construction opera-
tions. The Engineer shall determine the time and location of field sam-
pling and testing, and such additional sampling and testing as necessary
to determine that materials and equipment conform to data previously
furnished by the Contractor.
b. Arrangements for delivery of samples and test specimens to the testing
laboratory will be made by the Contractor. All laboratory tests shall be
performed within a reasonable time consistent with the specified stand-
ards and the Contractor shall furnish a written report of each test.
c. The Contractor shall furnish all sample materials and coordinate the
sampling and field testing activities. The Contractor shall furnish per-
sonnel and facilities to perform the testing activities.
d. If at any time during the construction process the testing services be-
come unacceptable to the Engineer, the Engineer may request in writing
that such services be terminated. If the Engineer determines that suffi-
cient cause exists, the Contractor shall terminate the services and en-
gage an acceptable testing laboratory.
4. Transmittal of Test Reports.
a. Written reports of tests and engineering data furnished by the Contrac-

tor for the Engineer's review of materials and equipment proposed to be
used in the Work shall be submitted as specified for Shop Drawings.
b. The testing laboratory shall furnish three copies of a written report of
each test performed by laboratory personnel in the field or laboratory.
Distribution shall be two copies of each test report to the Engineer's
Representative, one copy to the Contractor within three days after each
test is completed.
A General
1. Codes and Standards. Reference to the standards of any technical society, or-
ganization, or association, or to codes of local authorities, shall mean the latest
standard, code, specification, or tentative standard adopted and published at
the date of taking tender, unless specifically stated otherwise.
2. In the absence of a specified referenced code or standard, the Contractor may
propose other recognized international codes and standards, and in such a
case the Contractor shall demonstrate to the satisfaction of the Engineer, suit-
ability and equivalence of the substitute codes and standards as well as pro-
vide proof of previous successful use.
3. Work specified by reference to the published standard or specification of a
government agency, technical association, trade association, professional soci-
ety or institute, testing agency, or other organization shall conform or surpass
the minimum standards of quality for materials and workmanship established
by the designated standard or specification.
4. Where the specific date or issue of the standard is not included with the refer-
ence to the standard, the latest edition, including all amendments published
and available on the first published date of the Invitation to Tender, shall ap-
ply.
5. Where two or more standards are specified to establish quality, the product
and workmanship shall conform to or surpass the requirements of both. In
case of conflict between referenced standards, the more stringent shall apply.
6. Where both a standard and a brand name are specified for a product in the
Contract Documents, the proprietary product named shall conform to or sur-
pass the requirements of the specified reference standard.
7. The listing of a trade name in the Contract Documents shall not be construed
as warranting that such product conforms to the respective reference stand-
ard.
8. Copies of applicable referenced standards have not been bound in this Con-
tract Document. Where copies of standards are needed by the Contractor for
superintendence and quality control of the work, Contractor shall obtain a
copy or copies directly from the publication source and maintain in an orderly
manner at the jobsite, available to the Contractor's personnel, subcontractors,
Employer, and Engineer.
9. Contractors shall clearly identify and submit for approval any requests to use
products conforming to printed standards or publications with a different pub-
lication date from that effective under the Contract. Clearly indicate the
changes in product or workmanship quality involved in the proposed change, if
any, and reasons for the request.

B ISO/Third Party Inspection:
1. A copy of the MANUFACTURER's QA/QC plan shall be submitted to /End us-

ers/ENGINEER with its quotation for review and concurrence prior to award. If
MANUFACTURER's facility is ISO certified, QA audit requirements shall be
waived in favor of ISO 9000; ISO 9001:2000 registered or provide the services
of an Independent Inspection Agency. registrar audits, unless /End us-
ers/ENGINEER'S trend analysis program indicates areas of concern
C Factory Hydrostatic Test:
1. HDPE, the MANUFACTURER shall establish and maintain a current record of

test results according to the requirements of the applicable standards and this
specification. The MANUFACTURER shall perform all the tests required by ISO
4427 to demonstrate the characteristics and quality of the resin material and
the dimensional tolerances of the pipe. The MANUFACTURER shall document
all the tests, with frequencies and results as indicated in ISO 4427. The records
shall be kept for 10 years as a minimum.
2. DI, all pipes shall be subject to a factory hydrostatic test of at least 500 psi for a
period of not less than 10 seconds. All C153 fittings shall be subject to a factory
hydrostatic test of at least 350psi. All C110 fittings shall be subject to a factory
hydrostatic test of at least 250psi.
D Inspection:
1. All pipes, Valves, Irrigation equipment’s and fittings shall be subject to inspec-
tion at the place of manufacture, in accordance with the provisions of the ref-
erenced standards.
2. The Contractor shall give appropriate written notice to the Engineer not less
than 28 days before offsite inspection services are required, and shall provide
for the producer, manufacturer, or fabricator to furnish safe access and proper
facilities and to cooperate with inspecting personnel in the performance of
their duties.
E Tests:
1. All materials used in the manufacture of the pipes, fittings and specials shall be
tested in accordance with requirements as applicable.
F Test Costs:
1. The MANUFACTURER shall perform said material tests at no additional cost to

the OWNER. The ENGINEER shall have the right to witness all testing conduct-
ed by the MANUFACTURER, provided that the MANUFACTURER's and CON-
TRACTOR's schedule is not delayed for the convenience of the ENGINEER.
G Plant Access:
1. During the manufacture of the pipe, valves, irrigation equipment’s and fittings,
the ENGINEER shall be given access to all areas where manufacturing and test-
ing is in process and shall be permitted to make all inspections necessary to
confirm compliance with the Specifications.

H Affidavits:
1. Upon request the CONTRACTOR shall submit affidavits of compliance from the
MANUFACTURER for the following:
a. Ductile Iron
1) Ductile iron pipe in accordance with the requirements of AWWA C151

and these specifications.
2) Cement mortar lining of ductile iron pipe, specials, and fittings in ac-
cordance with the requirements of AWWA C104 and these specifica-
tions.
3) Polyethylene encasement for ductile iron piping in accordance with
AWWA C105 (if specified).
4) Rubber gasket joints for ductile iron pressure pipe and fittings in ac-
cordance with the requirements of AWWA C111 and these specifica-
tions.
5) Charpy impact testing of ductile iron used in the manufacture of pipe
shall be performed in accordance with AWWA C151.
6) Low temperature impact tests shall be made from at least 10% of the
test pipe to assure compliance.
b. HDPE
1) A copy of the raw material MANUFACTURER's "Certificate of Quality

Control Testing" covering each batch of raw material used for pipes
purchased under this specification, shall be available for inspection by
the End users/ENGINEER on request.
2) Pipe wall thickness shall be controlled by continuous scanning using ul-
tra-sound or other qualified devices. These devices shall be regularly
calibrated for accuracy by certificated agency.
3) Successful test performance and acceptable results for the testing
program outlined in this specification.
4) An acceptable inspection report from an independent third party in-
spection company according in the manufacturer's country.
5) When performed, acceptable results from an independent test audit
of any portion of the tests noted in ISO 4427 and this specification.
c. Valves
1) Manufacturer’s Name or Trademark

2) Nominal Diameter(s) (N.D) in mm.
3) Pressure Rating in Bars.
4) Individual Serial Number which relates directly to the Manufacturers
test certificate on steel plate
5) Date of Manufacture mentioned on steel plate fixed on valve
6) Weight of valve for sizes above 300mm dia.
I Warranty:
1. The MANUFACTURER shall provide the OWNER a 5 year warranty against

manufacturing defects.

1.7 DELIVERY, HANDLING AND STORAGE
A Vendor Documentation
1. Each pipe, fitting and special appurtenance shall be marked with permanent
identification which shall include but not necessarily limited to the following:
a. Nominal diameter
b. Name or trade mark of manufacturer
c. Serial number
d. Class of pipe, pressure rating in compliance with referenced standards
e. Date of manufacture
f. Type of service
g. Details on fittings such as angle of change and taper
h. Clearly marked on the inside and outside to indicate the top of the pipe
when laid.
i. Certificate from Manufacturer
j. Certificate from PE 100 + Association
k. Local agent name and address.
2. Each Valve shall furnish following vendor data as a minimum, with the bid:
a. Detailed reference list to fulfill criteria for acceptance.

b. Catalogues/Brochures.
c. Cross section drawings with detailed parts list, as applicable.
d. Detailed material specifications.
e. Completely filled-in and stamped data sheet.
f. Dimensioned general arrangement drawing, as applicable.
g. Complete details of testing facilities at manufacturers works.
h. Local agent name and address.
3. Bids not accompanied by any of above mentioned information/data shall be

considered incomplete, and liable to be rejected.
B Delivery
1. The acceptability of the pipes and fittings on delivery to the Site will be based
on the results of tests carried out by one or more of the following:
a. The manufacturer at the place of manufacturer

b. The Engineer
c. A third party on behalf of the Engineer
2. The Engineer shall be permitted at all reasonable times to visit places of manu-
facture to witness tests.
3. The Engineer may require checking dimensional accuracy of pipes and fittings
at the place of manufacture, the cost of such verification shall be borne by the
Contractor.
C Transport, Handling and Storage

1. Transport, handling and storage of pipes valves, irrigation equipment’s and fit-
tings shall be carried out as follows:
a. In accordance with the manufacturer’s recommendations subject to the

approval of the Engineer
b. Effective precautions shall be taken to prevent damage to the pipe,
valves and fittings.
2. During transport
a. Pipes and fittings shall be well secured and adequately supported along
their length
b. Bolsters and binding of approved type shall be used
c. Nesting of pipes (placing a smaller pipe inside a larger) may be permitted
for pipes of certain materials and size provided that methods state-
ments demonstrate that effective precautions will be taken to protect
all pipe surfaces and coatings from damage
d. No pipe shall overhang the end of a vehicle
e. Pipes and fittings of plastic materials shall be covered.
3. Handling shall be carried out as follows:
a. Pipes should be lifted singly and not handled as bunches

b. Pipes shall be handled only by means of
1) Approved hooks, of the type having a plate curved to fit the curva-
ture of the inside of the pipe, on ends of sections
2) Fabric slings not less than 250 mm wide
3) Other methods approved for the pipe used
c. Use of w ire rope, chains and fork lift trucks will not be permitted
d. For strings of pipe longer than the standard length precautions shall be
taken to avoid curvature and longitudinal stress in excess of allowable
limits
e. Pipes and fittings of plastic materials
1) Smaller than 300 mm diameter may be handled manually

2) Larger than 300 mm diameter and greater than 4 meters in length
shall be lifted using fabric lifting straps or large diameter rope slings
positioned at a quarter of the pipe length from each end
3) There should be enough slack in the slings to keep the hook approx-
imately 600 mm over the pipe
4) Steel chain or hooks shall not come into contact with the pipe
f. Pipes and fittings shall not be dropped or bumped

g. Pipes shall not be dragged over the ground
h. If rolled, pipes shall be rolled only over adequate timber bearers to pre-
vent damage
i. Where necessary, chocks shall be used to prevent lateral movement of
pipes.
j. Valves greater than 500 mm diameter shall be individually packed. Two
valves may have the packing joined provided the combined weight does
not exceed 3 tonnes. Gate valves (up to 300 mm diameter) may be
placed together provided that the packages do not exceed 4 tonnes in
weight and individual valves are prevented from moving within the
package. Air valves and fire hydrants shall be packaged in a similar man-
ner to gate valves. Each box shall be clearly marked with Municipality
name, order number, valve size and class. The following documents
shall be included in suitable wrapping and shall be enclosed with the
shipment:
1) Packing list.
2) General arrangement and catalogues.
3) Operation and maintenance manual as applicable.
4) Installation instructions
4. All pipes, valves, fittings and materials shall be stored in accordance with the
manufacturer’s recommendations and the following:
a. Pipes may be stored in the open on a flat level area and raised above the
ground on timber bearers so that the lowest point of any pipe or fitting
is not less than 150 mm above the ground
b. Timber bearers not less than 200 mm wide and 75 mm thick to be pro-
vide d at 4 m intervals maximum
c. If on pallets or crated, on the pallets or in their crates until required
d. If not on pallets or not crated, stacked one above the other as follows:
1) In accordance with the manufacturer’s recommendations but not to a

greater number of tiers than the following:
Pipes ≥ 900 mm diameter 2 tiers
< 900 mm ≥ 600 mm diameter 3 tiers
< 600 mm diameter 4 tiers
2) Suitable protective packing shall be placed between tiers to the ap-
proval of the Engineer
3) Wrapped pipes shall not be stacked
e. If spigot and socket, stacked so that successive pipe layers have sockets
protruding at opposite ends of the stack
f. With pipes of different sizes and thick ness stacked separately
g. With maximum height of stacked pipes not exceeding 2m, or that rec-
ommended by the supplier if less than 2 m.
h. Pipes and fittings of plastic materials shall be:
1) Stored under cover and out of direct sunlight

2) Adequately supported along their length
3) Provided with a free flow of air around the pipe.
i. Storage of jointing materials shall be as follows:
1) Under cover
2) Rubber ring gaskets shall
3) Stored in their original packing
4) Not be exposed to sunlight
5) Protected from exposure to greases and oils
6) Gasket lubricants shall be stored so as to prevent damage to the con-
tainer.
j. Pipes and fittings shall be protected in storage to the approval of the En-
gineer by means of an impermeable membrane which shall cover the
pipes and fittings and separate them from the ground on which they are
supported. The membrane shall be strong and durable in the prevailing
climate conditions.
k. Pipes and fittings shall be subject to visual inspections after off-loading

at site and before installation.
l. Storage of valves shall be as follows:
1) Valves should be stored in a location that protects the valve from any
pollution or contamination.
2) The valves must be stored in upright position and in an almost closed
position to prevent long-term compression of the wedge rubber.
3) The valve must be kept out of sunlight to prevent oxidation of the
rubber and coating. Valves stored in cold storage must be protected
against freezing.
4) Gate valves with PE pipe connection have to be stored and handled
carefully to avoid damage of the pipe.
5. The following procedures shall be followed for dealing with damaged pipes
and fittings:
a. Pipes and fittings damaged during transportation handling and storage

shall be set aside and the damage brought to the attention of the Engi-
neer
b. Pipes or fittings that show signs of corrosion or deterioration during
storage shall immediately be treated to arrest and prevent the corrosion
or deterioration or removed from Site, as the Engineer directs
c. Proposals for repair shall be submitted in writing for the Engineer’s ap-
proval
d. No attempt shall be made to repair damage without the Engineer’s ap-
proval
e. If in the Engineer’s opinion the nature of any damage is such that the
condition of a pipe has been impaired and cannot be repaired the pipe
concerned shall not be incorporated in the Works
f. All rejected pipes shall be immediately removed from the Site
g. Damaged pipe shall be replaced or repaired by the Contractor at his ex-
pense and such repairs shall be to the approval of the Engineer
PART 2 PRODUCTS
2.1 WARNING TAPES
A Service protection tapes shall be installed above all sewage pipelines and pressure
mains constructed or exposed under this contract excluding individual service con-
nections.

B Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and color-fast in all soil conditions at
pH values of 2.5 to 11.0 inclusive.
1. The tape shall be 150 mm wide and 250 micron thick and produced as a strong
composite laminate consisting of : -
2. 30 Micron polyester film top layer
3. 12 Micron detectable aluminum foil in between
4. 208 Micron bottom layer polyethylene.
5. The thickness of the tape (250 micron / 1000 gauge) shall be measured in ac-
cordance with BS 2782 : Part 6. Method 630 A.
6. The following properties shall be demonstrated by appropriate tests :-
a. Physical properties :- (Average of 5 tests)

b. Tensile strength Longitudinal (MD) : 160 N (Minimum)
c. (BS EN ISO 527 – 3 : 1996 Transversal (TD) : 150 N (Minimum)
d. Elongation (PE only)
e. (BS EN ISO 527 – 3 : 1996 MD : 450%, TD : 550%
f. Tear strength MD : 640 gram force
g. BS 2782 Part 3, 360A : 1991 TD : 700 gram force Minimum
h. Dart Impact
i. BS 2782 : P3 : 352F : 1996 1000 grams minimum
C Chemical resistance:-
1. The tape shall be remaining legible and colour fast in all soil conditions at PH
2.5 to 11.0, inclusive. The tape shall not show any adverse effect when in con-
tact with the sulphates, chlorides and other minerals present in sub soil and
water, oil, 5% Acetic Acid, 5% NaOH and Alcohol mix, if any.
D Detectability after installation and back filling
1. Text in Arabic and English indicating the protected services lying below the
tape shall be permanent ink bonded to resist prolonged chemical attack by
corrosive acids and alkalis with the message repeated at a maximum interval of
two meters. Tapes shall be colour coded as follows, with black text as indi-
cated. The sign and styles of the text shall be approved by the Engineer.
a. Water : Blue
b. CAUTION : Water Pressure Mains Below
c. Fire : Blue
d. CAUTION : Fire Water Pressure Mains Below
e. Municipality logo shall be printed in black between the spaces of re-
peated messages.
2.2 GEO-TEXTILE
A Geo textile for Pipe Bedding (Filter Fabric)
1. Geo textile shall be formed by continuous filament fibers of polypropylene and

then bonded to form a high strength, non-raveling, and non-woven sheet.
2. The equivalent opening size for the non-woven fabric used shall be 70 to 100
U.S. Std. Sieve (ESD) in accordance with ASTM D422 and the Corps of Engineers
Classification CW-02215-77. The water flow rate shall be a minimum of 194
I/sec/m2 as determined by ASTM D737 and the coefficient of permeability
shall be a minimum of 0.30 cm/sec.
3. The grab tensile strength shall be a minimum of 90 kg (200 lbs) and the grab
tensile elongation shall be a minimum of 60 percent as measured by ASTM
D1682.
4. The burst strength as measured by the Diaphragm Method of ASTM D3786
shall be a minimum of 25 kg/cm2 (360 psi). The minimum trapezoid tear
strength shall be 34 kg (75 lbs) in accordance with ASTM D1117.
5. The puncture resistance of the geo textile measured with 8 mm hemispherical
tip in accordance with Method ASTM D3787 shall be a minimum of 43 kg (95
lbs).
6. The material shall be resistant to rot, mildew, aging, rodents, and insects. The
geo-textile shall withstand the abuses of placement by men and equipment
without tearing or being punctured.
7. Geo textile shall be inert to acids and alkalis within a pH range of 3 to 13.
8. The geo textile shall be resistant to ultraviolet light exposure based on testing
in accordance with ASTM D4355.
2.3 PIPES, FITTINGS AND ACCESSORIES
2.3.1 High Density Polyethylene Pipes
A General
1. A PE piping material consists of a polyethylene polymer (commonly designated

as the resin) to which has been added small quantities of colorants, stabilizers,
antioxidants and other ingredients that enhance the properties of the material
and that protect it during the manufacturing process, storage and service. PE
piping materials are classified as thermoplastics because they soften and melt
when sufficiently heated and harden when cooled, a process that is totally re-
versible and may be repeated. In contrast, thermosetting plastics become
permanently hard when heat is applied.
2. Because PE is a thermoplastic, PE pipe and fittings can be fabricated by the
simultaneous application of heat and pressure. And, in the field PE piping can
be joined by means of thermal fusion processes by which matching surfaces
are permanently fused when they are brought together at a temperature
above their melting point.
3. PE is also classified as a semi-crystalline polymer. Such polymers (e.g., nylon,
polypropylene, polytetrafluoroethylene), in contrast to those that are essen-
tially amorphous (e.g., polystyrene, polyvinylchloride), have a sufficiently or-
dered structure so that substantial portions of their molecular chains are able
to align closely to portions of adjoining molecular chains. In these regions of
close molecular alignment crystallites are formed which are held together by
secondary bonds.
4. A beneficial consequence of PE’s semi-crystalline nature is a very low glass
transition temperature (Tg), the temperature below which a polymer behaves
somewhat like a rigid glass and above which it behaves more like a rubbery sol-
id.
5. In the case of amorphous polymers, their melting temperature, the tempera-
ture at which a transition occurs between the rubbery solid and the liquid
states, is not much higher than their Tg. Also for amorphous polymers, the
transition between a rubbery solid and a viscous liquid is not very emphatic.
This contrasts with semi-crystalline polymers, for which this transition corre-
sponds with the melting of all crystallites, and above which a highly viscous
liquid state is reached. This more emphatic transition in PE between the semi-
crystalline solid and highly viscous liquid states facilitates manufacture, fabri-
cation and field joining because it allows for more efficient ‘welding’ to be
conducted – when in a liquid state the polymer molecules are able to more ef-
fectively diffuse into each other and thereby, form a monolithic structure. In
contrast, the melting point of amorphous polymers is less defined and, across
this melting point there is not as definite a transition between a rubbery, or
plastic state, and a liquid viscous state.
6. All PE piping standards specify minimum material requirements based the on
the cell requirements of ASTM D3350, a simpler, short-hand, ASTM recognized
material designation code is commonly used for quickly identifying the most
significant engineering properties of a PE pipe material. An important feature
of this designation code is that it identifies the maximum recommended hy-
drostatic design stress (HDS) for water, at (23°C). Originally, this designation
code was devised to only apply to materials intended for pressure piping.
However, there is recognition that even in non-pressure applications stresses
are generated which makes it prudent to use a stress rated material. This has
led to the common practice of using this material designation code for quickly
identifying all PE piping materials intended for pipes of solid wall or, of profile
wall construction.
7. In Addition the pipes and fittings shall be manufactured from polyethylene
containing only those antioxidants, UV stabilizers and pigments necessary for
the manufacturing process to fulfill the requirements of the specification.
8. All pipes and fittings shall be suitable for butt fusion or electro fusion tech-
niques.
9. The pipe shall contain no recycled compound except that generated in the
manufacturers’ own plant
10. The pipe shall be homogenous throughout and free from visible cracks, holes,
foreign inclusions or other injurious defects. The pipe shall be as uniform as
commercially practical in color, opacity, density and other physical properties.
11. Contractor shall provide PE manufacturers guideline for the applicability of the
material used. If required PE manufacturers shall provide assistance and train-
ing.
B Pressure Pipelines
1. Materials used for the manufacture of polyethylene pipe and fittings shall be
made from a PE 3408 high density polyethylene resin compound meeting cell
classification 345434C per ASTM D3350; and meeting Type lll, Class C, Category
5, Grade P34 per ASTM D1238.
2. High Density Polyethylene (HDPE) pipe shall comply with AWWA Specifications
C906 / or Pipes and fittings shall be made of high density polyethylene (HDPE)
and shall comply with the requirements of ISO 4427 PE 100. The material shall
be produced by a member of the PE 100 + Association.
3. The material used for the manufacturer of pipes and fittings shall be in accord-
ance with Table 1 and Table 2 of clause 4.4 of ISO 4427-1
1. The minimum required strength (MRS) of the material compound shall be 10
MPa at 200 C. The design stress shall be 8 MPa. Lifecycle durability of 80 years
is to be confirmed.
2. If rework compounds are required, only those generated in the Manufacturer’s
own plant from resin compounds of the same class and type from the same
raw material supplier shall be used.
3. Dimensions and workmanship shall be as specified by ASTM F714 and ASTM
D3035. HDPE fittings and transitions shall meet ASTM D3261. HDPE pipe shall
have a minimum density of 0.955 grams per cubic centimeter. All HDPE pipe
and fittings shall have a Hydrostatic Design Basis (HDB) of 1,600 psi.
4. HDPE pipe and accessories shall be meeting the requirements of Standard Di-
mension Ration (SDR) 17 (PE 100) as MINIMUM STRENGTH as MINIMUM
STRENGTH for Potable Water and Irrigation Network
5. The pipe Manufacturer must certify compliance with the above requirements.
C Fittings
1. The PE pipe industry has worked diligently to make PE piping systems as com-
prehensive as possible. As such, various fittings are produced which increase
the overall use of the PE piping systems. PE fittings may be injection molded,
fabricated or thermoformed.
2. The following will briefly describe the operations of each technique.
3. Injection Molded Fittings
a. Injection molded PE fittings are manufactured in sizes through 12-inch

nominal diameter. Typical molded fittings are tees, 45° and 90° elbows,
reducers, couplings, caps, flange adapters and stub ends, branch and
service saddles, and self-tapping saddle tees. Very large parts may ex-
ceed common injection molding equipment capacities, so these are usu-
ally fabricated.
b. Typical quality inspections are for knit line strength, voids, dimensions
and pressure tests. A knit line is formed when the molten PE material
flows around a core pin and joins together on the other side. While
molding conditions are set to eliminate the potential for voids, they can
occur occasionally in heavier sections due to shrinkage that takes place
during cooling. Voids can be detected nondestructively by using x-ray
scans. If this is not available, samples can be cut into thin sections and
inspected visually. All molded fittings and fabricated fittings shall be fully
pressure rated to match the pipe SDR pressure rating to which they are
made. All fittings shall be molded or fabricated by the manufacturer. No
Contractor fabricated fittings shall be used unless approved by the Engi-
neer.
4. Fabricated Fittings
a. Fully pressure-rated, full bore fabricated fittings are available from select
fittings fabricators. Fabricated fittings are constructed by joining sections
of pipe, machined blocks, or molded fittings together to produce the de-
sired configuration.
b. Components can be joined by butt or socket heat fusion, electro-fusion,
hot gas welding or extrusion welding techniques. It is not recommended
to use either hot gas or extrusion welding for pressure service fittings
since the resultant joint strength is significantly less than that of the
other heat fusion joining methods.
c. Fabricated fittings designed for full pressure service are joined by heat
fusion and must be designed with additional material in regions of sharp
geometrical changes, regions that are subject to high localized stress.
The common commercial practice is to increase wall thickness in high-
stress areas by fabricating fittings from heavier wall pipe sections. The
increased wall thickness may be added to the OD, which provides for a
full-flow ID; or it may be added to the ID, which slightly restricts ID flow.
This is similar to molded fittings that are molded with a larger OD, heav-
ier body wall thickness. If heavy-wall pipe sections are not used, the
conventional practice is to reduce the pressure rating of the fitting. The
lowest-pressure-rated component in a pipeline determines the operat-
ing pressure of the piping system. Various manufacturers address this
reduction process in different manners. Reinforced over-wraps are
sometimes used to increase the pressure rating of a fitting. Encasement
in concrete, with steel reinforcement or rebar, is also used for the same
purpose. Contact the fitting manufacturer for specific recommendations.
d. Very large diameter fittings require special handling during shipping, un-
loading, and installation. Precautions should be taken to prevent bend-
ing moments that could stress the fitting during these periods. Consult
the fittings manufacturer for specifics. These fittings are sometimes
wrapped with a reinforcement material, such as fiberglass, for protec-
tion.
5. Thermoformed Fittings
a. Thermoformed fittings are manufactured by heating a section of pipe

and then using a forming tool to reshape the heated area. Examples are
sweep elbows, swaged reducers, and forged stub ends. The area to be
shaped is immersed in a hot liquid bath and heated to make it pliable. It
is removed from the heating bath and reshaped in the forming tool.
Then the new shape must be held until the part has cooled.
6. Electro fusion Couplings
a. Electro fusion couplings and fittings are manufactured by either molding

in a similar manner as that previously described for butt and socket fu-
sion fittings or manufactured from pipe stock. A wide variety of cou-
plings and other associated fittings are available from ½” CTS thru 28”
IPS. Fittings are also available for ductile iron sized PE pipe. These cou-
plings are rated as high as FM 200. Electro fusion fittings are manufac-
tured with a coil-like integral heating element. These fittings are in-
stalled utilizing a fusion processor, which provides the proper energy to
provide a fusion joint stronger than the joined pipe sections. All electro
fusion fittings are manufactured to meet the requirements of ASTM F-
1055.
7. Injection Molded Couplings
a. Some mechanical couplings are manufactured by injection molding in a

similar manner as previously described for butt and socket fusion fit-
tings. The external coupling body is typically injection molded and upon
final assembly will include internal components such as steel stiffeners,
o-rings, gripping collets, and other components depending upon the de-
sign. A wide variety of coupling configurations are available including
tees, ells, caps, reducers, and repair couplings. Sizes for joining PE pipe
and tubing are typically from ½” CTS through 2” IPS. All injection molded
couplings are manufactured to meet the requirements of ASTM D2513.
D JOINTING
1. PE pipe or fittings are joined to each other by heat fusion or with mechanical
fittings. PE pipe may be joined to other pipe materials by means of compres-
sion fittings, flanges, or other qualified types of manufactured transition fit-
tings. There are many types and styles of fittings available from which the user
may choose. Each offers its particular advantages and limitations for each join-
ing situation the user may encounter. Contact with the various manufacturers
is advisable for guidance in proper applications and styles available for joining
as described herein below:-
2. Thermal Heat Fusion Methods
a. There are three types of conventional heat fusion joints currently used
in the industry; Butt, Saddle, and Socket Fusion. Additionally, electro fu-
sion (EF) joining is available with special EF couplings and saddle fittings.
b. The principle of heat fusion is to heat two surfaces to a designated tem-
perature, then fuse them together by application of a sufficient force.
This force causes the melted materials to flow and mix, thereby resulting
in fusion. When fused according to the pipe and/or fitting manufactur-
ers’ procedures, the joint area becomes as strong as, or stronger than,
the pipe itself in both tensile and pressure properties and properly fused
joints are absolutely leak proof. As soon as the joint cools to near ambi-
ent temperature, it is ready for handling. The following sections of this
chapter provide a general procedural guideline for each of these heat
fusion methods.
3. Butt Fusion
a. The most widely used method for joining individual lengths of PE pipe
and pipe to PE fittings is by heat fusion of the pipe butt ends. This tech-
nique produces a permanent, economical and flow-efficient connection.
Quality butt fusion joints are produced by using trained operators and
quality butt fusion machines in good condition.
b. The butt fusion machine should be capable of:
1) Aligning the pipe ends

2) Clamping the pipes
3) Facing the pipe ends parallel and square to the centerline
4) Heating the pipe ends
5) Applying the proper fusion force
4. Saddle/Conventional Fusion
a. The conventional technique to join a saddle to the side of a pipe, con-

sists of simultaneously heating both the external surface of the pipe and
the matching surface of the “saddle” type fitting with concave and con-
vex shaped heating tools until both surfaces reach proper fusion tem-
perature. This may be accomplished by using a saddle fusion machine
that has been designed for this purpose.

b. Saddle fusion using a properly designed machine, provides the operator
better alignment and force control, which is very important to fusion
joint quality. The Plastics Pipe Institute recommends that saddle fusion
joints be made only with a mechanical assist tool unless hand fusion is
expressly allowed by the pipe and/or fitting manufacturer.
c. Most pipe manufacturers have detailed parameters and procedures to
follow. The majority of them helped develop and have approved the PPI
Technical Report for the generic saddle fusion joining procedure for PE
pipe and ASTM 2620.
5. Socket Fusion
a. This technique consists of simultaneously heating both the external sur-

face of the pipe end and the internal surface of the socket fitting until
the material reaches the recommended fusion temperature, inspecting
the melt pattern, inserting the pipe end into the socket, and holding it in
place until the joint cools. Mechanical equipment is available to hold
both the pipe and the fitting and should be used for sizes larger than 2”
CTS to help attain the increased force required and to assist in align-
ment. Most pipe manufacturers have detailed written procedures to fol-
low. The majority refer to ASTM F 2620.
b. Electro fusion (EF): This technique of heat fusion joining is somewhat dif-
ferent from the conventional fusion joining thus far described. The main
difference between conventional heat fusion and electro fusion is the
method by which the heat is applied. In conventional heat fusion joining,
a heating tool is used to heat the pipe and fitting surfaces. The electro
fusion joint is heated internally, either by a conductor at the interface of
the joint or, as in one design, by a conductive polymer. Heat is created
as an electric current is applied to the conductive material in the fitting.
PE pipe to pipe connections made using the electro fusion process re-
quire the use of electro fusion couplings.
c. General steps to be followed when performing electro fusion joining are:
1) Prepare the pipe (scrape, clean)

2) Mark the pipe
3) Align and restrain pipe and fitting per manufacturer’s recommen-
dations
4) Apply the electric current
5) Cool and remove the clamps
6) Document the fusion process
6. Mechanical Connections:
a. As in the heat fusion methods, many types of mechanical connection

styles and methods are available. This section is a general description of
these types of fittings based on a variety of specifications such as ASTM
F1924, F1973, and AWWA C219.
1) Mechanical Compression Couplings for Small Diameter Pipes

2) This style of fitting comes in many forms and materials. The com-
ponents, are generally a body; a threaded compression nut; an
elastomer seal ring or O-ring; a stiffener; and, with some, a grip
ring. The seal and grip rings, when compressed, grip the outside of
the pipe, effecting a pressure-tight seal and, in most designs,
providing pullout resistance which exceeds the yield strength of
the PE pipe. It is important that the inside of the pipe wall be sup-
ported by the stiffener under the seal ring and under the gripping
ring (if incorporated in the design), to avoid deflection of the pipe.
A lack of this support could result in a loss of the seal or the grip-
ping of the pipe for pullout resistance. This fitting style is normally
used in service lines for gas or water pipe 2” IPS and smaller. It is
also important to consider that three categories of this type of
joining device are available. One type provides a seal only, a sec-
ond provides a seal and some restraint from pullout and a third
provides a seal plus full pipe restraint against pullout.
7. Mechanical Bolt Type Couplings
a. There are many styles and varieties of “Bolt Type” couplings available to
join PE to PE or other types of pipe such as PVC, steel and cast iron in
sizes from 1¼” IPS and larger. As with the mechanical compression fit-
tings, these couplings work on the general principle of compressing an
elastomeric gasket around each pipe end to be joined, to form a seal.
b. The gasket, when compressed against the outside of the pipe by tighten-
ing the bolts, produces a pressure seal. These couplings may or may not
incorporate a grip ring, as illustrated, that provides pullout resistance
sufficient to exceed the yield strength of the PE pipe. When PE pipe is
pressurized, it expands a little and shortens slightly due to Poisson’s ef-
fect. In a run of PE pipe, the cumulative shortening may be enough to
cause separation of unrestrained mechanical joints that are in-line with
the PE pipe. This can be a particular concern where transitioning from PE
pipe to Ductile Iron pipe. Joint separation can be prevented by installing
external joint restraints (gripping devices or flex restraints; Additional
restraint mechanisms are available to supplement the pull resistance of
these types of fittings if needed.
c. The fitting manufacturer can help guide the user with that information.
Use of a stiffener is needed in this fitting style to support the pipe under
the area of the seal ring and any gripping devices incorporated for
pullout resistance.
8. Flanged Connections
a. PE Flange Adapters and Stub Ends When joining to metal or to certain

other piping materials, or if a pipe section capable of disassembly is re-
quired. The “Flange Adapter” and its shorter version, the “Stub End,” are
designed so that one end is sized the same as the PE pipe for butt fusion
to it. The other end has been especially made with a flange-type end
that, provides structural support, which eliminates the need for a stiff-
ener and, with the addition of a metal back-up ring, permits bolting to a
similar flanged end connection — normally a 150- pound ANSI flange.(1)
b. At lower pressure, typically 80 psi or less, a gasket is usually not re-
quired. At greater pressure, the serrated surface of the flange adapter
helps hold the gasket in place. The flange face serration’s should be indi-
vidual closed concentric serration’s as opposed to a continuous spiral
groove which could act as a leak path. Standard Back- up Rings is AWWA
C207 Class D for 160 psi and lower pressure ratings, or Class 150 for
higher pressure. Back-up ring materials are steel, primer coated steel,
epoxy coated steel, or stainless steel. Ductile iron and fiberglass back-up
ring materials are also available. In below ground service, coatings and
cathodic protection may be appropriate to protect metal back-up rings
from corrosion. One edge of the backup ring bore must be rounded or
chamfered. This edge fits against the back of the sealing surface flange.
c. An all-PE flange without a back-up ring is not recommended because PE
flanges require uniform pressure over the entire sealing surface. With-
out a back-up ring, a PE flange will leak between the bolts.
d. Flange adapters differ from stub-ends by their overall length. A flange
adapter is longer allowing it to be clamped in a fusion machine like a
pipe end. The back-up ring is fitted to the flange adapter before fusion,
so external fusion bead removal is not required.
e. A stub end is short and requires a special stub-end holder for butt fu-
sion. Once butt fused to the pipe, the external bead must be removed so
the back-up ring can be fitted behind the sealing surface flange. In the
field, flange adapters are usually preferred over stub-ends.
2.4 VALVE FEATURES, GENERAL
A Valve Features, General
1. All valves supplied shall be suitable for use with water temperatures up to 50o
C and in climatic and soil conditions encountered in the project area. The nom-
inal working pressure shall be 16 bar or as mentioned in the tender
2. The CONTRACTOR shall provide valves of an approved type for installation and
shall be suitable for potable water service. Prior to internal coating on the
valves, a certificate of non-toxicity of paint materials shall be submitted to
ENGINEER for approval. The certificate shall be signed by an internationally
recognized authority.
3. The valves shall have flanged connections with the flanges drilled in accord-
ance with the standards and ratings indicated in the relevant Data Sheets. All
bolts, nuts and washers shall be hot dipped galvanized or cadmium plated.
4. The valves shall be designed for pressure caused by the unbalanced closed po-
sition, and be suitable for the specified working and hydrostatic test pressures.
5. All valves shall close clockwise and be equipped with an open / closed position
indicator.
6. Valves shall be suitable for continuous operation as well as for intermittent
operation. All ferrous parts of the valves shall be coated, except for the fin-
ished or bearing surfaces. The type of the internal and external coating shall be
as specified on the respective data sheets for each type of valve. Valves,
strainers and other devices mounted in underground pipelines shall be in-
stalled in reinforced concrete chambers complete with all accessories and pro-
tection systems as per the project specifications and drawings. Valves, strain-
ers and other devices shall be adequately supported independently of the
pipes to which they connect to prevent the pipe having to bear the weight of
the valve.
7. The valves shall be supplied complete with all the required joint accessories,
approved gaskets, bolts, nuts and washers etc. for both flanges of each valve.
All valves shall have the name of the manufacturer, working pressure, diame-
ter and cast number on the body. Face to face dimensions for flange valves
shall be as per BS 5163.
8. Unless otherwise detail or specified here-in, gate and butterfly valves shall be
supplied complete with extension spindles and appurtenances such that the
square nut operation is within 500 mm of the top of the chamber cover slab.
Where required, special couplings shall be incorporated to absorb the weight
of the extension spindle at no extra cost.
9. The dimensions of stem cap of all valves and square nut operator in case of ex-
tension spindles or without extension spindle shall be in accordance with BS
5163. All valves shall be supplied with stem (spindle) cap made from ductile
iron. The spindle cap shall be fixed with spindle by a nut bolt passing through it
so that spindle cap is tied with spindle. The manufacturer shall fix spindle cap
to spindle by a nut bolt before dispatching (not acceptable as loose items) .
10. All valves to be supplied shall correspond to internationally accepted standards
as applicable in the relevant parts of this document. Any other equivalent na-
tional or international standard shall be considered subject to submission of
acceptable comparison statement. The CONTRACTOR shall attach to his offer
the English text of Standards as applicable.
11. The valves must be accompanied with a certificate guaranteeing their water
tightness and satisfactory operation for a period of not less than 10 years.
12. Contractors shall provide Material Certificates issued by the Manufacturers in
accordance with the requirements of EN 10204
13. Contractor shall ensure that all material in contact with potable water shall not
adversely affect the potable water quality requirement of Regulation & Super-
vision Bureau Regulation which refers to WHO. Furthermore international re-
quirements on non-toxicity certification and coating protection shall be met.
14. All gate valves shall be designed to provide 100 % water tight shut off at all
specified pressures and suitable for installation of electrical actuators when
required.
15. Hand wheels shall be providing for all valves when installed above ground,
when operation is within reach. Valve installed out of reach above ground shall
be provided with chain drive or remote control drive as the case may be.
16. All Valves Working Pressure: 16 bars unless specified otherwise and Test pres-
sure: 1.5 x Design pressure.
B Gate Valves 50 mm and Smaller
1. Service Connection Valve, Internal Thread
a. General
1) Resilient seated service connection valves, the wedge is vulcanized drinking

water approved EPDM rubber compound
2) Service connection valve for drinking water and neutral liquids to max. 70° C.
3) Designed according to EN 1074 part 1 & 2, Designed according to EN 1171
b. Features:
a) Wedge shaped with guides and designed with a special rubber profile
ensuring low closing torques
b) Stainless steel stem with rolled threads providing high strength
c) Full circle thrust collar provides fixation of the stem and low free running
torques

d) Triple safety stem sealing with an NBR wiper ring, a polyamide bearing with
four NBR O-rings and an EPDM rubber
e) EPDM bonnet gasket fixed in a recess
f) Countersunk and sealed stainless steel bonnet bolts encircled by the bonnet
gasket
g) Full bore
h) Low operating torque
i) Epoxy coating to DIN 30677-2
c. Construction Material
Description Material
Stem Stainless steel min. 13% Cr
Wiper ring NBR rubber
O-ring NBR rubber
Bearing Polyamide
Bonnet Ductile iron, GJS-500 (GGG-50)
Thrust collar Dezincification resistant brass CZ132
Manchette EPDM rubber
Bonnet bolt Stainless steel A2, sealed with hot melt
Bonnet gasket EPDM rubber
Wedge Dezincification resistant brass
Body Ductile iron, (GGG-50)
2. Service Connection Valve, Tensile socket joints
a. General
1) Resilient seated service connection valves are designed with built-in safety in
every detail. The wedge is vulcanized with drinking water approved EPDM
rubber compound.
2) Service connection valve with tensile socket ends for drinking water and
neutral liquids to max. 70° C
3) Designed according to EN 1074 part 1 & 2
4) The epoxy resin coating is electrostatically applied (inside and outside) with
a minimum thickness of 300.
b. Construction Material
Description Material Norms

Body Ductile Cast Iron GGG 50 DIN EN 1563
Bonnet Ductile Cast Iron GGG 50 DIN EN 1563
Gate Brass EN 12163/4/5
Gate Covering Entirely covered with EPDM Elasto- BS EN 681-1
mer
Stem Stainless Steel AISI 303
Mouth Sealing EPDM Elastomer BS EN 681-1
O-Rings EPDM Elastomer BS EN 681-1
Tension Ring POM (Polyoxymethylene)
Protection CAP EPDM Elastomer BS EN 681-1

Bolts Stainless Steel A2, Sealed with Silicone AISI 304
Coating Epoxy Paint DIN 30677
C Gate Valves, 60 mm and Larger
1. General
a. This specification describes resilient-seated gate valves with no rising stems

(NRS) and outside screw-and-yoke (OS&Y) rising stems, including tapping
gate valves, for water supply service having a temperature range of 33o-
125oF (0.6o – 52oC) following the requirements of ANSI/AWWA C509. These
valves are intended for applications where fluid velocity does not exceed 16
ft./sec when the valve is in full open position.
b. Sizes. Gate valves described by this standard are 3 inch. (75-mm), 4inch.
(100-mm), 6inch. (150-mm), 8inch. (200-mm), 10inch. (250-mm), 12inch.
(300-mm), 16inch. (400-mm), 20inch. (500-mm), 24inch. (600-mm), and
30inch. (750-mm) nominal pipe size (NPS). Sizes refer to the nominal diame-
ter inches (or millimeters), of the waterway through the inlet and outlet
connections and the closure area. ·
c. Valve pressure rating. The minimum design working water pressure shall be
200 psig (1,380 kPa (gauge]) for 3through 12inch. (75- through 300-mm) siz-
es and 150 psig (1,034 kPa [gauge]) for 16through 30inch. (400- through 750-
mm) sizes.
d. All parts shall conform to their required dimensions and shall be free from
defects that could prevent proper functioning of the valve. When assembled,
valves manufactured in accordance with this standard shall be well-fitted
and shall operate smoothly. All like parts of valves of the same model and
size produced by the same manufacturer shall be interchangeable.
e. Castings. All castings shall be clean and sound, without defects that will
weaken their structure or impair their service. Plugging, welding, or repairing
of cosmetic defects is allowed. Repairing of structural defects is not allowed
unless agreed to by the engineer. Repaired valves shall comply with the test-
ing requirements of this specification after repairs have been made. Repairs
within the bolt circle of any flange face are not allowed.
f. The purpose of this specification is to provide Contractor, and suppliers with
the minimum requirements for resilient-seated gate valves for water supply
service, including materials, application, inspection, handling, and shipping.
2. Material
a. General.
1) Materials shall comply with the requirements of the Safe Drinking Water Act
and other local requirements. it is the contractor and supplier’s
responsibility to verify the current requirements of local regulations. And
international regulations when reference is made to ANSI, ASTM, AWWA, BS
or other standards, it shall be understood that the latest revision thereof
shall apply. All materials used in valves produced according. to this standard
shall conform to the requirements stipulated in the following sections.
2) Mechanical and chemical properties. The requirements of ANSI, ASTM,
AWWA, BS or other standards to which reference is made in this
specification shall govern the mechanical and chemical characteristics of the
valve components. Whenever valve components are to be made in

conformance with AWWA, ANSI, ASTM, BS or other standards that include
test requirements or testing procedures, the contractor and or supplier shall
comply with those procedures. The records of all tests shall, if required by
this specification, be made available to the Engineer.
3) Ductile iron, Ductile iron shall conform to the requirements of ASTM A.395
or ASTM A536. In addition, ductile iron shall contain no more than 0.08
percent phosphorus.
4) Copper alloys which contact drinking water shall comply with the Safe
Drinking Water Act. All copper alloys, must meet the performance
requirements of this specification, including but not limited to minimum
yield strength, chemical requirements, and corrosion resistance. Any copper
alloy used in the cold-worked condition shall be capable of passing the
mercurous nitrate test in accordance with ASTM B154 to minimize
susceptibility to stress corrosion.
5) Valve components manufactured from some grades of manganese bronze or
some other materials are subject to stress corrosion. The manufacturer shall
design the valve and select materials to minimize stress corrosion.
6) O-rings. O-rings shall meet the requirements of ASTM D2000 and have
physical properties suitable for the application.
7) Packing. Stuffing-box packing shall be made of flax. Hemp, asbestos, or jute
packing shall not be used.
8) Coatings. Unless otherwise specified by this specification, valve coatings, for
water-based enamel coating, or black asphalt coatings, or ANSI/AWWA C550
for epoxy coatings, or equal.
9) Elastomers. Elastomers shall comply with the following:
a) Rubber seats shall be resistant to microbiological attack, copper poison-ing,

and ozone attack.
b) Rubber-seat compounds shall contain no more than 8 parts per million
(ppm) of copper ion and shall include copper inhibitors to prevent copper
degradation of the rubber material.
c) Rubber-seat compounds shall be capable of withstanding an ozone
resistance test when tested in accordance with ASTM D1149. The tests shall
be conducted on unstressed samples for 70 hr. at 104oF (40oC) with an
ozone concentration of 500 parts per billion (ppb) without visible cracking in
the surfaces of the test samples after the test.
d) Rubber-seat compounds shall have a maximum compression set value of 20
percent when tested in accordance with ASTM D395, method B, for 22 hr. at
158oF
e) Rubber-seat compounds shall contain no more than 1.5 parts of wax per 100
parts of rubber hydrocarbon and shall have less than 2 percent volume
increase when tested in accordance with ASTM D471 after being immersed
in distilled water at 73.4oF ± 2oF (23oC ±1oC) for 70 hr. Reclaimed rubber
shall not be used.
f) Rubber-seat compounds shall be free of vegetable oils, vegetable-oil
derivatives, animal fats, and animal oils.
b. Specification
1) Structural design: All parts of all valves shall be designed to withstand,

without being structurally damaged, (1) an internal test pressure of twice
the rated design working pressure of the valve; and (2) the full-rated internal

working pressure when the closure member is cycled once from a fully open
to a fully closed position against the full-rated unbalanced working water
pressure. In addition to these pressure requirements, the valve assembly
and mechanism shall be capable of withstanding an input torque as follows:
3inch., and 4inch. (75-mm and 100-mm) NPS- 200 ft.*lb (270 N*m); 6 inch.
(150 mm), 8 inch. (200 mm), 10 inch. (250 mm), and 12 inch. (300 mm) NPS-
300 ft.*lb (406 N*m). For sizes larger than 12 inch. (300 mm), consult the
manufacturer.
2) Size of waterway with the valve open, an unobstructed waterway shall be
provided. The waterway shall have a diameter equal to or larger than the full
nominal diameter of the valve. For tapping valves, the size of the waterway
shall include appropriate clearance for the diameter of the tapping machine
cutter recommended by the valve manufacturer. Some valves may require
an undersized cutter, which is smaller than the nominal diameter of the
valve.
c. Detailed Specification
1) Body and bonnet
a) Material: The body and bonnet shall be made of ductile iron.

b) Shell thickness. Shell thickness measurements taken at point’s
dia-metrically opposite to each other shall, when added together and
divided by two, equal or exceed the minimum metal thicknesses shall be in
compliance with ANSI/AWWA C509 Table 1. Shell thickness at no point shall
be more than 12.5 percent thinner than the minimum metal thickness shall
be in compliance with ANSI/AWWA C509 Table 1, and no continuous area of
deficient thickness shall exceed 12.5 percent of the pressure-containing shell
area of the casting.
c) Body seating surfaces. Resilient seats shall seat against a corrosion- resistant
surface. The surface may be either metallic or nonmetallic, applied in a
manner to withstand the action of the line fluids and the operation of the
sealing gate during long-term service. A metallic surface shall have a
corrosion resistance equivalent to or better than bronze. A nonmetallic
surface shall be in compliance with ANSI/AWWA C550.
d) Valve ends. End connections shall conform to one of the following

requirements:
e) Flanged ends. The end flanges of flanged valves shall conform to dimensions
and drillings of ANSI B16.1 Class 125 or ANSI/AWWA C110/A21.10 unless
explicitly provided otherwise in this specification. the bolt holes of the end
flanges shall not be spot-faced except when the thickness at any point within
the spot-face area, as defined in MSS SP-9, exceeds the required minimum
flange thickness of ASME/ANSI B16.l by more than indicated in ANSI/AWWA
C509Table 2 or if the flange is not sufficiently flat. Bolt holes shall straddle
the vertical centerline of the valve. The laying lengths of flanged valves 12
inch. (300 mm) and smaller shall conform to the requirements for double-
disc gate valves listed in Table 1of ANSUASME B16.10.
f) Mechanical-joint ends. Mechanical-joint bell dimensions shall confirm to
ANSI/AWWA C111/A21.11. Slots with the same width as the diameter of the
bolt holes may be provided instead of holes in the bell flange at those places
where the valve body or bonnet interfere with the joint assembly.

g) Push-on joint ends. Push-on joints, shall conform to the requirements of
ANSI/AWWA C111/A21.11.
h) Tapping-valve ends.
i. The end flange of a tapping valve that forms a joint with the tapping
sleeve shall conform to the dimensions of MSS SP-60 in sizes 3inch. (75-
mm) through 12inch. (300-mm) NPS. For larger sizes, flange dimensions
shall be as per the manufacturer recommendation.
ii. The connecting end of the tapping valve mating with the tapping machine
must be parallel and concentric with the opposite flange and concentric
with the waterway to provide proper alignment for the tapping
operation. The end flange of a tapping valve that forms a joint with the
tapping machine shall conform to the dimensions of MSS SP-113.
i) Yokes on OS&Y valves. On OS&Y valves, the yoke on bonnets may be integral
or of bolted-on construction. If the yoke is not an integral part of the bonnet,
it shall be made of ductile iron. The design shall be such that a hand cannot
be jammed between a yoke and the hand wheel.
2) Gate
a) Material. The metal reinforcement of the gate shall be ductile iron

b) Resilient seat. Resilient seats shall be bonded or mechanically attached to
the gate. The proof of design test method used for bonding or vulcanizing
shall be ASTM D429, either method A or method B. For method A, the
minimum strength shall not be less than 250 psi (1,725 kPa). For method B,
the peel strength shall not be less than 75 lb./in. (13.2 N/mm). All exposed
mechanical attaching devices and hardware used to retain the resilient seat
shall be of a corrosion-resistant material.
3) Guides
a) If guiding is required to obtain shutoff, the design shall be such that

corrosion in the guide area does not affect sealing.
4) Bolting
a) Bolting materials, excluding joint accessories, shall have the mechanical

strength requirements of ASTM A307 and shall have either regular square or
hexagonal heads with dimensions conforming to ANSI Bl8.2.1. Bolts, studs,
and nuts shall be (1) cadmium-plated (ASTM B766) or zinc-coated (ASTM
A153 or B633), or (2) made corrosion resistant by some other process
disclosed to and acceptable to the purchaser. The purchaser may specify
bolts, studs, and nuts made from a specified corrosion-resistant material,
such as low-zinc bronze, nickel-copper alloy, or stainless steel.
5) Stem, stem nut, and copper-alloy gates.
a) Stems, stem nuts, and copper-alloy gates shall be made from a copper alloy
as indicated in ANSI/AWWA C509 Table 3.
i. Valve stems shall be made from copper alloys that have a yield strength

of 20,000 psi (137,800 kPa) or greater.
ii. Stem nuts shall be made from copper alloys that have a yield strength of
14,000 psi (95,000 kPa) or greater.
b) NRS stems. The stem must have an integral thrust collar.

c) OS&Y stems. OS&Y valve stems shall be of sufficient length so as to be at
least flush with the top of the stem nut when the gate is fully closed. The
design shall be such as to prevent any possibility of the gate leaving the stem
or the stem turning during the operation of the valve.
d) Threads. The threads of stems and stem nuts shall be of Acme, modified
Acme, stub Acme, or one-half V type. Stems and stem nuts shall be threaded
straight and true and shall work true and smooth and in perfect line
throughout the lift of opening and thrust of closing the valve.
e) Diameter. The minimum stem diameters and number of turns to open shall
be as indicated in ANSI/AWWA C509 Table 4.
f) Stem sealing. The sealing system shall be designed to be watertight at the
rated working pressure of the valve.
i. NRS valves
 Materials. A stem seal plate or O-ring packing plate, if necessary, shall be

made of ductile iron. Stem openings, if bushed, or stem-seal cartridges
shall be of a copper alloy or a synthetic polymer with properties suitable
for the application. Stem-seal plate bolts and nuts shall conform to the
requirements as specified in the above section “Bolting”.
 Stem seal plate. On NRS valves, the stem opening, thrust-bearing recess,
and bonnet face of the stem-seal plate shall be machined or finished in a
manner that will provide surfaces that are smooth and either parallel or
perpendicular to the stem axis within 0.5o.
 Stem seal. When an O-ring or other pressure-actuated stem seal is used,
the design shall incorporate at least two such seals.
ii. Stem seal replacement.
 NRS valves. NRS valves shall be designed so that the seal above the stem
collar can be replaced with the valve under pressure in the fully open
position.
 OS&Y valves. Design of the valve shall be such that the stuffing box can be
packed when the valve is in the fully open position and under pressure.
 Caution. Stem seal or packing replacement under pressure is hazardous
and is not recommended.
6) Wrench nuts and hand wheels
a) Wrench nuts and hand wheels shall be made of ductile iron; the wrench nuts
shall be 115/16inch. (49.2-mm) square at the top, 2 inch. (50.8-mm) square
at the base, and 13/4inch. (44.5-mm) high. The outside diameter of hand
wheels shall not be less than indicated in ANSI/AWWA C509 Table 5. Nuts
shall have a flanged base on which shall be cast an arrow at least 2inch.
(50.8-mm) long showing the direction of opening. The word "OPEN," in 1/2
inch. (12.7-mm) or larger letters, shall be cast on the nut to indicate clearly
the direction to tum the wrench when opening the valve. Hand wheels shall
be of the spoke type only. Webbed or disc types are not permissible. An
arrow showing the direction to tum the hand wheel to open the valve, with
the word "OPEN" in 1/2 inch. (12.7-mm) or larger letters in a break in the
arrow shaft, shall be cast on the rim of the hand wheel so as to be readily
readable.
 Operating mechanism. NRS valves are to be supplied with wrench nuts or

hand wheels. OS&Y valves are to be supplied with handwheels.
 Direction of opening. The standard direction of opening is counter-
clockwise as viewed from the top. Valves opening in the opposite
direction (clockwise) may be specified.
 Method of securing. Wrench nuts or hand wheels shall be secured by
mechanical means to the valve stem on NRS valves. Hand wheels shall be
secured by mechanical means to the stem nut on OS&Y valves.
 Color coding. Wrench nuts and hand wheels that' open the valve by
turning to the right (clockwise) shall be painted red, wrench. nuts, and
hand wheels that open the valve by turning to the left
(counterclockwise)·shall be painted black.
7) Gaskets
a) Gaskets, O-rings, or other suitable elastomeric seals shall be used on all

flanged joints intended to be watertight.
8) Gearing
a) If gearing is required, the following should be considered: -
 Gears. Gears shall be accurately formed and smooth-running, with a

pinion shaft operating in a bronze, self-lubricating or, permanently sealed
anti-- friction bearing.
 Material. Geared valves shall be equipped with ductile-iron gears. If a
cast-iron gear is supplied, the pinions shall be steel. Material for steel
gears shall be ASTM A27 grade U-60-30 or equal.
 Gear ratio. Gear ratios shall not be less than indicated in ANSI/AWWA
C509 Table 6.
 Gear cases. Valves having O-ring or V-type stem seals may have the gear
case attached directly to the valve. When geared valves are supplied,
enclosed gear cases are required unless specifically excluded by the
purchaser's requirements.
 Indicators. When required by this specification, means shall be provided
to indicate the position of the gate in relation to the waterway for geared
valves.
3. Valve Design Data Sheet
a. Potable water &Irrigation
1) The valves shall be of the resilient seated with non-rising stem in compliance
with AWWA C509 and C515, the pressure rating and the drilling of the
flanges shall be as per the Data Sheets and the BOQ.
2) The valves requirements shall apply for gate valves (isolation valves) which
shall be used for pipeline of size of DN 250 mm dia (inclusive) and smaller
unless specifically mentioned otherwise.
3) The valve shall have necessary provision to be coupled with an electrical
actuator if required at a later date.
4) Material. The body and bonnet shall be ductile iron
5) The wedge of the gate valve shall be fully encapsulated with an EPDM
rubber.
6) The valve shall be closed by clockwise movement
7) Gate valves shall be shall be of the double flange type with overall length
(flange to flange) complying with ASME B16.10 / ANSI B16.10, ISO 5752
Series 14 or series 15 standards
Description Material Reference Standard
Material
Body Ductile Iron A536 65-45-12
Bonnet Bolt & Nuts Stainless Steel AISI 316
Bonnet O-Ring Nitrile ASTM D2000
Bonnet Ductile Iron A536 65-45-12
Ductile Iron, SBR Encapsulat- A536 65-45-12 + Rubber Encapsulation,
Wedge
ed SBR
Anti- friction Washer (2) Acetal
Stuffing Box w/dirt seal Ductile Iron A536 65-45-12
Guide Cap Bearings Acetal
Stem Nut Bronze ASTM B62
Hand wheel Ductile Iron A536 65-45-12
Wrench Nut Cap Screw Stainless Steel AISI 304
Stem Stainless Steel AISI 420
Wrench Nut Ductile Iron A536 65-45-12
Stuffing Box Seal Nitrile ASTM D2000
Wrench Nut Cap Screw Stainless Steel AISI 316
Stem O-Ring Nitrile ASTM D2000
Stuffing Box Bolts & Nuts Stainless Steel AISI 316
Pressure Rating
Potable Water PN 10
Irrigation PN 10
D Service Connection
1. General
a. All materials for service connections shall be subject to ENGINEER ap-

proval.
b. Prior to the complete ordering of the required service connection mate-
rials, certain lengths of sample polyethylene pipes and a number of
sample saddle straps, ferrules (combined with stopcock), gate valves,
lockable valves, water meters, non-return valves and fittings such as; el-
bows, tees, reducers, couplings, adapters, connectors, etc. (all of differ-

ent sizes) shall be assembled at site and be subject to a test pressure of
16 bar (nominal working pressure 9 bar), all in the presence and to the
approval of the ENGINEER.
2. Polyethylene Pipes
a. Polyethylene service connection pipes shall be high density polyethylene

and shall comply with the requirements of ISO 4427 type PE 100 SDR 11
(standard dimension ratio) or BS 6730 and following the above sections
b. The pipes shall be manufactured from polyethylene containing only

those antioxidants, UV stabilizers and pigments necessary for the manu-
facturing of the pipes and confirming to the requirements of ENGINEER
and the specification.
c. Polyethylene pipes shall be clearly marked at intervals of one meter in-

dicating the manufacturer name, nominal diameter, standard number,
pipe class, pressure rating and date of pipe manufacturing. The word
"WATER" shall also be marked every one meter. The marking shall be by
means of paint or engraved marks. All markings shall be in blue color.
d. The pipes shall be supplied in coils of 150 m and shall be kept shaded at
all times. The coils shall be wrapped and shall not be exposed to direct
sunlight.
3. Saddle Straps
a. DI tapping saddles for service connections designed for long life Suitable for
tapping up to 2" diameter. The Saddles shall be suitable for making service
connections under pressure or dry using approved tapping machine into
HDPE or PVC pipes. The saddle shall be of two parts fitted with EPDM seal-
ing gasket, stainless steel nuts, bolts and washer to ISO 3506 and shall be
suitable for a working pressure of up to 16 bar.
b. Tapping saddle for PVC and PE pipes for water and wastewater treatment
to max. 70° C
c. Saddle of ductile iron with epoxy coating according to DIN 30677-2
d. Short BSP thread with no raw threads exposed to the medium.
e. Main gasket of drinking water approved EPDM rubber.
f. Bolts of stainless steel A2.
g. Nuts of acid-resistant stainless steel A4 with antifriction coated surface, lo-

cated in a recess in the lower part.
h. SBR rubber lining covers the internal surface to avoid direct contact be-
tween the ductile iron saddle and the pipe surface.
i. The bolt holes are fully epoxy coated to protect against corrosion.
j. The name of manufacturer, patent number, pipe diameter to which the

strap is suitable, and pipe material shall be engraved on the saddle strap.
k. The supply shall be accompanied by manufacturer's certificate stating date

of manufacture, material specification, name and address of local agent.
l. Material specification
1) Saddle upper part, ductile iron, min. (GGG-40)
2) Gasket, EPDM rubber
3) Lining, SBR rubber
4) Saddle lower part, ductile iron, min (GGG-40) / st. steel A2
5) Bolt, Stainless steel A2
6) Nut, Stainless steel A4
4. Service Connection Fittings
a. Fittings for polyethylene service connection pipes such as tees, connect-

ors, adapters, elbows, couplings etc. shall be compression type or push
fit type as per the particular specifications.
1) Compression Fittings
a) Compression fittings shall meet the requirements of BS

5114.
b) Compression fittings shall be made from gunmetal to BS
1400-LG2. The fittings shall be suitable for direct connection
to polyethylene pipes. The compression ring shall be of
EPDM suitable for drinking water.
c) The thread shall be BSP to BS 21. The inserts shall be of
copper and male / female fittings shall be chamfered to
suite assembling and to avoid crossing of threads.
d) The fittings shall be capable of sustaining a working pres-
sure of upto 16 bar without leakage.
e) The rubber compression rings shall be capable of reuse for
at least 10 times.
f) The fittings shall be resistant to pull out. No solvent welding
shall be used in assembly.
2) Push fit Fittings
a) Push fit fittings shall be suitable for use underground and

above ground installation suitable for polyethylene pipes.
The fitting shall consists of body with internal taper, grip
ring for end load resistance, 'O' ring for water tightness seal
and liner. The fittings shall be suitable for working pressure
up to 16 bar without leakage.
b) The fittings shall be of acetal or polypropylene material
supplied complete with pre-assembled and captivated grip
ring and 'O' ring. The grip ring shall be of acetal and the 'O'
ring of EPDM.
c) The seal of the joint shall be obtained using water pressure
as a thrust medium and no other tools or nuts shall be used
to obtain a watertight joint.
d) The ends of the polyethylene pipe shall be marked at two
locations corresponding to the two points of resistance pro-
vided by the grip ring and the 'O' ring.
e) Extractor tools for the dismantling of the push fit fittings
shall be supplied with the fittings, 5 sets of metal extractor
tools shall be supplied with each consignment. The tools
shall be suitable for the diameter and type of push fit fit-
tings supplied.
f) The push fit fittings shall have the name of manufacturer,
size and standard number marked on the fittings.
5. Detectable Warning Tape
a. Detectable warning tape shall be installed 250mm above the top of pol-
yethylene pipes over entire length of the house connection in green and
unpaved areas.
b. The tape shall be 250mm wide, blue coloured, plastic and aluminum
coated with the detection strip sealed at the edge. The tape shall have
the warning "CAUTION – WATER MAIN BELOW" in Arabic and English
printed on it.
E Accessories
1. Buried Gate Valve Accessories
a. Surface Box Materials
1) Surface box shall be manufactured from ductile iron materials (Spheroidal

Graphite Iron) and complying with BS EN 124: 1994.
2) Casting shall be smooth, true to pattern and free from projections, sand holes,
blowholes or other distortions. Surface Box shall meet or exceed minimum
wheel loading requirements as defined for CLASS D 400. When located under
the road and Class C 250 when located under the curb
3) The manufacturer/supplier shall forward his proposal to achieve water - tight-
ness. The surface box shall be double seal and with GRP sealing plate. The frame
shall be square and cover shall be round with 150mm dia. opening. The cover
shall be in one piece (solid top) and one keyhole (standard) for lifting. The mark-
ing on cover shall be (i) manufacturer name and (ii) ‘WATER’ (iii) ↔ (arrow
mark). The surface box shall be installed in such a way that arrow direction
marked on cover is parallel to the pipeline.
b. Extension Spindle:
1) The extension spindle shall be in one piece i. e. the main spindle shall be ex-
tended without connecting coupling. Alternatively, extension spindle with con-
necting coupling shall be supplied.
2) The height of extension spindle shall be such that spindle cap is 300mm from
surface box. The size and material of extension spindle shall be as per manufac-
turer recommendation and to ensure by manufacturer / tenderer that it can
withstand heavy torque during operation. The connecting coupling joining to
main spindle and extension spindle shall be attached by nut bolt of stainless
steel grade 316 and passing through. The spindle cap on the extension spindle
shall be as per dimension shown in BS 5163. The spindle cap shall be attached to
extension spindle by nut bolt of stainless steel grade 316 and passing through
extensional spindle and cap. Round supporting plate shall be welded to exten-
sion spindle at 100 mm below spindle cap and dia. of round supporting plate
shall be 5 mm less than internal dia. of PVC pipe. This is required to keep exten-
sion spindle in the center of PVC pipe. Extension spindle, connecting coupling
and spindle cap shall be epoxy coated in blue color. The following marking shall
be provided on top of round plate: Name of Manufacturer, Contract No. and
Date of Manufacturing.
3) The PVC pipe piece shall be 100mm dia and class C/D/E. It shall have length of
1.3m for valve size 150mm dia. and below and 1.0 m for valve size above 150
mm dia. More length shall be provided if valve is laid deeper than normal depth.
PVC pipe piece shall be fitted over the neck of valve with watertight adaptor.
The top of PVC pipe shall be cut up to bottom of frame of manhole cover, at site.
4) Watertight adapter or any other suitable arrangement is to be given which shall
be used to connect the neck of valve and PVC pipe. It shall be watertight so that
groundwater cannot enter inside PVC pipe after fixing over the neck of valve.
2. Bolts, Nuts and Washers
a. Except as stated otherwise, all fastening steel bolts for connecting valve flanges
with pipeline flanges shall be of high tensile steel (400 N/mm²). The bolts, nuts
and washers shall be either cadmium plated or hot dipped galvanized steel as
indicated in the applicable data sheets or in the piping specification of the re-
spective project.
/ Or
b. Nuts & bolts with washers shall be of AISI type 316 Stainless Steel complying
with ASTM A276 or equivalent. The grade shall be embossed on bolts. They shall
be supplied with two stainless steel grade 316 standard washers. Unless other-
wise indicated on the drawings, all stainless steel (whether nut bolts or any oth-
er items) shall be Type 316 with a mill finish
3. Coupling and Flange Adaptors
a. Where flexible couplings are required, they shall be of the tied or restrained
type, flexible couplings or equal. The supplier shall follow the manufacturer’s
Recommendations as to the methods and equipment to be used in assembling
the joints. In particular, the supplier shall ensure that rubber rings are correctly
positioned and free of twists. The rubber rings and any recommended lubricants
should be obtained only from the coupling manufacturer.
b. Flexible couplings and flange adaptors shall be capable of withstanding the test
pressure appropriate to the pipes for which they are supplied.
c. Material Specification (at a glance):
1) Flange Adaptor Body and End Rings, Ductile Iron to BS EN1563:

1) Gaskets, Standard: EPDM to BS EN681-1, TYPE WA, WC Nitrile to BS EN682:
2) Tee Bolts/Bolts, Standard: Steel to BS EN ISO 898-1, option Stainless Steel to BS

EN ISO 3506-1:
3) Nuts - Standard: Steel to BS EN 20898-2, Option: Stainless Steel to BS EN ISO
3506-2:
4) Washers - Stainless Steel to BS1449:
5) Coatings, Flange adaptor body and end rings coated with: Standard Rilsan Nylon
coating to full unit including studs, nuts, bolts and suitable to for fit in contact
with potable water (certificate to be attached) minimum thickness - 250 microns
d. Details of couplings for incorporation in the works shall be submitted to the En-
gineer for approval
e. Rating: Shall be as follows:
1) Pressure Rating is the same as the valve or the pipe connected to the stepped
coupling
2) Test pressure equals to 1.5 working pressure.
4. Dismantling Joints
a. Dismantling joints shall be installed at selected locations within the piping of the
pump station and in the valve chambers along the pipeline as shown on the de-
tailed drawing to facilitate future removal of valves and other equipment for
servicing/replacement.
b. Features
1) For applications where a full-face flange is required.

2) Longitudinal adjustment facilitates installation and removal of flanged equip-
ment.
3) Studs independent of the tie rods compress the gasket ensuring long term seal-
ing performance that is not effected due to any external loading.
4) The use of high tensile steel in the tie rods reduces the number required to ac-
commodate end load forces, reducing the overall weight of the product.
5) The flange adaptor and flange spigot are coated with approved Rilsan Nylon 11
providing excellent protection from transport, storage, site and corrosion dam-
age. The tie bars are Zinc Plated as standard with other coatings, grades and fin-
ishes available on request. The nuts and bolts are Sheraplex coated, offering
long term protection against corrosion
6) Harnessing is provided within the bolt circle, eliminating other complex anchor-
ing systems and reducing space requirements.
c. The dismantling joints shall be of the tied/restrained type having the following
specifications:
1) Flange Drilling, ANSI/AWWA C207-01

2) Fabricated Flange Adaptor
a) Body - Rolled Steel to BS EN 10025-2

b) End Rings - Ductile Iron to BS EN1563, or Rolled Steel to BS EN 10025-2
c) Sleeve - Steel Tube to BS EN10255, or Steel Tube to BS EN10216-1, or Rolled
Steel to BS EN 10025-2:
3) Flanged Spigot
a) Flange - Rolled Steel to BS EN 10025-2:
b) Spigot - Steel Tube to BS EN10255, or Steel Tube to BS EN10216-1, or Rolled
Steel to BS EN 10025-2
4) Gaskets, BS EN681-1
5) Steel Tie Rods & Nuts
a) Tie Rods - BS EN10269

b) Nuts - BS EN20898-2
6) Stainless Steel Tie Rods & Nuts
a) Tie Rods - Stainless Steel to BS EN3506-1

b) Nuts (sizes up to and including 2 1/4”) 4 per Tie Rod - Stainless Steel to
BSEN3506-2, Nuts (sizes over 2 1/4”) 6 per Tie Rod - Stainless Steel to BS
EN3506
7) Studs/Nuts/Washers
a) Studs - Steel to BS EN ISO898-1

b) Nuts - Steel to BS4190
c) Washers - Stainless Steel to BS1449
8) Coatings (Others available on request)
a) Fabricated Flange Adaptor - Rilsan Nylon 11

b) Flanged Spigot - Rilsan Nylon 11
c) End Ring - Rilsan Nylon 11
d) Studs/Nuts - Sheraplex
e) Steel Tie Rods/Nuts - Zinc coated
d. Rating: Shall be as follows:
1) Pressure Rating is the same as the valve or the pipe connected to the
Dismantling joints
2) Test pressure equals to 1.5 working pressure
5. Stepped Couplings
a. Stepped couplings shall be used to connect the spigot ends of two pipes of dif-
ferent nominal diameters.
b. A range of universal straight couplings, stepped couplings and flange adaptors
for ductile iron, steel, and uPVC, stepped couplings are easy to mount due to the
anti-friction coated bolts and nuts and the possibility of up to ±4° angular deflec-
tion. The stainless steel bolts and nuts and the high quality coating offer a dura-
ble corrosion protection.
c. Features
1) ±4° angular deflection

2) Drinking water approved EPDM gasket
3) The bolts and nuts are anti-friction coated to offer easy tightening and to
prevent galling
4) The bolt ends are protected with plastic caps
5) The moulded ribs in the gasket absorb minor imperfections in the pipe
6) Versatile design tolerances typical 26 mm to cover all pipe materials
7) Ductile iron with epoxy coating according to DIN 30677-2
d. The Stepped Couplings shall be of the universal straight couplings type having
the following specifications:
1) Protection cap, Plastic

2) Washer, Stainless steel
3) Nut, Acid-resistant stainless steel
4) Bolt, Stainless steel
5) Gland ring, Ductile iron (GGG-40)
6) Gasket, EPDM rubber
7) Centre sleeve, Ductile iron (GGG-40)
e. Rating: Shall be as follows:
stepped coupling
2) Test pressure equals to 1.5 working pressure.
6. Split tees for under pressure connections
a. The sealing mechanism shall be by rubber ring set in a locating groove around
the branch opening and held firmly against the mainline pipe by the pressure of
the opposite bolted half or alternatively by full length rubber gaskets along the
mating halves and at the separate end flanges. The rubber gaskets shall be
EPDM to ISO 4633 suitable for drinking water. The bolts, nuts, washers shall be
stainless steel 316. The split tees shall be coated with nontoxic fusion bonded
epoxy powder or a Nylon based polyimide 11 coating system with normal dry
film thickness of 300 microns and a minimum DFT of 250 microns.
7. Puddle flanges and Trust Anchor Flanges
a. Thrust/anchor flanges shall be used where D.I. pipes or fittings are cast into the
chamber wall and shall be designed to restrain the connecting valves or other
equipment installed inside the chamber. Thrust/anchor flanges shall be integral-
ly cast or factory welded on to the pipe piece. Bolted or screwed on thrust
flanges are not acceptable. The coating to the thrust/anchor flange shall be simi-
lar to that of the pipe/fitting. The position of the thrust/anchor flange shall be as
shown on the drawings or determined on site.
b. Rating: Shall be as follows:
stepped coupling

2) Test pressure equals to 1.5 working pressure
2.5 IRRIGATION EQUIPMENT AND ACCESSORIES
A Electric Remote Control Valves With Pressure Regulation:
1. The electric remote control valve shall be a normally closed 24 VAC 50/60 Hz
(cycles/sec) solenoid actuated globe pattern design capable of having a flow
rate and pressure as indicated on the drawings. The valve pressure rating shall
not be less than 200 psi (13,8 Bars).
2. The valve body shall be constructed of heavy-duty glass-filled UV-resistant ny-
lon and have stainless steel studs and flange nuts; diaphragm shall be of nylon
reinforced nitrile rubber.
3. The valve shall have both internal and external manual open/close control (in-
ternal and external bleed) for manually opening and closing the valve without
electrically energizing the solenoid. The valve's internal bleed shall prevent
flooding of the valve box.
4. The valve shall house a fully-encapsulated, one-piece solenoid. The solenoid
shall have a captured plunger with a removable retainer for easy servicing and
a leverage handle for easy turning. This 24 VAC 50/60 Hz solenoid shall open
with 19.6 VAC minimum at 200 PSI (13,8 Bars). At 24 VAC, average inrush cur-
rent shall not exceed .41 amps. Average holding current shall not exceed 0.28
amps.
5. The valve shall have a brass flow control stem for accurate manual regulation
and/or shut-off of outlet flow. The valve must open or close in less than 1 mi-
nute at 200 PSI (13,8 Bars) and less than 30 seconds at 20 PSI (1,4 Bars).
6. The PESB valve shall have a self-cleaning stainless steel screen designed for use
in dirty water applications.
7. The valve construction shall be such as to provide for all internal parts to be
removable from the top of the valve without disturbing the valve installation.
8. Pressure Regulating Modules When so indicated on the design, the 1", 1 1/2",
and 2" electric remote control plastic valves shall have a pressure regulating
module capable of regulating outlet pressure between 1,04 and 6,90 Bar +/-
0,21 Bar. The pressure regulator module shall have an adjusting knob for set-
ting pressure and Schrader valve connection for monitoring pressure. The
pressure shall be adjustable from the pressure regulator when the valve is in-
ternally manually bled or electrically activated.
B One-Piece Quick Coupling Valve:
1. The quick coupling valve shall be a one-piece type capable of having a dis-
charge rate of 7 m3/Hr. with a pressure loss not to exceed 1.15 bars.
2. The valve body shall be constructed of red brass. The cover shall be a durable,
protective self-closing rubber cover. When so specified, the cover shall be a
locking rubber cover (LRC).
3. The valve shall be opened and closed by a brass key of the same manufacturer
having a 1" (FNPT) outlet. The valve throat shall have a key-way with detent
positions for regulating water flow.
4. Reinforced Rubber Hoses: According to BS 5119 rubber, vinyl or other high
tensile thermoplastic material reinforced with woven fabric, with quick cou-
plings to match the hose taps. Hose to be flexible, of such construction as to
prevent snaking and allow easy coiling.
5. The hoses should be made of reinforced fabric to be continuous nylon or poly-
ester fibers; inner and outer liners to be high tensile thermoplastic of high re-
sistance to heat and sun and abrasion when dragged over concrete.
6. End connections shall be of brass, factory installed on hose and watertight.
7. Head End: quick coupling, water tight swivel female thread or socket snap-on-
type to fit the water tap outlet.
8. Tail end: male threaded with all brass hand-trigger type discharge nozzles with
adjustable pattern and flow to complete shut off. Springs to be of stainless
steel.
9. The hose is to maintain its flexibility and pressure requirements between 2 and
60 deg. C. Hose is to withstand pressure of 6 bars when discharge nozzle is
closed, and comply with the requirements of ASTM D3901-85 as appropriate
for the materials selected.
10. Hose is to have an inside diameter of 25 mm and a length of 30 m excluding
end fittings.
C Rectangular Valve Boxes
1. Valve boxes shall be used as durable, rigid enclosures for valves or other irriga-
tion system components requiring subsurface protection for installation or
maintenance.
2. The valve box shall be made of structural foam HDPE resin that is resistant to
UV light, weather, moisture, and chemical action of soils.
3. The standard rectangular body shall have knock-outs molded into the sides
that can be readily removed. The knock-outs shall remain an integral part of
the body unless removed to run pipes or wires through the valve box.
4. The valve box shall have corrugated sides. Rectangular valve boxes shall have
a grooved feature on one side, just below the lid at the top of the box, for in-
serting a shovel blade or other prying tool to provide easy lid removal. This is
useful following compaction of the surrounding soil or after the eventual ac-
cumulation of thatch over the valve box.
5. Extension models shall have vertical ribs inside that make them capable of be-
ing mounted directly over the top of another box.
6. Boxes shall have a stepped feature on the bottom that securely interlocks two
boxes together when mated bottom-to-bottom for use in a deep installation.
7. There shall be no hole in the valve box lid unless the bolt-hole knock-out is
removed in order to use the locking bolt. Lids shall have beveled edges to min-
imize potential damage from lawn equipment. Lids shall be clearly marked
with the words “Irrigation Control Valve” molded onto the top. Lids shall have
a marking area measuring at least 6” by 2” that is suitable for branding or oth-
er means of identification.
D pressure regulating Y-screen filters
1. Pressure Regulating Filter (PRF) combines filtration and pressure regulation in

one integrated unit for protection of downstream components of drip irriga-
tion system. PRF component specifications include:

a. Compact “Y” filter body and cap configuration constructed of glass-filled,
UV-resistant polypropylene, with 120 PSI (8,3 bar) operating pressure
rating. Maximum dimensions of filter body; Height: 4 1/2" (11,4 cm),
Length: 5 1/2" (14 cm), Width: 2" (5,1 cm)
b. Standard 200 mesh (75 micron) filter screen constructed of durable pol-
yester fabric attached to propylene frame. Screen is serviceable for
cleaning purposes by unscrewing cap from filter body and removing fil-
ter element.
c. Normally-open pressure regulating device with preset outlet pressure of

approximately 40 PSI (2,8 bar). Pressure regulating device allows full
flow with minimal pressure loss unless inlet pressure is greater than pre-
set level. As inlet pressure increases above preset level, internal spring
compresses to reduce downstream pressure.
d. Male threaded 1” (25 mm) inlet and outlet connections.
E Pop-Up Spray Sprinkler
1. The sprinkler body, stem, nozzle and screen shall be constructed of heavy-
duty, ultra-violet resistant plastic. It shall have a heavy-duty stainless steel re-
tract spring for positive pop-down and a ratcheting system for easy alignment
of the pattern. The sprinkler shall have a soft elastomer pressure-activated co-
molded wiper seal for cleaning debris from the pop-up stem as it retracts into
the case to prevent the sprinkler from sticking up.
2. The sprinkler shall have a plastic variable arc nozzle with an adjusting screw
capable of regulating the radius and flow. The sprinkler shall be capable of
housing filter screens under the nozzle.
F BUBBLERS
1. Adjustable Bubblers for Trees and Palms: The bubbler shall be of adjustable
flow and radius type by turning outer cap.
2. The bubbler shall have Four convenient installation connections available for
design flexibility: 10-32 self-tapping thread, 1⁄2" FPT, 1⁄4" barb, and 5" spike.
3. The bubbler shall be capable of covering a 0.38 (meter) at 2.0 (Bars) with a dis-
charge rate of 132.5 (l/h).
G MULTI-OUTLETS
1. Multi-outlet Pressure Compensating Emitters for Shrubs: Pressure compensat-

ing outlets in one emission device. Each outlet is self-regulating and The Multi-
Outlet emitter provides six independently operating, pressure-self-flushing.
With a flow rate of 1.0 GPH (3,79 lph) per outlet
2. These emitters are also available in both barbed and 1/2” female pipe thread
inlet.
3. The outlets are easily opened by removing the tip with cutting pliers. For une-
ven terrain, long laterals, pipe friction loss and mainline variations, the pres-
sure compensating design assures a high level of uniformity.
H Polyethylene (P.E.) Tubing
1. P.E Drip-In Lines for Ground Covers and Vines: tubing; brown in color, con-
forming to an outside diameter (O.D.) of 0.634 inches (16 mm) and an inside
diameter (I.D.) of 0.536 inches (13,6 mm) and wall thickness of 0.049 inches
(1,2 mm)
2. Factory installed, pressure-compensating, inline emitters welded to the inner

circumference of the polyethylene tubing at spacing specified by model num-
ber
3. Inline emitters designed to pressure-compensate by lengthening the emitter’s

turbulent flow path
4. Consistent flow rate from each installed inline emitter when emitter inlet
pressure is supplied between recommended operating range of 8.5 to 60 PSI
(0,7 to 4,1 bar)
5. Required filtration for drip line tubing and emitters is 120 mesh (125 micron)
6. P.E Tubing: Extruded from virgin linear low density polyethylene resin, free of
splits and kinks, resistant to stress, cracking and rolling, suitable for use above
or below ground, specifically manufactured for receiving drip irrigation emit-
ters, maximum working pressure of 4 bars.
7. The fittings for laterals are to be durable with minimum flow resistance, com-
pression type couplings. Connection to manifold to be achieved using com-
pression fittings or insert barbs with external retaining clamps or collars. Fit-
tings to attach to the manifold by solvent cement for HDPE manifold and by
threaded connection or rubber grommet for polyethylene. Ends of laterals to
be folded over and held in place by a slide collar.
I Program Controllers
1. The irrigation system Controller shall be of a hybrid type that combines elec-
tro-mechanical and microelectronic circuitry capable of fully automatic or
manual operation. The controller shall be housed in a wall-mountable, weath-
er-resistant plastic cabinet with a key-locking cabinet door suitable for either
indoor or outdoor installation.
2. The controller shall have a base station capacity of 8 or 12 stations as well as 3

expansion slots capable of receiving station modules of 4, 8, or 12 stations to
create a controller capacity of up to 48 stations. All stations shall have the ca-
pability of independently obeying or ignoring the weather sensor as well as us-
ing or not using the master valve. Station timing shall be from 0 minutes to 12
hours. The controller shall have a Seasonal Adjustment by program which ad-
justs the station run time from 0 to 300% in 1% increments.
3. The controller shall also have a Monthly Seasonal Adjustment of 0 to 300% by

month. Station timing with Seasonal Adjustment shall be from 1 second to 16
hours.

4. The controller shall have 4 separate and independent programs which can
have different start times, start day cycles, and station run times. Each pro-
gram shall have up to 8 start times per day for a total of 32 possible start times
per day. The 4 programs shall be allowed to overlap operation based on user-
defined settings which control the number of simultaneous stations per pro-
gram and total for the controller.
5. The controller shall allow up to 5 valves to operate simultaneously per pro-

gram and total for the controller including the master valve/pump start circuit.
The controller shall have an electronic, diagnostic circuit breaker that shall
sense a station with an electrical overload or short circuit and shall bypass that
station and continue to operate all other stations.
6. The controller shall have a 365-day calendar with Permanent Day Off feature
that allows a day(s) of the week to be turned off on any user selected program
day cycle. (Custom, Even, Odd, Odd31, & Cyclical). Days set to Permanent Day
Off shall override the normal repeating schedule and not water on the speci-
fied day(s) of the week.
7. The controller shall also have a Calendar Day Off feature allowing the user to
select up to 5 dates up to 365-days in the future when the controller shall not
start programs. The controller shall incorporate a Rain Delay feature allowing
the user to set the number of days the controller should remain off before au-
tomatically returning to the auto mode.
8. The controller shall have Cycle+Soak water management software which is ca-
pable of operating each station for a maximum cycle time and a minimum soak
time to reduce water run-off. The maximum cycle time shall not be extended
by Seasonal Adjustment.
9. The controller shall incorporate a Flo-Manager feature providing real-time

flow, power, and station management. Flo-Manager shall manage the number
of stations operating at any point in time based on water source capacity, sta-
tion flow rate, number of valves per station; user defined simultaneous sta-
tions per program and for the controller. The controller shall provide station
priorities to determine the order in which stations shall operate. The controller
shall ignore the station number and instead operate the highest priority sta-
tions first and the lower priority stations last.
10. The controller shall offer Water Windows for each program. This function sets
the allowed start and stop time where watering is allowed. If the watering
cannot be completed by the time the Water Window closes, the stations with
remaining run time are paused and watering automatically resumes when the
Water Window opens the next time.
11. The controller shall have an alarm indicator light on the front panel visible
through the outer door with the door closed and locked. The alarm light shall
prompt the user to select the alarm soft key to review the alarm condition(s).
J Cabling For Irrigation Control
1. Cables Between Controllers And Solenoid Valves:

a. Direct Burial valves wire Insulation: Polyethylene, Sizes: 14 Awg - 10 Awg
Solid
2. Scope:
a. This specification covers single conductor insulated wire sizes 14 AWG,

through 10 AWG, utilizing low density high molecular weight polyeth-
ylene insulation, suitable for direct burial applications for operating
temperatures up to 60°C. Listed by UL or ETL or CSA.
3. Construction:
a. Conductor: Soft drawn bare copper meeting the requirements of ASTM

specifications B-3 0r B-8.
b. Temperature Rating: -55ºC + 60ºC
c. Insulation Thickness: 0.045"
d. Manufacturer's Identification: Surface marked with Paige-Electric, volt-

age rating, size and type, Listing file number, RoHS.
e. Sunlight Resistance: Available as an option
f. Listing for valve wire: All wire listed for use in the USA shall be tested
physically and electrically in accordance with UL Standards 493 and
83. These wires will carry a 600V rating.
g. Dual rated wire, listed for use in the USA and Canada, shall be tested
physically and electrically in accordance with UL Standards 493 & 83,
and CSA Rule C22.2 No. 35. These wires will carry a 30V rating.
h. The construction of the above described wires is identical.
4. Splicing Recommendations:
a. Underground splices shall be made in accordance with National Electri-

cal Code® Articles 300.5 (Underground Installations) and 110.14 (Electri-
cal Connections) using 3M DBY-6 or DBR-6 connectors, which are UL
listed under "UL 486D-Direct Burial", for wet or damp locations, 600
volts. Connectors that are not listed at all, or listed under UL Standard
UL 486C as "Compression Connectors", shall not be allowed.
PART 3 EXECUTION
3.1 GENERAL
A All pipe work, fittings are to be installed in strict accordance with the manufacturer
instructions and in accordance with this specification. The excavation, pipe bedding
and back filling shall comply with Section 3200 “Earthwork”

3.2 PIPES
A Excavation
1. The requirements of “Earthwork” Section shall be applied, except as otherwise

specified in this Clause.
2. Excavation for trenches shall be carried out for a maximum of four pipe lengths
in advance of the pipe laying or as determined by the ENGINEER. The trenches
shall be excavated to the required line and level as shown on the drawings or
as approved by ENGINEER, and shall, at all times, be drained and braced to en-
sure safe and efficient pipe laying. In locations where services, ruins, or other
structures are near the pipeline route, only hand excavation will be permitted.
3. The CONTRACTOR shall provide and maintain suitable temporary crossings
over pipe trenches at those positions where the excavation of a pipe trench
prevents the normal movements of traffic. To permit the passage of pedestri-
an, vehicular and other traffic the CONTRACTOR shall phase the excavation,
pipe laying, jointing and reinstatement in such a way as to provide reasonable
access to houses, roads, footpaths, etc.
4. All pipes shall not have a cover of less than 900mm, or as shown on the draw-
ing, measured from the surrounding or finished surface level except where the
pipe may be lifted or lowered when crossing other services as instructed by the
ENGINEER.
5. Where trenches are required to be deeper than the general depth mentioned
above, the CONTRACTOR shall dig the trench to the required depth with a
gradual slope necessary for the proper laying of the pipeline. Pipelines shall
not be laid closer than 300mm to other pipelines, services or structures or as
directed by the ENGINEER.
6. The trench width is dependent on the nature of the ground, depth, and pipe
size. The clear width of the trench at any level shall be minimum of one pipe
outside diameter, plus 300mm clearance on either side. In all cases the trench
shall be excavated sufficiently wide to ensure efficient laying and jointing of
the pipes.
7. Excavation in rock shall be made to provide a minimum of 150mm clearance
on each side of and below all pipes or fittings. Blasting shall not be carried out
in any part of the WORKS without the permission in writing of the ENGINEER
8. Wherever practical, mechanical excavation methods shall be used, except
where such methods may cause damage to existing structures, services or ru-
ins. In such locations, the CONTRACTOR shall hand excavate only. Where shor-
ing is used to stabilize excavations, the shoring shall be removed progressively
to ensure that adequate backfilling is carried out without leaving voids. All ex-
cavated material shall be placed so as to avoid any danger or hindrance to oth-
ers.
9. The CONTRACTOR shall keep all excavations stable at all times during construc-
tion of the pipeline. When excavating in unstable soils or where the excava-
tions are necessarily deep, the CONTRACTOR shall submit to the ENGINEER his
detailed proposals for supporting the excavations at the site at least seven
days prior to commencement of any excavation work. His proposal shall take
into account the nature of the ground to be excavated, the water table level at
the site and the closeness of adjacent buildings and roads. If, in the opinion of
the ENGINEER the support proposed by the CONTRACTOR is insufficient, then
the ENGINEER will order the provision of stronger or alternative support for
the excavations than that proposed by the CONTRACTOR. In this event the
CONTRACTOR shall adopt the same at no extra cost to the Client. The
CONTRACTOR shall not remove any temporary works supporting the excava-
tion until in the opinion of the ENGINEER; the permanent work is sufficiently
advanced to permit such removal. This shall then be executed under the per-
sonal supervision of a competent foreman.
B Line and Grade
1. The Engineer shall provide the Contractor with benchmark, base line and
points of reference to be used by the Contractor in laying out the work. From
the benchmark, base line and points of reference the Contractor shall do his
own layout. The Contractor shall notify the Engineer if for any reason these
benchmarks, base line and pints of reference are disturbed, lost or destroyed.
The Contractor shall be charged the cost necessary to replace and relocate all
bench marks, base line and points of reference so disturbed, lost or destroyed.
2. The Contractor shall be responsible for true and proper laying out of the work
and for the correctness of position, levels, dimensions and alignment of all
parts of the work and for the provision of all necessary survey instruments,
equipment, labor, stakes, templates, batter boards, material and supplies nec-
essary for the laying out of the work and maintenance thereof.
3. If at any time during the progress of the work any error shall appear or arise in
the position, levels, dimensions or alignment of any part of the work the Con-
tractor shall, at his own expense, rectify such error to the satisfaction of the
Engineer.
4. The checking of any layout or of any line or level by the Engineer shall in no
way relieve the Contractor of his responsibility for the correctness thereof.
C Pipe Distribution
1. Distribute material on the job no faster than it can be used to good advantage.
Unload pipe, which cannot be physically lifted by workers from the trucks, by a
forklift or other approved means. Do not drop pipe of any size from the bed of
week’s supply of material in advance of laying, unless otherwise approved by
the Engineer.
D Pipe Preparation and Handling
1. Inspect all pipe and fittings prior to lowering into trench to ensure no cracked,
broken or otherwise defective materials are being used. Clean ends of pipe
thoroughly. Remove foreign matter and dirt from inside of pipe and keep clean
during and after laying.
2. Pipe and accessories that are chipped, cracked or contain other imperfection
or do not meet the test requirements shall be marked with a permanent mark-
ing as rejected and shall be promptly removed from the Site.
3. Use proper implements, tools and facilities for the safe and proper protection
of the work. Lower pipe into the trench in such a manner as to avoid any phys-
ical damage to it. Remove all damaged pipe from the Site. Do not drop or
dump pipe into trench under any circumstances.
E Underground Warning Tape
1. Warning tapes shall be laid above all utility pipes. Tapes shall be durable and
detectable by electro-magnetic means using low output generator equipment.
They shall remain legible and color fast in all soil conditions at pH values of 2.5
to 11.0 inclusive.
2. Warning tapes shall be placed in compacted backfill material, approximately
300 mm below finish grade and as indicated on drawings.
3. The tapes shall be flexible and subject to the Engineer’s approval. Width of the
tape shall be at least 6” (150 mm).
4. Tapes shall have different colors for different utilities and with black text in Ar-
abic and English as “CAUTION WATER PRESSURE MAIN BELOW” for water
mains, etc. The text on the tape shall be permanent ink bounded to resist pro-
longed chemical attack by corrosive acids and alkaline with message repeated
at a maximum interval of two (2) meters.
5. The tape shall be laid continuous over pipelines and at joints there shall be a
minimum of one (1) meter overlapping. Tape shall be terminated inside valve
boxes to allow clipping of detector equipment to the tape.
6. Warning tape shall not be separately measured or paid for, but shall be con-
sidered as a subsidiary obligation under the respective items included in the
Bill of Quantities.
F Geotextiles
1. Store and handle geotextiles in accordance with ASTM D 4873. Place and in-
stall in accordance with manufacturer’s written instructions and as follows, to
the approval of the Engineer
a. Overlaps shall not, in any case, be less than 25 mm

b. Place bedding layer as soon as possible after placement of the geotex-
tile, in accordance with approved methods, to thickness shown on Draw-
ings
c. Remove and replace any geotextile damaged or punctured either be-
fore, during or after laying
G Soil Tests
1. During buried pipe installation, work should be checked throughout the con-
struction period by an inspector who is thoroughly familiar with the jobsite,
contract specifications, materials, and installation procedures. Inspections
should reasonably ensure that signify cant factors such as trench depth, grade,
pipe foundation (if required), quality and compaction of embedment backfill,
and safety are in compliance with contract specifications and other require-
ments. To evaluate soil stability, density and compaction, appropriate ASTM
tests may be required in the contract specifications.
H Laying and Joining Pipe and Fittings
1. General: Take the necessary precautions required to prevent excavated or

other foreign material from getting into the pipe during the laying operation.
At all times, when laying operations are not in progress, at the close of the
day’s work or whenever the workers are absent from the job, close and block
the open end of the last laid section of pipe to prevent entry of foreign materi-
al or creep of the gasket joints.
2. It shall be the CONTRACTOR's responsibility to accurately survey the route of
the pipeline before commencing construction. The CONTRACTOR shall estab-
lish and maintain center-line, change and level reference points to the satisfac-
tion of the ENGINEER. The CONTRACTOR shall submit proposed profile and
alignment for every pipeline to the ENGINEER for approval. The profile shall be
agreed in accordance with the parameters and any other requirements in-
structed by the ENGINEER.
3. Before pipes are lowered into the trench, the suitability of the material in the
bottom of the trench shall be subject to approval of the ENGINEER and if found
unsuitable be replaced with approved material.
4. If groundwater exists, take all precaution necessary to prevent the “uplift” or
floating of the line prior to the completion of the backfilling operation.
5. Where the pipe is connected to concrete structures, the connection shall be
made as shown on Drawings. If the connection is not shown, make connection
such that a standard pipe joint is located no more than 450 mm from the struc-
ture.
6. When pipe is laid within a movable trench shield, take necessary precautions
to prevent pipe joints from pulling apart when moving the shield ahead.
7. Temporary Plugs: Watertight plug and timber bulkhead or gasket steel plug.
8. Temporary plugs shall be removable without damage to pipe stub outs and
shall be capable of withstanding internal pressure, external loads and external
pressures without leakage.
9. Where pipelines are to be laid in ducts, the Contractor shall propose for the
Engineer's approval a suitable system of guides, supports and slides to ensure
that the pipe is installed to the required levels as shown on the Drawings.
10. The Contractor's installation system shall ensure that no damage occurs to the
pipe, linings or coatings to the pipe, or to the duct.
11. It is the CONTRACTOR's responsibility to ensure that the pipeline is clear and
free of all foreign matter at all times until taken over by the Engineer. Suffi-
cient backfill shall be placed on the pipe to prevent flotation if the trench is
flooded either by groundwater or rainfalls. Any pipe that has floated shall be
removed from the trench and relayed in a dry trench. The ENGINEER’s decision
is final as regards the suitability of the weather for pipe laying.
12. Temporary support, adequate protection, and maintenance of all underground
and surface utilities encountered during construction of the WORKS, shall be
furnished by the CONTRACTOR. Where the grade or alignment of the pipe is
obstructed by existing utilities, such as conduits, ducts, pipes, branch connec-
tions etc. the obstructions shall be supported,
13. Relocated, removed, or reconstructed by the CONTRACTOR at his own cost un-
less otherwise provided to be paid for separately. Whenever it is necessary to
determine the location of existing underground utilities, the CONTRACTOR, af-
ter an examination of available records, shall make all explorations and excava-
tions as may be directed by the ENGINEER’S to determine these locations. Only
such tools and equipment as have been approved by the ENGINEER’S shall be
used by the CONTRACTOR to execute the work in a safe and efficient manner.
14. After the pipe has been tested the annular space between the external face of
the pipe and the internal face of the duct shall be filled as directed by the En-
gineer's Representative.
I INSPECTION
1. Pre-Construction: Inspections and tests begin before construction. Jobsite

conditions dictate how piping may be installed and what equipment is appro-
priate for construction. Soil test borings and test excavations may be useful to
determine soil bearing strength and whether or not native soils are suitable as
backfill materials in accordance with project specifications.
2. In slip line or pipe bursting rehabilitation applications, the deteriorated pipe-
line should be inspected by remote TV camera to locate structurally deterio-
rated areas, obstructions, offset and separated joints, undocumented bends,
and service connections.
3. The installer should carefully review contract specifications and plans. Differ-
ent piping materials require different construction practices and procedures.
These differences should be accurately reflected in the contract documents.
Good plans and specifications help protect all parties from unnecessary claims
and liabilities. Good documents also set minimum installation quality require-
ments, and the testing and inspection requirements that apply during the job.
J Pipe Cutting
1. Where pipes are required to be cut on the Site the cutting shall be done by the
Contractor in accordance with the manufacturer’s recommendations and in a
manner approved by the Engineer.
2. The pipe and methods of jointing shall be such that the locations of fittings and
lengths of pipe can be adjusted to suit Site conditions.
3. Cutting of reinforced concrete pipes will not be allowed. Special lengths of
pipes shall be manufactured for closures as required. Other pipes such as GRP,
ductile iron, vitrified clay, MDPE, HDPE, PVC-U and cast iron pipes shall only be
cut if approved by the Engineer.
4. The cutting of vitrified clay pipes, MDPE, HDPE, PVC-U, and ductile iron pipes
for inserting specials, fittings or closure pieces shall be carried out as follows:
a. cutting shall be carried out in a neat and workmanlike manner with an

approved cutting machine without damage to the pipe and so as to
leave a smooth end at right angles to the axis of the pipe
b. Cutting by hacksaw shall not be permitted unless approved by the Engi-
neer.
c. only experienced men shall be employed by the Contractor on this work
d. The Contractor shall take every precaution to ensure that both the
measurement tolerances and the cutting of pipes are to the accuracy
required. Should any errors occur the Contractor shall correct the de-
fects to the approval of the Engineer.
K Laying High Density Polyethylene Pipes (HDPE):
1. Joining and Connections
a. For satisfactory material and product performance, system designs and

installation methods rely on appropriate, properly made connections. An
inadequate or improperly made field joint may cause installation delays,
may disable or impair system operations, or may create hazardous con-
ditions. Joining and connection methods will vary depending upon re-
quirements for internal or external pressure, leak tightness, restraint
against longitudinal movement (thrust load capacity), application and
operation conditions, construction and installation requirements, and
the products being joined.
b. PE pressure piping products are connected to themselves and to piping
products from other materials using methods that seal and restrain
against longitudinal thrust loads. These methods include butt, socket
and saddle fusion, electro fusion couplings and saddles, and mechanical
methods such as MJ Adapters, flanges, and restrained mechanical cou-
plings.
c. In some circumstances, external restraint may be necessary for connec-
tions between PE and non-PE piping, such as for connections between
butt-fused PE pressure pipe and bell and spigot joined PVC or ductile
iron pipe. Longitudinal thrust forces that may develop in PE pressure
pipe may be sufficient to disjoin unrestrained PVC or ductile iron joints
that seal but do not restrain. To restrain longitudinal thrust forces, PE
pressure pipe may be fitted with a wall anchor or electro fusion re-
straints to anchor against movement from longitudinal thrust forces.
d. PE non-pressure piping may require less or no restraint and may be con-
nected using gasket bell and spigot joints, extrusion welding, compres-
sion couplings, and various types of elastomeric seals. Sealed, unre-
strained joints that may be suitable for non-pressure service are not
suitable for PE pressure service.
e. Before using a joining or connection method, the limitations of the join-
ing or connection method must be taken into account. Where a joining
or connection method is suitable, the manufacturer’s joining proce-
dures, tools and components required to construct and install joints in
accordance with manufacturer’s recommendations should always be
used.
f. Field connections are controlled by and are the responsibility of the field
installer. Some joining procedures such as heat fusion, electro fusion and
thermal welding require trained and qualified personnel. Some joining
equipment such as larger butt fusion machines, saddle fusion and elec-
tro fusion equipment require persons that are properly trained in
equipment operation. For regulated pipelines, the authority having ju-
risdiction may require certification of joining proficiency. Before heat fu-
sion or electro fusion joining is performed at the jobsite, the contractor
should obtain joining procedures and inspection criteria from the PE
product manufacturer, and should obtain documentation of joining pro-
ficiency and qualification for persons making heat fusion or electro fu-
sion joints.
g. Ductile iron pipe ends shall be thoroughly cleaned, both internally and
externally, the socket gasket fitted and lubricating paste applied to the
spigot end and gasket before commencing to make the joint. Individual
lengths of pipes and fittings shall be coupled together by an approved
jointing system and fitted in the manner recommended by the manufac-
turer of the joints. Joints shall be left uncovered until completion of
pressure testing unless otherwise agreed by the ENGINEER. At joints
permitting expansion, the pipe ends shall be pushed hard up against
each other and then withdrawn 5mm.
2. Cleaning Before Joining
a. All field connection methods and procedures require component ends to

be clean, dry, and free of detrimental surface defects before the connec-
tion is made. Contamination and unsuitable surface conditions usually
produce an unsatisfactory connection. Casketed joints may require ap-
propriate lubrication. Cleaning component ends before joining may re-
quire removing surface deposits to planning (facing), abrading or scrap-

ing the pipe surface. Surface dust and light soil may be removed by wip-
ing the surfaces with clean, dry, lint free cloths. Heavier soil may be
washed or scrubbed off with soap and water solutions, followed by
thorough rinsing with clear water, and drying with dry, clean, lint-free
cloths.
b. Before using chemical cleaning solvents, the user should know the po-
tential risks and hazards and appropriate safety precautions should be
taken. Hazard information is available from chemical manufacturer’s in-
structions and the MSDS for the chemical. Some solvents may leave a
residue on the pipe, or may be incompatible or deleterious when used
with PE, for example, solvents that contain hydrocarbon liquids such as
WD-40 or kerosene will contaminate the pipe and prevent heat fusion
bonding
c. Surface damage that could detrimentally affect sealing or pipe perfor-
mance generally requires removing the damaged section.
3. Field Fusion Joining
a. Heat fusion joining may be performed in any season and in hot or cold
conditions. During inclement weather, a temporary shelter should be
set-up around the joining operation to shield heat fusion operations
from rain, frozen precipitation, and high wind conditions. Wind chill can
reduce heating plate temperature or chill melted component ends be-
fore joining. If fusion joining operations cannot be protected against
dust contamination during severe windblown dust conditions, joining
may need to be temporarily suspended until conditions improve.
b. Most heat fusion equipment is electrically powered, but is not explosion
proof. The fusion equipment manufacturer’s instructions should be ob-
served at all times and especially when heat fusion is to be performed in
an atmosphere that may be volatile, such as coal or grain dust or in are-
as where gas or gas fumes may be present.
c. When installing large diameter PE pipe in a butt fusion machine, do not
bend the pipe against an open fusion machine collet or clamp. The pipe
may suddenly slip out of the open clamp, and cause injury or damage.
4. During Construction and Installation:
a. Tests and inspections performed during construction may include dam-

age Inspections, butt fusion joint quality tests, soil tests, pipe deflection
tests for DI controlled products such as extruded profile wall pipe, or
pressure leak tests.
1) Damage Inspections
a) Damage such as cuts, scrapes, gouges, tears, cracks, punc-

tures, and the like may occur during handling and installa-
tion. Damage may affect joint integrity or sealing, or may
compromise pipeline performance. The following guidelines
may be used to assess surface damage significance.
b) For PE pipelines, damage should not exceed about 10% of
the minimum wall thickness required for the pipeline’s op-
erating pressure or the minimum wall thickness required to
meet structural design requirements. Excessive damage
generally requires removing the damaged section or rein-
forcement with a full encirclement repair clamp. Excessively
deep cuts, abrasions or grooves cannot be repaired by using
hot gas or extrusion welding to fill the damaged area with
PE material because these methods do not provide suffi-
cient bond strength for pressure service or to restore struc-
tural strength.
c) If damage is not excessive, the shape of the damage may be
a consideration. Sharp notches and cuts may be dressed
smooth so the notch is blunted. Blunt scrapes or gouges
should not require attention. Minor surface abrasion from
sliding on the ground or insertion into a casing should not
be of concern.
d) Damage such as punctures and tears will generally require
cutting the pipe to remove the damaged section and re-
placement with undamaged pipe. Small punctures may oc-
casionally be repaired with patching saddles that are saddle
fused or electro fused over the puncture.
2) Butt Fusion Joint Quality
a) Visual inspection is the most common butt fusion joint

evaluation method for all sizes of conventionally extruded
PE pipe. Visual inspection criteria for butt fusion joints
should be obtained from the pipe manufacturer. Hydraulic
butt fusion equipment is typically fitted for connection to
data logging devices that can record equipment tempera-
ture, time and pressure conditions during joining. The rec-
ord may be used to document equipment conditions when
making field fusions, and to supplement field joining quality
assurance using visual inspection and procedural oversight.
Data logger records may be used to compare equipment
operation during field fusion joining to data logger equip-
ment operation records of properly made fusions where
joint integrity has been verified.
b) To confirm joint integrity, operator procedure, and fusion
machine set-up, fusion joints may be destructively tested.
Destructive laboratory tests of tensile specimens prepared
from butt fusion joined pipes may be performed per ASTM
D 638 (standard tensile) or ASTM F 2634 (tensile impact).
Tensile tests are usually compared to specimens without
joints prepared from the parent pipe. Bent strap tests are
usually limited to smaller pipe sizes. Bent strap test speci-
mens from pipe with heavier walls require considerable
bending force and attention to safety.
c) Specially designed hydraulic press equipment may be used
in the shop to conduct bend tests of heavy wall products.
Bent strap tests in the shop or in the field require safety
measures against inadvertent release, joint failure or spring
back during bending.
3) Deflection Tests for ID controlled Pipes

d) Deflection tests are typically based on an allowable percent
vertical deflection of the pipe inside diameter. Deflection
tests are generally limited to ID controlled PE piping such as
extruded profile wall pipe.
e) Conventionally extruded solid wall pipe is OD controlled so
it is difficult if not impossible to determine a base ID for ver-
tical deflection tests. Solid wall pipe extrusion also produces
in a slight toe-in at the pipe ends. While internal fusion
beads have negligible effects on fluid flows, the ID at butt
fusions is reduced at butt fusions. For these reasons deflec-
tion testing is limited to ID controlled pipes and is not rec-
ommended for OD controlled conventionally extruded solid
wall PE piping. For ID controlled extruded profile pipes, pipe
deflection may be used to monitor the installation quality.
f) Improperly embedded pipe can develop significant deflec-
tion in a short time, thus alerting the installer and the in-
spector to investigate the problem.
g) Inspection should be performed as the job progresses, so
errors in the installation procedure can be identified and
corrected.
h) Initial deflection checks of ID controlled extruded profile
pipe may be performed after embedment materials have
been placed and compacted. The inside diameter of the
pipe is measured after backfill materials have been placed
to the pipe crown, and compacted. Then final backfill mate-
rials are placed and compacted, and the pipe inside diame-
ter is measured again at the exact location where the prior
measurement was taken.
i) Another method to measure deflection is to pull a pre-sized
mandrel (sewer ball) through the pipe. The mandrel should
be sized so that if the pipe exceeds allowable deflection, the
mandrel is blocked.
j) To properly size the mandrel, the allowable vertical diame-
ter of the pipe must be established. It is necessary to ac-
count for pipe ID manufacturing tolerances and any ovality
that may occur during shipping. Pipe base ID dimensions
and tolerances should be obtained from the manufacturer.
L Installation of Service Connections
1. The CONTRACTOR shall make the under pressure tapping for the connection to
the main water pipeline, install the polyethylene service connection pipe in-
cluding all auxiliary fittings from the tapping point up to the consumer water
entry point.
2. Saddle straps shall be installed on to the main water pipeline. The tapping to
the pipeline shall be done though the saddle strap using tapping machine ap-
proved by the ENGINEER.
3. Install Gate valves for service connection to allow for the isolation of the con-
sumer connection. The valve shall directly installed to the BSP Saddle thread-
ed, the polyethylene pipe shall connected to the socket end of the pipe and
shall be laid from the socket end up to the consumer entry point.
4. The polyethylene pipe shall be laid from the ferrule up to the consumer entry
point.
5. Connectors, bends, adapters shall be provided as necessary. The polyethylene
pipe shall be installed in uPVC protection pipe class 10 for protection and ease
of maintenance. The uPVC pipe shall be 110 mm diameter for ½ " and ¾ " pol-
yethylene pipes and 160 mm diameter for 1", 1 ½ " and 2" polyethylene pipes.
The uPVC protection pipe shall be provided at all green and unpaved areas. In
sidewalk and paved area the uPVC protection pipe shall be encased in rein-
forced concrete. Warning tape shall be provided over the polyethylene pipe /
uPVC protection pipe in green and unpaved areas.
6. For future consumers the polyethylene service connection pipe shall be termi-
nated and plugged within the consumer limits.
M Connections to Existing Mains and Service Pipes
1. The Engineer will issue to the Contractor detailed instructions regarding each
interconnection that has to be made to the existing mains and service pipes.
Cutting into an existing main or service pipe and effecting the interconnection
shall only be made in the presence of a representative from the Employer's
Maintenance Section at the time specified by the Employer.
2. Cutting into the existing main or service pipe and installation of the intercon-
necting pipe work shall be carried out efficiently and rapidly so as to reduce to
a minimum the interruption of the public water supply. It may be necessary to
undertake such work at night, when water demands are reduced and/or to
schedule such work to be performed during the winter.
3. Existing mains and service pipes shall only be cut using special equipment ap-
proved by the Engineer. The cut shall be perpendicular to the centerline of the
pipe and special care shall be taken with respect to the location of the cut to
ensure that the new pipe work shown on the Drawings may be installed. The
Contractor shall agree with the Engineer the length of existing pipe work to be
removed.
4. The Contractor shall take every care to avoid any dirt or extraneous material
entering the existing main or service pipe.
5. The Contractor shall have available at the site of the connection an efficient
dewatering pump before commencing any cut into the existing main or service
pipe in order that the excavation remains dry at all times and to reduce the risk
of dirty or contaminated water entering the existing distribution system. The
work shall be carried out in a clean and efficient manner. The Contractor shall
provide at the site of the connection sufficient quantities of clean water con-
taining 10 ppm chlorine in solution. Every item of new pipe work to be in-
stalled shall be submerged in the chlorine solution for at least 15 minutes im-
mediately before being installed in the permanent works.
6. The Employer may put the interconnection into use as soon as possible after
its installation and will carry out an inspection to detect any evidence of leak-
age; any remedial work necessary to eliminate leakage shall be carried out by
the Contractor. No pipe work shall be covered or backfilled until the Engineer
is totally satisfied that the interconnection is free of all leakage.
N Cleaning, Testing and Disinfection
1. Cleaning
a. Swabbing and Sterilization
1) Before final commissioning of the pipeline, the Contractor shall swab

and scour the pipeline to ensure that it is free from obstructions, de-
bris and sediment.
2) Pressure piping systems may be cleaned with the water-jet process, or
may be pigged. Pigging involves forcing a resilient plastic plug (soft pig)
through the pipeline. Soft pigs must be used with PE pipe. Scraping fin-
ger type or bucket type pigs may severely damage a PE pipe and must
not be used.
3) Usually, hydrostatic or pneumatic pressure is applied behind the pig to
move it down the pipeline. Pigging should employ a pig launcher and a
pig catcher.
4) All materials, equipment and water required for hydraulic swabbing,
sterilization shall be responsibility of the Contractor.
b. Swabbing
1) One of the following methods shall be used to swab the pipeline. En-
gineer shall instruct the Contractor as to which method is to be uti-
lized.
a) Hydraulic Swabbing
b) A foam plastic cylinder swab, inserted into the pipeline and driven
by hydraulic pressure through the pipeline. The dimensions of the
swab shall be as follows:
i. Pipe diameter less than 300mm

Swab diameter = 1.25 x pipe diameter
Swab length = 2 x pipe diameter
ii. Pipe diameter greater than 300mm
Swab diameter = pipe diameter + 75mm
Swab length = 1.5 x pipe diameter
c) The pipe shall be swabbed in one length or in series of sections as

directed by the engineer
d) Should the swab jam at any point, it will be the Contractor’s re-
sponsibility to either dislodge the swab or to locate it and remove
a section of pipeline adjacent to the swab to facilitate removal of
both the swab and the blockage.
e) Swabbing will be continued until such time as all obstruction are
removed and the swab freely through the main.
f) Dry Swabbing
2) A form plastic cylinder swab which meets the approval of Engineer

shall be inserted into the pipeline at the beginning of pipe laying and
pulled through each pipe as it is laid by means of a rope, thus providing
an effective dry swab. To avoid contamination and infestation, an ex-
pandable plug shall be fitted at the end of the pipe at each break in the
working day and when pipe laying is suspended. The swab shall be re-
placed at regular intervals to ensure a tight all round fit
c. Scouring

1) After the pipeline has been successfully swabbed, the pipeline is to be
flushed with clean water. The scouring shall be continued until the wa-
ter runs clear and the Contractor shall ensure that no erosion or silting
occurs in the water courses or drains into which the water is dis-
charged
2. Testing
a. General
1) The installation to be tested shall be inspected for compliance with

drawings and specifications. Significant variations shall be investigated
and corrected, if required by the Engineer, before proceeding with the
test.
2) To avoid the risk of contamination, water used for testing shall be po-
table water from the public water supply system unless otherwise in-
dicated.
3) Pipes shall adequately anchor by means of thrust blocks and/or side fill
prior to hydraulic testing.
4) Manometers shall be calibrated according to the level at which they
are used.
5) All defects revealed by the test shall be rectified and a new test shall
be carried out until a satisfactory result is obtained.
6) Hydraulic testing shall comply with Standard(s) and regulations as indi-
cated.
7) Hydraulic Testing according to BS 6700
8) The pipes shall be slowly and carefully filled with water so that all air is
expelled, and then, tested under pressure in accordance with clauses
given for rigid or elastomeric pipes depending on the material from
which the pipeline is constructed.
9) The system shall be subjected to twice the maximum working pressure
of the pipeline.
b. Test Procedure for Rigid Pipes
1) After being vented, the pipework shall be slowly filled with water and
subjected to the required test pressure.
2) Where there are significant differences between the ambient temper-
ature and the water temperature, there shall be an initial period of 30
min before the commencement of the test period, to permit tempera-
ture equilibrium after the test pressure has been applied.
3) There shall be no visible leakage of water and the test pressure shall
be maintained for a test period of one (1) hour.
c. Test Procedure for Elastomeric Pipes
1) After being vented, the pipework shall be slowly filled with water and
shall be subjected to the required procedures of test procedure A or
test procedure B. The selection of test procedure shall be agreed by
the Engineer.
a) Test Procedure A

i. Apply the required test pressure by pumping, in accordance
with, for a period of 30 min. Inspect the pipework to identi-
fy any visible leaks in the system.
ii. Reduce the pressure in the pipework by draining water
from the system to 0,5 times the maximum working pres-
sure.
iii. Close the drain valve. If the pressure remains at, or greater
than, 0,5 times the maximum working pressure, the system
is regarded as leak tight.
iv. Visually check for leakage and monitor for 90 min. The test
criteria are met if there is no reduction in pressure.
b) Test Procedure B
i. Apply the required test pressure by pumping, in accordance

with Figure 6 / Annex 6, for a period of 30 min and note the
pressure in the pipeline at the end of the period. Inspect
the pipework to identify any visible leaks in the system.
Continue the test without further pumping.
ii. Note the pressure after a further 30 min. If the pressure
drop is less than 60 kPa (0,6 bar), the system can be consid-
ered to have no obvious leakage.
iii. Visually check for leakage and monitor for 120 min. The test
criteria are met if the pressure drop in the system is less
than 20 kPa (0,2 bar)
d. Hydraulic Testing according to AWWA Regulations
1) PVC Pipes
a) Hydraulic Testing shall comply with AWWA C 605.
2) PE Pipes
b) Hydraulic testing shall comply with AWWA C 901.
3) Ductile Cast-Iron Pipes
c) Hydraulic testing shall comply with AWWA C 600.
e. Recording Results of Field Quality Control
1) For every test and visual inspection, record the following information
and provide copies to the Engineer as required:
a) The location of pipeline or other item inspected or tested and the

date of the inspection or test.
b) The results
c) The personnel involved
f. Subsequent Failure
1) Infiltration of groundwater in an amount greater than 18.5 liters per

day per millimeter of pipe diameter per kilometer of pipeline, follow-
ing a successful test as specified, shall be considered as evidence that
the original test was in error or that subsequent failure of the pipeline
has occurred. The Contractor shall correct such failures in a manner
approved by the Engineer at no additional cost to the Employer.
g. Final Inspection
1) Facilitate the final inspection of the pipe system and ensure access to
the work by the Engineer. Notify the Engineer when any portion of the
work is ready for final inspection and witness the inspection.
2) The Engineer reserves the right to employ any means to accomplish
the final inspection including the use of television inspection equip-
ment.
3) The Contractor shall provide necessary lamps, ropes, bulkheads, plugs,
temporary pumping, ventilation equipment, ladders and other equip-
ment to allow the Engineer to properly and safely inspect the work.
3. Disinfection
a. General
1) The water distribution system shall be thoroughly flushed prior to

commencement of the disinfection procedure.
2) The water distribution system, or parts of the system or a section of a
pipe shall not be used during the disinfection procedure and all outlets
shall be marked with adequate warning in Arabic and English.
3) Chemicals used for disinfection of drinking water installations shall be
those which are listed, approved and certified.
4) Disinfection chemicals shall be used only
5) In combination with appropriate professional equipment to provide a
controlled concentration to the water to be disinfected.
6) Under the direct supervision of a person who is familiar with the phys-
iological, chemical, and physical properties of applied chemicals, and
who is trained and equipped to handle any emergency that may arise.
7) When appropriate safety precautions are prepared and observed to
protect working personnel and the public.
8) After disinfection the system, or parts of the system or a section of a
pipe, the piping network shall be immediately flushed so often until
measurements show that the concentration of chemicals in the water
is not higher than that generally prevailing and accepted in the public
water supply.
9) Any new water pipes shall be kept isolated from existing water distri-
bution pipes until satisfactory bacteriological samples have been taken
and tests are completed.
10) The bacteriological test results shall certify that the water sampled and
tested is free from coliform bacteria contamination, and to be equal or
better than the water quality required by the local water authority.
11) The disinfection procedure shall follow the method(s) and Standard(s)
indicated.
b. Disinfection according to AWWA C 651
1) Possible forms of chlorine used for disinfection shall be liquid chlorine,

sodium hypochlorite solution and calcium hypochlorite granules.
2) Chlorination shall be carried out by one of the following methods:
a) Tablet Method:
i. Place calcium hypochlorite granules or tablets at the up-

stream end of a section of pipe, at the upstream end of
each branch, and at 150 m intervals as pipes are being in-
stalled.
ii. The quantity of chlorine granules to be used shall be as giv-
en in below Table
iii. Calcium Hypochlorite Granules Placed at the Beginning and
End of Pipe Section
Pipe Diameter Calcium Hypochlorite

Granules
in. (mm) (g)
4 100 14
6 150 28
8 200 57
12 300 113
16 and larger (400 and larger) 227
iv. When using calcium hypochlorite tablets instead of gran-

ules, a 5-gram tablet shall be placed in each section of pipe
and each appurtenance. The number of tablets to be used
shall be given in below Table.
v. Number of 5-g Hypochlorite Tablets Required for Dose of
25mg/Liter
Pipe Diameter mm Length of Pipe Section, m

4.0 or les 5.5 6.1 9.1 12.2
(Number of 5-g Calcium Hypochlorite Tablets *)
100 1 1 1 1 1
150 1 1 1 2 2
200 1 2 2 3 4
250 2 3 3 4 5
300 3 4 4 6 7
400 4 6 7 10 13
vi. * Based on 3.25-g available chlorine per tablet; any portion

of tablet rounded to next higher integer.
vii. The tablets shall be attached by food-grade adhesive inside
and at the top of the pipe, with approximately equal num-
bers of tablets at each end of a given pipe length.
viii. If the tablets are attached before the pipe section is placed
in the trench, their position shall be marked so that it can
be readily determined that the pipe is installed with the
tablets at the top.
ix. When installation has been completed, the system, or a
part of the system or a pipe section shall be filled with wa-
ter at a rate such that water within the pipe will flow at a
velocity not greater than 0,3m/s. Precautions shall be taken
that all air pockets are eliminated. The water shall remain in
the pipe for at least 48 hours.
x. Warning: The tablet method shall not be used on solvent
cemented plastic or on screwed steel pipes because of the
danger of fire or explosion from the reaction of the joint
compounds with calcium hypochlorite!
b) Continuous-Feed Method:
i. Place calcium hypochlorite granules in pipe sections during
installation to provide a strong chlorine concentration in
the first flow of flushing.
ii. The flushing velocity shall be not less than 0,76 m/s.
iii. After flushing, the system, or a part of the system or a pipe
section shall be slowly filled with potable water and chlo-
rinated at a constant rate of chlorine such that the water
will have not less than 25 mg/liter free chlorine. Below table
gives the amount of chlorine required for each 30 m of pipe
section of various diameters. Solutions of 1% chlorine may
be prepared with sodium hypochlorite or calcium hypo-
chlorite. The latter solution requires 450 grams of calcium
hypochlorite in 30 liters of water.
iv. Chlorine Required to Produce 25-mg/Liter Concentration in
30 m of pipe
Pipe diameter, mm 100% chlorine 1% chlorine solution

gm Litre
100 5.9 0.6
150 13.6 1.4
200 24.5 2.5
250 38.6 3.9
300 54.4 5.4
400 98.4 9.8
v.
vi. The equipment for chlorinating shall be a solution feed,
vacuum-operated chlorinator and a booster pump.
vii. After 24 hours, the treated water in all portions of the pipe
section shall have a residual of not less than 10 mg/liter free
chlorine.
viii. During the 24 hour period all valves and appurtenances
shall be operated to ensure disinfection.
ix. For pipe diameter DN 600 and larger, a special procedure
shall be agreed between the Contractor and the Engineer.
c) Slug Method:

i. Place calcium hypochlorite granules in the pipe section dur-
ing installation to provide an adequate chlorine concentra-
tion in the first flow of flushing.
ii. The flushing velocity shall be not less than 0,76 m/s.
iii. After flushing, the system, or a part of the system or a pipe
section shall be slowly filled with potable water and chlo-
rinated at a rate such that the water shall have not less than
100 mg/liter free chlorine. The chlorine shall be applied
continuously and for a sufficient period of time to develop a
solid column, or ‘slug’ of chlorinated water that will expose
all interior surfaces of pipes and appurtenances for at least
3 hours.
iv. The free chlorine residual shall be measured in the slug as it
moves through the pipe section. If at any time the concen-
tration drops below 50 mg/liter, the flow shall be stopped
and the chlorination equipment relocated at the head of
the slug. As flow of water is resumed, additional chlorine
shall be applied to restore a concentration not less than 100
mg/liter.
v. As chlorinated water flows, all valves and appurtenances
shall be operated to ensure disinfection.
d) Disinfection according to BS 6700
i. The pipe section shall be filled with chlorinated water at an

initial concentration of 50 mg/liter for a period of 1 hour.
ii. If the free residual chlorine measured at the end of this pe-
riod is less than 30 mg/liter, the disinfection process shall
be repeated.
iii. When approved disinfectants other than chlorine are being
used, the pipe section shall be filled with the approved dis-
infectant solution at the initial concentration and for the
period of time as specified by the manufacturer.
iv. If the residual of the approved disinfectant at the end of
this period is less than the manufacturer’s recommenda-
tion, the disinfection procedure shall be repeated.
O BACKFILLING

2. Backfilling shall normally be carried out using selected excavated materials
similar to the in situ materials in which the trench or structure is being con-
structed. Where the Engineer's Representative designates the excavated mate-
rial as unsuitable, suitable material shall be imported, at no extra cost.
3. Material for backfilling may be selected from any part of the site and methods
of selection may include sieving to remove large particles or methods of hand
or machine sorting.
4. Where the excavation is near an existing structure liable to subsidence, where
part of the works may later be constructed over or near it or in emergencies
the Contractor may be instructed to backfill with concrete.
5. Backfilling shall be carried our as defined below:

a. Cohesive Soils
1) Cohesive soils shall be placed in layers not greater than 150mm thick
(compacted thickness) and compacted such that throughout each layer
placed the dry density is not less than 95% of the in situ dry density of
the soil prior to excavation when tested in accordance with relevant BS
specification.
2) The placement moisture of the soil shall be within the range 2% below
to 1% above the natural in situ moisture content of the soil before ex-
cavation. It is to be noted that the cohesive soils or hard materials
from excavations shall be broken down to suitable sizes to be used for,
backfilling, of the top two layers for stability or as per Engineer’s in-
structions at no extra cost.
b. Granular Soils
1) Granular soils shall be placed in layers not greater than 150mm thick
(compacted thickness) and compacted such that throughout each layer
placed the dry density is not less than 95% of that obtained in the vi-
brating hammer compaction test when the test is carried out on the
same soil at the same moisture content in accordance with relevant BS
specification.
2) Unless otherwise directed the moisture content shall be maintained
and if necessary adjusted by approved means to fall within the range
plus 1.5% to minus 3% of optimum moisture content determined in
the vibrating hammer compaction test.
3) For free draining granular soils that have no clearly defined optimum
moisture content, compaction shall be carried out to achieve a relative
density of not less than 95%. During compaction the soil shall be made
as wet as practicable.
c. Testing of Backfill
1) The Contractor shall provide at his own cost the services of approved
and backfilled soil properties and shall maintain with a copy to the En-
gineer, a daily log of tests carried out.
2) All back fills shall be carried out in layers of 150 mm thick. In-situ soil
compaction tests shall be carried out for pipe line trenches at the rate
of one test per 100mtrs of trench length for each layer of 150mm
thick, starting from 450 mm above the crown of the pipe. Deep test
shall not be carried out as the test location may not be representative.
Also, the Contractor shall continue backfilling the next upper layer only
if the test result for the previous layer is available and found to have
passed as per the requirements. In addition to the pipeline trench
backfilling and testing the chambers pits and pits forming at the sides
of the Thrust blocks shall backfilled in accordance with the relevant
specifications and tested for compaction for every 150 mm thick layers
of backfills. The initial layer to be tested shall be the excavated for-
mation level for the Thrust Block or chamber pits, which shall be tested
prior to placing the structure. The remaining in-situ soil compaction
tests to be carried out as the backfilling progresses layer by layer.
3) Where a land drain passes through an excavation the backfill shall first
be taken up to form a bed for replacement pipes. The severed drains
shall then be exposed at each side of the trench excavation. This new
drain shall be of similar pipes of the same diameter as those in the ex-
isting drain. Before any further backfilling is done the Contractor shall
notify the owner or occupier to enable him to see the reinstated land
drain. The replacement drain shall be surrounded with pipe bedding
material to a minimum thickness of 150mm before further backfilling.
P Valves
1. Inspection and Testing at Manufacturer's Premises
a. ENGINEER and/or third party Inspection Authority reserve the right for
stage inspection of material, manufacturing process, testing, etc. by
their authorized representatives. Such inspection shall not relieve the
CONTRACTOR of the responsibility for suitable design and workmanship.
b. Each individual component of the valve (body, disk, shaft etc.) shall be
subjected to heat treatments and tests (including NDT) as required by
the specific applicable material specification.
c. The material certificate indicating above details shall be inspected and
certified by ENGINEER's inspectors prior to starting shop tests of the
valve.
d. The Manufacturer/CONTRACTOR shall provide full assistance and co-
operation for any such inspection, when required by ENGINEER.
e. ENGINEER and/or Third Party Inspection Authority shall be informed of
all defects arising during manufacture and fabrication of the valves and
only the above shall authorize repair or rejection of faulty material or
workmanship.
f. The programme for the tests shall be prepared by the CONTRACTOR and
shall be subject to ENGINEER approval.
g. The below mentioned certificate requirements shall apply to the quality
Control Plan.
1) Certificate of compliance for Valve body, disk/wedge, shaft shall

be issued for the following criteria in accordance to EN 10204 -
Type 2. For mass produced valves and for Butterfly, Control
Valves and other valves which are not mass produced.
a) Heat treatment after coating (if required)

b) Chemical analysis
c) Physical properties
2) Certification of compliance for the following tests shall be issued

by the manufacturer according to EN 10204 – Type 3.1
a) Functional tests
b) Strength test for the body
c) Leak test for the disk /seat
d) Rubber lining checks after vulcanization
e) Coating thickness checks (internally & externally)
f) Dimensional checks
3) The above certificates shall be reviewed and certified by the re-

spective inspection authority. The Rubber lining checks after vul-
canisation shall include the following:
a) Visual inspection
b) Adhesion test
c) Dielectric test
d) Shore D hardness test
e) Thickness test by electronic device
4) Non Toxicity Certificate for material in contact with potable water
a) The CONTRACTOR/MANUFACTURER shall make suitable

provisions for testing and inform ENGINEER sufficiently (at
least one month) in advance to enable their representatives
to witness the test. If witnessing of any tests is not satisfac-
tory and a retest is required, the cost of the witnessed re-
tests shall be borne by the CONTRACTOR.
h. MANUFACTURER shall ensure that all the applicable codes and stand-
ards are available at their works for ENGINEER's reference during their
visit to manufacturer's works for shop inspection/tests.
i. Testing shall be carried out in accordance with applicable codes and
standards for the particular valves. Besides mechanical operation tests,
each valve shall be subjected to hydrostatic body pressure/leakage test
of 1.5 times the design pressure and a disc strength/ leakage test of 1.1
(hydrostatic) times the design pressure before leaving the manufactur-
er's works. Tests shall be witnessed by ENGINEER as specified and each
valve shall be accompanied by manufacturer's test certificates.
j. 5% of each size and type of valves supplied (butterfly, gate, non-return
and air valves) or a minimum of 1 No. of each size and type whichever is
greater shall be made available to ENGINEER witness testing. If the test
on any valve fails, the percentage of valves to be tested will be raised to
10%. Flow control valves, pressure sustaining valves, pressure reducing
valves & altitude valves shall be 100% witness tested by ENGINEER.
k. If any defect is detected during the tests before completion or during
the warranty period, the faulty equipment shall then be rectified imme-
diately by the VENDOR/CONTRACTOR at his expense. If the fault cannot
be rectified, the VENDOR/CONTRACTOR must then replace the defective
equipment which must also be proven to be free from defect.
2. Installation, General
a. Locate valves for easy access and provide separate support where nec-
essary.
b. Install valves in horizontal piping with stem at or above the center of the
pipe.
c. Install valves in a position to allow full stem movement.
d. Support piping systems and align components to minimize bending at
the valve connections
e. Place the valve on firm footing in the trench to prevent settling.
f. Install the valve in alignment with the pipe to prohibit excessive strain
on the connection to the pipe. Preventing any strain on the connection
is critical in flanged installations. Flange fracture can result from unequal
strains set up by improper makeup and tightening of the joints.
1) Support and align valves.
2) Clean dirt and grit particles from all parts.
3) Insert bolts and nuts and tighten by hand.
4) Tighten bolts and nuts by using the crossover method. Tighten the
bolts and nuts across the connection from each other in order un-
til the joint is uniformly tight (do not tighten the bolts and nuts in
rotation). This crossover method will load both pipe and valve
evenly and eliminate any concentrated stresses.
g. Install valves in the closed position to prevent any foreign material from
entering the valve.
h. Install swing check valves for proper direction of flow with hinge pin lev-
el.
i. Locate flow meter as recommended by manufacturer with respect to
other piping components to ensure flow meter will meet specified accu-
racy.
j. Flanged Connections: Align flange surfaces parallel. Assemble joints by
sequencing bolt tightening to make initial contact of flanges and gaskets
as flat and parallel as possible. Use suitable lubricants on bolt threads.
Tighten bolts gradually and uniformly using a torque wrench.
k. All exposed bolts nuts shall be heavily coated with 2 coats of bituminous
paint.
l. All valves shall be equipped with dismantling joint to enable removal and
installation of flanged valves as shown on Drawings. Install buried gate
valve complete with valve box and install valves inside valve chambers
complete with hand wheels/or spindle with valve box
m. Wrap buried valves, flanged joints, mechanical joints, flanged pipe
spools with thrust collars, and adapters with polyethylene material,
complete the wrap prior to placing concrete anchor blocks. Repair poly-
ethylene material damaged during construction.
n. Provide a valve box or vault for each valve used in a buried-service appli-
cation. The valve box should be installed so as not to transmit shock
loads or stress to the valve or valve actuator. When valves with exposed
gearing or operating mechanisms are installed belowground, a vault
must be provided to allow pipe clearance and prevent settling on the
pipe.
o. If groundwater or surface water enters the vault, the vault floor should
include a recessed drainage area and a pump to remove water from the
vault.
p. Center the valve box over the operating nut of the valve. The box cover
should be flush with the surface of the finished area. The operating nut
should be accessible from the top opening of the vault with a valve key.
Valve box should be installed in a manner that will not exert force creat-
ed from street traffic to the valve.
q. If installing a larger valve that uses smaller bypass valves, install a second
valve box over the bypass valve operating nut.
r. If the valves must be buried in an unusually deep trench, install a riser
on the stem to permit a normal key to be used, or make a notation in
the valve records that a long key will be required for operation.

INSTALLATION, RESILIENT SEATED GATE VALVE
Underground Installation
1. Valves in water-distribution lines shall, where practical, be located in easily ac-
cessible areas.
2. During installation, there is the possibility of foreign materials inadvertently en-
tering the valve. Foreign material can damage internal working parts during op-
eration of the gate valve. For this reason, gate valves should be installed in the
closed position. Each valve should be placed on firm footing in the ‘trench to
prevent settling and excessive strain on the connection to the pipe. Piping sys-
tems should be supported and aligned to avoid damage to the valve.
3. A valve box or vault should be provided for each valve used in a buried service
application. The valve box should be installed so as not to transmit shock loads
or stress to the valve. The valve box should be centered over the operating nut
of the valve with the box cover flush with the surface of the finished area or
such other level as directed by the engineer. Valve boxes should be designed so
that a traffic load on the top of the box is not transmitted to the valve.
4. Valves buried in unusually deep trenches should have special provisions for op-
erating the valve. Either a riser on the stem to permit use of a normal key or a
notation on valve records that a long key will be required.
5. When valves with exposed gearing or operating mechanisms are installed be-
lowground, a vault designed to allow pipe clearance and prevent settling on the
pipe should be provided. The operating nut should be accessible from the top
opening of the chamber with a valve key. The size of the chamber should pro-
vide for easy removal of the valve bonnet and internal parts of the valve for pur-
poses of repair. Consideration should be given to the possible entry of ground-
water or surface and to the need to provide for the disposal thereof.
Installation, Dismantling Joints
General
1. Dismantling joints shall be installed at selected locations inside the valve

chambers along the pipeline as shown on the detailed drawing to facilitate
future removal of valves and other equipment for servicing/replacement.
2. The Dismantling joints are normally supplied with tie rods as an assembled
unit ready for use, dismantling of all parts is unnecessary.
3. Examine fitting before assembling to ensure that no damage has occurred
during transit.
4. Check that the flange connection indicated on the label of the fitting is com-
patible with both the connecting flange/pipe of the valve.
5. Check that the actual working pressure of the pipeline does not exceed the
PN rating of the dismantling joint.
6. Check that the gap between the connecting flanges is compatible with that
of the dismantling joint.
7. Check that both flange connections to which the dismantling joint is to be
connected to are level and in line with each other.
Assembly
1. Remove nut/washers from the extreme ends of the fittings and loosen nuts
behind flange.
2. Collapse dismantling joint and push tie rods through until flush with flange
that is to be mated with.
3. Assemble dismantling joint, together with gaskets/tie rods between flanges
of pipeline and valve.
4. Tighten up first flange joint to recommended torque.
5. Expand dismantling joint to required length and centralize tie rods, tighten
the tie rods to recommended torque.
6. Tighten the gland ring nuts to the recommended torque, it is essential that
the nuts are tightened in the correct sequence to ensure that the compres-
sion of the sealing element is consistent around its circumference.
7. Typical tightening sequence for the seal housing center flange.
a. Firstly, tighten all the gland seal nuts to the initial torque
b. On the second pass tighten the nuts to the mid-range torque.
c. Tighten for the final torque on the third pass.
SITE TESTS
General
After installation and before pressurization, inspect all pressure-containing bolting (bon-
net, seal-plate, bypass, and end connections) for adequate tightness to prevent leakage.
After installation and before commissioning, the CONTRACTOR shall carry out site tests,
to be witnessed by ENGINEER representatives as well as valves manufacturer's repre-
sentative.
Inspect all tapped and plugged openings of the valve interior for adequate tightness.
Proper inspection at this time will minimize the possibility of leaks once the piping sys-
tem is pressurized.
The test pressure should not exceed the rated valve pressure when resilient-seated gate
valves or butterfly valves are used to isolate a test section.
Examine valve interior through the end ports, for cleanliness, freedom from foreign mat-
ter and corrosion. Remove special packing materials such as blocks used to prevent disc
movement during shipping and handling. Actuate valve through an open-close and
close-open cycle. Examine functionally significant features such as guides and seats
made accessible by such actuation. Following examination, return the valve closure
member to the shipping position.
Examine mating flange faces for conditions which might cause leakage. Check bolting
for proper size, length and material. Check gasket material for proper size, material
composition suitable for service and freedom from defects and damage.
When metal-seated gate valves are being used as closure pieces for a test, the test pres-
sure should not exceed twice the rated valve pressure. Metal seated valves have an al-
lowable leakage, and this should be determined before the test. For tests at pressures
greater than the rated valve pressure, the test setup should include a reduction of the
line pressure to the rated valve pressure (independent of the valve) on completion of
the test. The valve can then be opened enough to release trapped pressure and equalize
it with the line pressure. The valve should not be opened or closed at differential pres-
sures above its rated working pressure.
Any problems/defects detected during these tests shall be promptly remedied / rectified
by the CONTRACTOR/Manufacturer at no additional cost to ENGINEER.
Replace defective valves with new valves.
When installation is complete, installers should make complete records of the installa-
tion on a permanent record that will serve as a reference during maintenance and re-
pair.
Test certificates shall be issued immediately after site testing and copies of the same
should be incorporated in the O&M manuals.
Q Irrigation:
1. General
a. This work shall consist of furnishing and installing complete irrigation

systems to provide water for the trees, ground cover and lawn areas as
shown on the drawings in accordance with the specifications and as di-
rected by the Engineer.
b. The system shall be a combination of drip irrigation utilizing bubblers
and sprinkler system utilizing pop-ups and shall include buried main and
sub-main and either buried lateral piping for sprinklers. The system shall
have control valves, air valves, pressure gauges, and computerized con-
trol system.
c. The system as shown on the drawings is diagrammatic only. The final
layout of system is to be established in the field by the Contractor and is
subject to review and approval by the Engineer. The various components
of the system shall be installed so as to provide complete and adequate
coverage of the areas to be watered.
d. The contractor shall stake out the location of each run of pipe and all
valve and equipment locations prior to ditching. Before installation is
started in any given area, the engineer will check all locations and give
his approval.
e. All pipe fittings, valves, and concrete access boxes shall be carefully
placed in the trenches with concrete thrust blocks poured at all changes
in pipe alignment and at all fittings and valves, and where required by
the engineer. The interior of pipes shall be kept free from dirt and debris
and when pipe laying is not progress, open ends of pipe shall be closed
by approved means.
f. The sub-main and lateral lines shall be installed to the depth as shown
on the drawings and/or as directed by the engineer. Excavation, trench-
ing and backfill shall be carried out in accordance with the relevant sec-
tion of these Specifications and as directed by the engineer.
2. Pipes

a. Main and Sub-main pipes shall be laid in such a manner that there will
be a minimum loss of load upgrade, otherwise the natural slope of the
terrain should be followed in longest possible straight line. Provisions
shall be made for expansion and contraction as recommended by the
manufacturer.
b. Plastic pipe shall be cut with a hand saw or hack saw with the assistance
of a square in sawing vice, or in a manner so as to ensure a square cut.
Burrs at cut ends shall be removed prior to installation so that a smooth
unobstructed flow will be obtained.
c. All plastic-to-plastic joints shall be solvent-weld joints. Only the solvent
recommended by the pipe manufacturer shall be used. All plastic pipe
and fittings shall be installed as outlined and instructed by the pipe
manufacturer and it shall be the Contractor's responsibility to make ar-
rangements with the pipe manufacturer for any field assistance that may
be necessary. The Contractor shall assume full responsibility for the cor-
rect installation.
d. All plastic-to-metal joints shall be made with plastic male adopters.
e. The solvent weld joints shall be made in the following manner:
f. The mating pipe and fitting shall be thoroughly cleaned with a clean dry
cloth.
1) A uniform coat of solvent shall be applied to the outside of the

pipe with a non-synthetic bristle brush.
2) Solvent shall be applied to the fitting in a similar manner.
3) A light coat of solvent shall be applied to the pipe quickly inserted
into the fitting.
4) The pipe or fitting shall be given a quarter turn to ensure even dis-
tribution of the solvent.
5) The pipe shall be inserted to the full depth of the fitting socket.
6) The joint shall be held in place for 15 seconds.
7) Excess of solvent that appears at the outlet shoulder of the fitting
shall be wiped off.
g. Care shall be taken so as not use an excessive amount of solvent, there-

by causing a burr or obstruction to form on the inside of the pipe.
h. The joints shall be allowed to set at least 24 hours before pressure is ap-
plied to the system.
i. All piping under roadways shall be concrete encased. The concrete en-
casement shall conform to Division 3 of these Specifications. Locations
and sizes of encasements are as shown on the drawings and as directed
by the engineer. Pipe and encasement, shall be placed prior or during
construction of the roadway. Any piping installed after completion of the
roadway construction shall only be placed by first jacking a pipe sleeve
under the roadway. Under no circumstances will the contractor be al-
lowed to cut the roadway section for pipe installation.
3. Cleaning
a. Flush dirt and debris from piping before installing sprinklers and other
devices.
4. System Components

a. Installation of miscellaneous components such as base mounting, fittings
and valves of the system shall be in accordance with manufacture's in-
structions and as directed by the engineer.
b. All remote control solenoid valves, air valves, pressure access boxes of
proper size for easy access. Access boxes shall be complete with lockable
covers. All access boxes shall be installed on suitable base of gravel for
proper foundation of box and easy leveling of box to proper grade and
also to provide proper drainage of the access box.
c. Automatic-Control System Installation
1) Place and secure anchorage devices. Use setting drawings, tem-

plates, diagrams, instructions, and directions furnished with items
to be embedded.
2) Install anchor bolts to elevations required for proper attachment
to supported equipment.
3) Equipment Mounting: Install exterior freestanding controllers on
precast concrete bases.
4) Place and secure anchorage devices. Use setting drawings, tem-
plates, diagrams, instructions, and directions furnished with items
to be embedded.
5) Install anchor bolts to elevations required for proper attachment
to supported equipment.
6) Install control cable in same trench as irrigation piping and at least
51 mm below or besides piping. Provide conductors of size not
smaller than recommended by controller manufacturer. Install
cable in separate sleeve under paved areas.
d. Connections
1) Drawings indicate general arrangement of piping, fittings, and

specialties.
2) Ground equipment according to Electrical Division "Grounding”.
3) Connect wiring according to Electrical Section “Wires and Cables.”
4) Tighten electrical connectors and terminals according to manufac-
turer's published torque-tightening values. If manufacturer's
torque values are not
5) Indicated, use those specified in UL 486A and UL 486B.
e. Labeling and Identifying
1) Equipment Nameplates and Signs: Install engraved plastic-

laminate equipment nameplates and signs on each automatic con-
troller.
2) Text: In addition to identifying unit, distinguish between multiple
units, inform operator of operational requirements, indicate safe-
ty and emergency precautions, and warn of hazards and improper
operations
5. Testing
a. Before any portion of pipeline is backfilled, and where directed by the

engineer, water shall be turned into that portion of the line and main-
tained at full pressure for a period of not less than eight consecutive
hours after all air has been expelled from the line. Any leaks that devel-
op in portion of the system installed by the contractor shall be repaired
and all defective materials shall be replaced by him and the test repeat-
ed until satisfactory results are obtained
6. Field Quality Control

a. Perform the following field tests and inspections and prepare test re-
ports:
1) E.1 Pressure Test

2) E.2 Leak Test:
3) E.3 Operational Test: After electrical circuitry has been energized,
operate controllers and automatic control valves to confirm prop-
er system operation.
b. Test and adjust controls and safeties. Replace damaged and malfunc-
tioning controls and equipment.
c. Remove and replace units and [retest] as specified above.
7. Start-up Service
a. Verify that controllers are installed and connected according to the Con-
tract Documents.
b. Verify that electrical wiring installation complies with manufacturer's
submittal and installation requirements in electrical Division.
c. Complete start-up checks according to manufacturer's written instruc-
tions.
8. Adjusting
a. Adjust settings of controllers.

b. Adjust automatic control valves to provide flow rate of rated operating
pressure required for each sprinkler circuit.
c. Adjust sprinklers so they will be flush with, or not more than 1/2 inch
(13 mm) above, finish grade
9. Demonstration
a. Engage a factory-authorized service representative to train Owner's

maintenance personnel to adjust, operate, and maintain automatic con-
trol valves and controllers.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
0 March 2022 I.K. 61 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. SEWAGE COLLECTION NETWORKS
CAIRO - EGYPT 333000 – 2874 0

CONTENTS
SECTION 333000
SEWAGE COLLECTION NETWORKS

Page
PART 1 GENERAL 2
1.2 Description Of Work 2
1.3 Reference Standard 2
1.4 Submittal 4
1.7 Delivery Storage And Handling 7
PART 2 PRODUCTS 7
2.1 Warning Tapes 7
2.2 High Density Polyethylene Liner (Hdpe) 9
2.3 Geotextile 10
2.4 Oil-Water-Debris Separator 10
2.5 Reliner Inside Drop System 12
2.6 Pipes, Fittings And Accessories 13
2.7 Draiange Structure 19
PART 3 EXECUTION 29
3.1 Specialists, Inspection And Testing 29
3.2 Soil Corrosivity Study 30
3.3 Earth Work 30
3.4 Pipe Laying 39
3.5 Drainage Structure 50
Sewage Collection Networks Section 333000

SECTION 333000 – SEWAGE COLLECTION NETWORKS
PART 1 GENERAL

1.2 DESCRIPTION OF WORK
A. This section specifies the construction of all types of manholes, Inspection

chamber and catch basin as required by the Contract. Extent of these structures is
indicated on Drawings.
B. The Contractor shall provide equipment, materials, transportation and labor
required for proper construction of the structures
1.3 REFERENCE STANDARD
A. The work shall be performed in strict accordance with the stipulations of

European Standard (British Standard European Norm (BS EN), British Standard
(BS)), American Standard (American Concrete Institute (ACI), American Society for
Testing and Materials (ASTM)), International Organization for Standardization
(ISO) as noted herein below or other equivalent approved Standards and Sound
Practice.
1.3.1 EUROPEAN STANDARD
BS 1452 Grey Iron Casting

BS 3396 Woven glass fabrics for plastics reinforcement.
BS 3416 Black Bitumen Coating Solution for Cold Application
BS 3532 Method of specifying unsaturated polyester resin systems.
BS 4164 Coal Tar Based Hot Applied Coating Materials
BS 5400-2 Steel, concrete and composite bridges. Specification for loads.
BS 5834-2 Surface boxes, guards and underground chambers for gas and
waterworks purposes. Specification for small surface boxes.
BS EN 10088-1 Stainless steels. List of stainless steels.
BS EN 124 Gully tops and manhole tops for vehicular and pedestrian areas.
Design requirements, type testing, marking, quality control.
BS EN 13101 Steps for underground man-entry chambers – Requirements, marking,
testing and evaluation of conformity
BS EN 14020-1 Reinforcements. Specification for textile glass roving's. Designation.
BS EN 14020-2 Reinforcements Specification for textile glass roving's. Methods of test
and general requirements.
BS EN 14020-3 Reinforcements. Specification for textile glass roving's Specific
requirements.
BS EN 14118-1 Reinforcement. Specifications for textile glass mats (chopped strand and
continuous filament mats). Designation.

BS EN 14118-2 Reinforcement. Specifications for textile glass mats (chopped strand
and continuous filament mats). Methods of test and general
requirements.
BS EN 14118-3 Reinforcement. Specifications for textile glass mats (chopped strand
and continuous filament mats). Specific requirements.
BS EN 14364 Plastics piping system for drainage and sewerage with or without
pressure. Glass reinforced-thermosetting plastics (GRP) based on
unsaturated polyester resin (UP). Specifications for pipes and fittings
BS EN 681-1 Elastomeric seals. Material requirements for pipe joint seals used in
water and drainage applications. Vulcanized rubber.
ISO 1083 Spheroidal graphite cast iron - classification.
ISO 9000 Quality management systems.
1.3.2 AMERICAN STANDARD
ACI 301-99 Standard Specifications for Structural Concrete.

ACI 304.2R-96 Placing Concrete by Pumping Methods.
ACI 304R-00 Guide for Measuring, Mixing, Transporting and Placing Concrete.
ACI 305R-99 Hot Weather Concreting.
ACI 306R-88 Cold Weather Concreting.
ACI 308-01 Standard Practice for Curing Concrete.
ACI 315-92 Details and Detailing of Concrete Reinforcement.
ACI 347R-03 Guide to Formwork for Concrete.
ACI 350.1R-01 Tightness Testing of Environmental Engineering Concrete Structures.
ACI 350R-01 Environmental Engineering Concrete Structures.
ACI 381-02 Building Code Requirements for Structural Concrete and Commentary.
ASTM A 36 Structural Steel
ASTM C 39 Compressive Strength of Cylindrical Concrete Specimens
ASTM A48 / A48M Standard Specification for Gray Iron Castings.
ASTM C 76 Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe
ASTM C 94 Standard Specification for Ready-Mixed Concrete
ASTM C 109 Standard Test Method for Compressive Strength of Hydraulic Cement
Mortars
ASTM C 144 Aggregate for Masonry Mortar
ASTM C 150 Specification for Portland Cement
ASTM C 157 Standard Test Method for Length Change of Hardened Hydraulic Cement
Mortar and Concrete
ASTM C172-04 Sampling Freshly Mixed Concrete.
ASTM C 234 Standard Test Method for Comparing Concretes on the Basis of the Bond
Developed with Reinforcing Steel
ASTM C 267 Standard Test Methods for Chemical Resistance of Mortars, Grouts, and
Monolithic Surfacing’s and Polymer Concretes
ASTM C 348 Standard Test Method for Flexural Strength of Hydraulic-Cement
Mortars
ASTM C 387 Packaged, Dry, Combined Materials for Mortar and Concrete
ASTM C 443 Standard Specification for Joints for Concrete Pipe and Manholes, Using
Rubber Gaskets
ASTM C 469 Standard Test Method for Static Modulus of Elasticity and Poisson’s
Ratio of Concrete in Compression

ASTM C 478 Specification for Precast Reinforced Manhole Sections
ASTM C 496 Standard Test Method for Splitting Tensile Strength of Cylindrical
Concrete Specimens
ASTM C 642 Standard Test Method for Density, Absorption, and Voids in Hardened
Concrete
ASTM C 666 Standard Test Method for Resistance of Concrete to Rapid Freezing and
Thawing
ASTM C 858 Underground Precast Concrete Utility Structures
ASTM C 882 Standard Test Method for Bond Strength of Epoxy-Resin Systems Used
With Concrete By Slant Shear
ASTM C 923 Specification for Resilient Connectors Between Reinforced Concrete
Manhole Structures and Pipes
ASTM D 570 Standard test method for water absorption of plastics.
ASTM D 4101 Specification for Molded Polypropylene
ASTM D 2583 Standard test method for indentation hardness of rigid plastics by means
of a barcol impresser.
ASTM E 84 Standard test method for surface burning characteristics of
building materials. .
ASTM F 1759-97 Standard Practice for Design of High Density Polyethylene (HDPE)
Manholes for Subsurface Application
1.4 SUBMITTAL
A. Submit the following in accordance with Conditions of the Contract and Division-1
1. Pipes
a. In order to verify compliance with the specification the Contractor shall submit
information for all products and materials used in the Works to the Engineer for
approval sufficiently in advance of their use in accordance with the Contract
programme allowing for ordering and approval times. Information to be
submitted for each proposed production shall comprise but not necessarily be
limited to:
1) Material technical specifications list and manufacturer’s data of the pipes

include its jointing material (rubber gaskets), fittings, accessories, and
supporting details
2) Material technical specifications list and manufacturer’s data of the covers, step
iron, ladders, bedding, warning tape, material and geo-textiles.
3) Manufacturer’s name.
4) Supplier’s name.
5) Product name, if applicable.
6) Product description.
7) Manufacturer’s technical data.
8) Test results or certificates.
9) Material Certificates of compliance.
10) Certificates of origin.

11) Storage instructions.
12) Installation instructions.
13) Representative samples
14) Pipe diameters and pressure ratings.
15) Support details.
16) Connection details.
17) Manufacturer’s quality control and test procedures.
18) Manufacturer’s hydraulic test reports.
19) Manufacturers guarantee.
20) Joint materials and gaskets.
21) Detailed information on coatings.
b. Should any details of the pipes and fittings be altered in any way during
manufacture from those proposed and approved by the Engineer, submit for the
Engineer's approval the revised details and test results.
2. Drainage Structure
a. Manufacturer's instructions for installation

b. Construction sequence.
c. Detailed structural calculations for different types of drainage chambers
d. For pre-cast drainage structure: shop drawings for each structure showing, at a
minimum, the Project and Contractor's name: manufacturer's name and plant
location; applicable specifications; list of materials (such as adjusting rings,
boots, gaskets, and pre-cast sections) by type and quantity; elevation view
showing diameter or size, ring and cover size and elevation, ring type (bolted or
unbolted, flared top or flared bottom) wall thickness, elevations of transitions
from large diameter sections to smaller diameter sections, base width and
thickness, total depth, size of openings, reinforcement, and length of each pre-
cast section; structure identification number and station location; pipe line
identification; pipe material and size; pipe flow line elevations; plan view
showing azimuthal orientation (based on 360 degrees clockwise) of the pipes
relative to the outflow pipe; technical data sheets covering pipe-to-manhole or
pipe-to-junction box connectors, and gaskets
e. For hydraulic cement concrete; mix components and proportions, material
sources, materials test results
f. For mortar: mix components and proportions, material sources, materials test
results
g. For non-shrink grout: technical data sheet indicating ASTM type and containing
instructions on surface preparation, mixing, placing, and curing procedures
h. For drainage structure coatings and linings: technical data sheets that include
instructions on surface preparation, mixing, placing, and curing procedures
i. Product Data: Provide manhole different components, frame and covers, step
irons, metal components, GRP components, flap valve, …. etc. Catalog cuts,
samples, manufacturer's data and listing of applicable standards, and
dimensions. Furnish certificate of compliance for all items, the submittal shall
include but not limited to the following: -
1) Details of manufacturer's name and place of manufacture,

2) An original certificate bearing the chop of the manufacturer showing that the
materials comply with the requirements of this specification and the related
standard
3) Drawings showing details, layout position, sizes, and support of the different
types of standards,
4) Details of methods of fixing and of rag, indented, expansion and resin bonded
bolts, including manufacturer's literature, and Design details in accordance
5) Samples of materials
6) Test reports.
7) Project Record Documents.
3. Method of Statement
a. The Contractor shall submit method statements to the Engineer for approval 4
weeks in advance of commencing the site activity. These shall comprise but not
necessarily be limited to:
1) Procedures for handling, storage and installation of pipes and manholes

including cleaning and repair.
2) Hydrostatic testing procedures.
3) Deflection measurement procedures
4) A detailed statement for local application of coatings.
5) Excavation and backfilling in accordance
6) Construction of cast in place and/or precast manholes, chambers and structures
7) Protection to concrete structures in accordance
8) General fabrication methods for Glass Reinforced Plastic (GRP) products.
9) Procedures for making connections to existing drainage systems
A. The following sections include requirements, which relate to this section:
Earthwork Section
Cast-in-Place Concrete Section
Unit Masonry Assemblies Section
Metal Fabrications Section
Corrosion Protection and Odor Control Section
1.6 QUALITY CONTROL
A. Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time to allow the Engineer the
opportunity to inspect and test the product and/or material prior to delivery in.
B. Products and materials shall be from a manufacture/supplier who operates a
quality system which is registered to ISO 9000 series or approved equal.
C. To allow the Engineer to inspect the works the Contractor shall give the Engineer
a minimum of 24 hours’ notice of carrying out the following activities on site:

1. Commencement of excavation.
2. Casting of blinding concrete.
3. Pouring of cast in place concrete.
4. Manufacturing of precast concrete units.
5. Manufacturing of GRP units
6. Installation of precast concrete units.
7. Installation of GRP manholes
8. Installation of concrete protective coatings and linings and concrete
waterproofing.
9. Placement of backfill.
10. Installation of fittings, covers, gratings, ladders, step iron, grp products, Steel
products, drop bowl, slot drain, etc.
11. ix. Making connections to existing drainage systems.
1.7 DELIVERY STORAGE AND HANDLING
A. Delivery, storage and handling of products and materials shall be in accordance

with the manufacturer’s recommendations, Section 01000-09 of the
specification and the following provisions.
B. Delivery, storage and handling shall at all times be performed in a manner to
avoid product damage.
1. Only nylon slings shall be allowed for lifting products.

2. Products shall be stored off the ground on timber blocks of sufficient size and
spacing to provide adequate support.
3. Products shall be stored at site in a temperature, humidity etc. environment as
recommended by the manufacturer.
4. Products that are stored outside at site shall be stored under cover to prevent
ultra violet deterioration and as recommended by the manufacturer.
5. The Contractor shall visually inspect all products upon delivery to site and report
any damage to the Engineer.
a. Any products damaged during delivery, storage and handling shall be marked by
the Contractor and set aside.
b. Proposals for repair of any damaged products shall be submitted in writing to
the Engineer for approval.
c. Any damaged products deemed unsuitable for repair by the Engineer shall be
removed from site and replaced.
PART 2 PRODUCTS
2.1 WARNING TAPES
A Service protection tapes shall be installed above all sewage pipelines and
pressure mains constructed or exposed under this contract excluding individual
service connections.

B Tapes shall be durable and detectable by electro-magnetic means using low
output generator equipment. They shall remain legible and color-fast in all soil
conditions at pH values of 2.5 to 11.0 inclusive.
C The tape shall be 150 mm wide and 250 micron thick and produced as a strong
composite laminate consisting of: -
1. 30 Micron polyester film top layer

2. 12 Micron detectable aluminum foil in between
3. 208 Micron bottom layer polyethylene
D The thickness of the tape (250 micron / 1000 gauge) shall be measured in
accordance with BS 2782: Part 6. Method 630 A.
E The following properties shall be demonstrated by appropriate tests :-
1. Physical properties :- (Average of 5 tests)
a. Tensile strength: According to BS EN ISO 527 – 3
1) Longitudinal (MD) : 160 N (Minimum)

2) Transversal (TD) : 150 N (Minimum)
b. Elongation (PE only): BS EN ISO 527 – 3
1) MD : 450%
2) TD : 550%
c. Tear Strength: BS 2782
1) MD: 640 gram force

2) TD: 700 gram force Minimum
d. Dart Impact: BS 2782 : P3 : 352F : 1000 grams minimum
2. Chemical resistance:
a. The tape shall be remaining legible and colour fast in all soil conditions at PH 2.5
– 11.0, inclusive. The tape shall not show any adverse effect when in contact
with the sulphates, chlorides and other minerals present in sub soil and water,
oil, 5% Acetic Acid, 5% NaOH and Alcohol mix, if any.
F Detectability after installation and back filling
1. Text in Arabic and English indicating the protected services lying below the tape
shall be permanent ink bonded to resist prolonged chemical attack by corrosive
acids and alkalis with the message repeated at a maximum interval of two
meters. Tapes shall be color coded as follows, with black text as indicated. The
sign and styles of the text shall be approved by the Engineer
a. Sewage: Yellow

b. CAUTION: Sewage Network Below
2. Municipality logo shall be printed in black between the spaces of repeated

messages.
2.2 HIGH DENSITY POLYETHYLENE LINER (HDPE)
A General
1. The high density polyethylene (HDPE) geo-membrane shall be manufactured

from first quality, high molecular weight and manufactured specifically for the
purpose of liquid containment in hydraulic structures and chemically resistant to
untreated wastewater. The geo-membrane material shall be textured on both
sides.
2. The geo-membrane material shall be so produced as to be free of holes, blisters,
undispersed raw materials, or any sign of contamination by foreign matter. The
geo-membrane shall be free of plasticizers and other leachable additives.
3. The sheets shall have NSF label of approval and shall be manufactured in a
minimum 5 m seamless width. Labels on the roll shall identify the thickness,
length, width and manufacturer's lot number.
4. The geo-membrane shall be suitable for the intended application as shown on
the Drawings. The manufacturer shall inform the Engineer through the
Contractor if the product is not suitable.
B Properties
1. The geo-membrane rolls shall meet the minimum properties as per

manufacturer recommendation and below table, this value
represents the minimum acceptable test value for a roll as tested
according to Manufacturing Quality Control Manual.
2
Property Unit Test Method Minimum
1
Thickness mm avg. ASTM D5199 1.52 (60 mil)
1
Thickness mm min. ASTM D5199 1.37 (54 mil)
Density g/cc min. ASTM D1505 0.940
Tensile Properties-Minimum Average Roll Values 1
ASTM D638
(Each Direction)
MPa 15.2 (2200 psi)
Yield Strength min.
N/cm 231 (132 lb/in)
MPa 10.3 (1500 psi)
Break Strength min.
N/cm 158 (90 lb/in)
Elongation at Yield % min. 13
Elongation at Break % min. 150
N/cm 1313 (750 lb/in)
Tear Resistance Puncture min. ASTM D1004
N 200 (45 lbs)
N/cm 3152 (1800 lb/in)
Resistance min. ASTM D4833
N 480 (108 lbs)
Law Temperature C max. ASTM D746 (-60)
ASTM D1204 +2.0
Dimensional Stability % max.
1 hour @ 1080

Environmental Stress 1
Hours min. ASTM D5297 1500
Crack
Carbon Black Content 2.0 to 3.0
% range ASTM D4218
Carbon Black Dispersion 1
N/A rating ASTM D5596 A1, A2, or B1
C Other Materials
1. Extradite welding rods shall be of the same compound as the geo-membrane

and supplied by the manufacturer and shall be delivered in the original sealed
containers. Each container shall have a label bearing the brand name,
manufacturer's lot number and complete directions as to proper storage.
2. Boots and shrouds for pipe penetration and attachments to structures shall fit
snugly around the pipe and/or structure. Prefabricated material shall be
designed to fit site specific conditions for the intended slope and size of pipe
and structure.
2.3 GEOTEXTILE
A Geo textile for Pipe Bedding (Filter Fabric)
1. Geo textile shall be formed by continuous filament fibers of polypropylene and

then bonded to form a high strength, non-raveling, and non-woven sheet.
2. The equivalent opening size for the non-woven fabric used shall be 70 to 100
Std. Sieve (ESD) in accordance with ASTM D422 and. The water flow rate shall
be a minimum of 194 I/sec/m2 as determined by ASTM D737 and the coefficient
of permeability shall be a minimum of 0.30 cm/sec.
3. The grab tensile strength shall be a minimum of 90 kg (200 lbs) and the grab
tensile elongation shall be a minimum of 60 percent as measured by ASTM
D1682.
4. The burst strength as measured by the Diaphragm Method of ASTM D3786 shall
be a minimum of 25 kg/cm2 (360 psi). The minimum trapezoid tear strength
shall be 34 kg (75 lbs) in accordance with ASTM D1117.
5. The puncture resistance of the geo textile measured with 8 mm hemispherical
tip in accordance with Method ASTM D3787 shall be a minimum of 43 kg (95
lbs).
6. The material shall be resistant to rot, mildew, aging, rodents, and insects. The
geo-textile shall withstand the abuses of placement by men and equipment
without tearing or being punctured.
7. Geo textile shall be inert to acids and alkalis within a pH range of 3 to 13.
8. The geo textile shall be resistant to ultraviolet light exposure based on testing in
accordance with ASTM D4355.
2.4 OIL-WATER-DEBRIS SEPARATOR
A GENERAL

1. The SNOUT Oil-Water-Debris Separator is a patented plastic composite water
quality hood or trap that covers the outlet pipe in a sumped storm water
structure.
2. The SNOUT attaches to the wall of a storm water catch basin or other water-
quality structure over the outlet pipe in such a manner as to reduce the
discharge of floating debris, trash, and oil while retaining settled solids.
3. Advantages of The SNOUT Oil-Water-Debris Separator
a. Easy to install
b. Easy to clean
c. Low head loss with high flow abilities
d. Reduces pipe cleaning maintenance
e. Highly corrosion resistant
f. Lightweight high-strength construction
g. Converts existing sump structures into oil—debris trap
h. Prevents siphoning of trapped contaminants
B Composition and Materials:
1. The SNOUT is hand fabricated from marine grade fiberglass. The attachment
hardware is stainless steel, the anti-siphon device is schedule 40 PVC and the
access hatch is ABS plastic. These materials have proven to be extremely
durable and maintenance free.
2. The SNOUT is adaptable to any type catch basin construction and is available in
flat or rounded back styles.
C Technical Data
1. The SNOUT Oil-Water-Debris Separator components consist of: -
a. Standard size composite Hoods

b. Gasket, screw down, watertight, clean-out access port
c. Stainless steel mounting hardware
d. PVC SCH 40 fittings and pipe for anti-siphon device
e. Pressure sensitive oil resistant foam rubber gasket
2. SNOUT composite components are hand and chopper gun laminations of these
of Unsaturated Polyester Resin Reinforced Laminates, with the following
physical properties: -
a. Flexural Strength (psi) ASTM D-790 27,100

b. Flexural Modulus (psi) ASTM D-790 1,157,000
c. Tensile Strength (psi) ASTM D-638 16,700
d. Tensile Modulus (psi) ASTM D-638 1,457,000
e. Tensile Elongation (%) ASTM D-638 1.54
f. Hardness, Barcol 934.1 ASTM D-2583 55 - 60
3. Physical Properties of ISO Gel Coat

a. Tensile Strength 6,218 6,581
b. Elongation, % 2.70 1.90 Flexural Strength, psi 11,363 11,329
c. Heat Distortion, oF 0.544 x 106 0.713 x 106 Mandrel Flex,
d. Mandrel diameter in Inches
D Specification
1. SNOUT OIL-WATER-DEBRIS SEPARATOR: All new and / or existing catch basin

structures shall be outfitted with the SNOUT Oil-Water-Debris Separator over
the outlet pipe. The size and position shall be determined by pipe style and
sump depth per manufacturer's recommendations. The anti-siphon device shall
extend above the hood (a 12" length of vent pipe is included in the installation
kit.) The hood shall be securely attached to the catch basin wall with 3/8"
diameter stainless steel bolts and sealed to the structure with gasket material
supplied in installation kit.
2.5 RELINER INSIDE DROP SYSTEM
A. Product Description
1. RELINER INSIDE DROP SYSTEM is a plastic composite collection device that

facilitates the controlled drop of effluent into the main stream flow of a sanitary
manhole. RELINER composite components are hand and chopper gun
laminations. The Drop Bowl permits easy inspection and cleaning without the
need to enter the structure. The custom made adjustable stainless steel straps
fully support the drop pipe.
B. Advantages
1. Reduce maintenance
2. Eliminate confined space entry
3. Speed Inspection
4. Simplify cleaning
5. Reduce turbulence and odor
6. Solids and liquids remain together
7. Erosion of structure eliminated
8. High corrosion resistance
9. Allow workers entering structure without risk of effluent contact
C. Technical Data
1. RELINER INSIDE DROP components consist of
a. Standard size composite Drop Bowls

b. Stainless steel adjustable clamping brackets
2. Physical Properties of Unsaturated Polyester Resin Reinforced Laminates

Flexural Strength (psi) ASTM D-790 27,100
Flexural Modulus (psi) ASTM D-790 1,157,000
Tensile Strength (psi) ASTM D-638 16,700
Tensile Modulus (psi) ASTM D-638 1,457,000
Tensile Elongation (%) ASTM D-638 1.54
Hardness, Barcol 934.1 ASTM D-2583 55 - 60
3. Physical Properties of ISO Gel Coat
Room Temperature Post Cured at 50_ for

Cured Post Cured for 45 24 hours
hours
Tensile Strength 6,218 6,581
Elongation, % 2.70 1.90
Flexural Strength, psi 11,363 11,329
Heat Distortion, °F 0.544 x 106 0.713 x 106
Mandrel Flex, Mandrel ----- 1.0
Diameter in Inches
4. Stainless steel clamping bracket materials:
a. 304 series non-magnetic stainless steel

b. 18-8 series non-magnetic stainless steel
5. All new and/or existing manhole structures employing inside drop connections
for services and collector sewers shall use the RELINER® Inside Drop Bowl
components, Bowl size shall be determined by incoming pipe sizes and flow
rates. The bowl shall be installed as per manufacturer's instructions using
stainless steel fasteners. The drop pipe of SDR 35, Schedule 40 or other shall be
securely attached to the manhole wall using stainless steel RELINER Adjustable
Clamping Brackets and stainless steel fasteners. Bracket interval shall be 4 feet
maximum (minimum of 2 brackets). The connection of Drop Bowl to drop pipe
shall be by flexible external pipe coupler. The turn-out at the base end of the
drop pipe shall be accomplished with an appropriately angled PVC pipe elbow
(45 degree recommended).
2.6 PIPES, FITTINGS AND ACCESSORIES
2.6.1 Un-Plasticized Polyvinyl Chloride (PVC-U)
A. General
1. The material from which the pipes, fittings and valves are made shall be an
unplasticized poly (vinyl chloride) compound or formulation. This compound or
formulation shall consist of PVC-U resin/powder, to which shall be added those
additives which are needed to facilitate the manufacture of pipes and fittings
conforming to BS EN 1401-1:2009 as applicable.
B. Raw Material

1. The PVC-content shall be at least 80 % by mass for pipes and 85 % by mass for
injection-moulded fittings.
2. A further reduction of the PVC-U content to ≥ 75 % by mass for pipes only is
permitted provided the PVC-U is substituted by coated or uncoated CaCO3
conforming to the following: -
a. The composition of the CaCO3, before coating if any, shall conform to the
following:
1) Content of CaCO3 ≥ 96 % by mass;

2) Content of MgCO3 ≤ 4 % by mass;
3) Content of CaCO3 and MgCO3 in total ≥ 98 % by mass.
b. The physical properties of the material shall conform to the following:
1) Mean particle size D50 ≤ 2,5 μm;

2) Top cut D98 ≤ 20 μm.
C. Pipe Material
1. The pipe material shall have characteristics conforming to the requirements

given in Table 1 BS EN 1401-1:2009. The pipe material shall be tested in the
form of a pipe.
a. Test Characteristic: - Resistance to internal pressure

b. Requirements: - No failure during the test period
c. Test method: - EN ISO 1167-1:2006
D. Fitting Material
1. The fitting material shall have characteristics conforming to the requirements

given in Table 2 BS EN 1401-1:2009.
2. The fitting material shall be tested, in the actual formulation, in the form of an
extruded or injection-moulded pipe.
3. Fabricated fittings or parts of fabricated fittings shall be made from pipes
conforming to BS EN 1401-1:2009, except for the requirements for the wall
thickness, and/or mouldings from PVC-U which conform to material,
mechanical and physical characteristics as required BS EN 1401-1:2009
a. Test Characteristic: - Resistance to internal pressure

b. Requirements: - No failure during the test period
c. Test method: - EN ISO 1167-1:2006
E. Compound Characteristics
1. The compounds of pipes and fittings conforming to BS EN 1401-1:2009 have

generally these characteristics:
a. Modulus of elasticity E(1min) ≥ 3 200 MPa

b. Average density ≈ 1,5 g/cm3
c. Average coefficient of linear thermal expansion ≈ 0.08 mm/mK
d. Thermal conductivity ≈ 0,16 WK−1m−1
e. Surface resistance > 1012 Ω
f. Poisson ratio 0.4
F. Ring Stiffness
1. The ring stiffness of pipes conforming to BS EN 1401-1:2009, when determined

in accordance with EN ISO 9969, is as follows:
a. ≥ 2 kN/m2 for SDR 51

b. ≥ 4 kN/m2 for SDR 41
c. ≥ 8 kN/m2 for SDR 34.
2. Consequently, fittings are classified with the corresponding pipe stiffness. The
actual value of stiffness of the fittings can be determined in accordance with
ISO 13967 [7].
3. Fittings according to this standard, because of their geometry, have a stiffness
greater than the stiffness of the corresponding pipe. Therefore, the following
applies:
a. Fittings marked with SDR 41 may be used with pipes up to SN 8 (SDR 34) ;
b. Fittings of DN ≥ 400 marked with SDR 51 may be used with pipes up to SN 4
(SDR 41).
G. Creep Ratio
1. The creep ratio for pipes and fittings conforming to BS EN 1401-1:2009, when
determined in accordance with EN ISO 9967 [8], is less than 2. For fittings the
full cylindrical length of the socket or spigot is used as a test piece and the pre-
load force, F0, is decreased relative to the actual length of the test piece.
H. Chemical Resistance
1. PVC-U piping systems conforming to this BS EN 1401-1:2009 are resistant to

corrosion by water with a wide range of pH-values such as domestic waste
water, rainwater, surface water and ground water.
I. Abrasion Resistance
1. Pipes and fittings conforming to BS EN 1401-1:2009 are resistant to abrasion.
J. Hydraulic Roughness
1. The internal surfaces of pipes and fittings conforming to BS EN 1401-1:2009 are

hydraulically smooth. The design of joints and fittings ensure good hydraulic
performances.

K. Diametric Deflection
1. In normal installation conditions, the expected average deflection of the

outside diameter of the pipes will be less than 8 %. However, deflections up to
15 %, e.g. caused by soil movement, will not affect the proper functioning of
the piping system.
L. General Characteristics
1. Appearance, when viewed without magnification, the following requirements

apply:
a. The internal and external surfaces of pipes and fittings shall be smooth, clean
and free from grooving, blistering, impurities and pores and any other surface
irregularity
b. Pipe ends shall be cleanly cut and the ends of pipes and fittings shall be square
to their axis.
2. Color, the pipes and the fittings shall be colored through the wall. The color
should preferably be orange-brown (approximately RAL 8023 1)) or dusty grey
(approximately RAL 7037 1)). Other colors may be used.
M. Geometrical Characteristic
1. Pipe
a. Dimensions, shall be measured in accordance with EN ISO 3126.

b. Outside diameters, the mean outside diameter, dem, shall conform to Table 3 BS
EN 1401-1:2009
c. Out of roundness, the out-of-roundness, measured directly after production,
shall be less than or equal to 0,024dn.
d. Length of pipes, the effective length of a pipe, l, shall be not less than that
declared by the manufacturer when measured
e. Chamfering, if a chamfer is applied, the angle of chamfering shall be between
15 ° and 45 ° to the axis of the pipe, the remaining wall thickness of the end of
the pipe shall be at least 1⁄3 of emin.
f. Wall thickness, the wall thickness, e, shall conform to Table 4 BS EN 1401-
1:2009, where a maximum wall thickness at any point up to 1,2 emin is permitted
provided that the mean wall thickness, em, is less than or equal to the specified
em,max.
2. Fittings
a. Outside diameters, the mean outside diameter, dem, of the spigot shall conform
to Table 3 BS EN 1401-1:2009
b. Design lengths (Z), the Z-length(s) of fittings shall be given by the manufacturer.
c. Wall thicknesses, minimum wall thickness, emin, of the body or the spigot of a
fitting shall conform to Table 4 BS EN 1401-1:2009, except that a reduction of 5
% resulting from core shifting is permitted. In such a case, the average of two

opposite wall thicknesses shall be equal to or exceed the values given in Table 4
BS EN 1401-1:2009.
d. Where a fitting or adaptor provides for a transition between two nominal sizes,
the wall thickness of each connecting part shall conform to the requirements for
the applicable nominal size. wall thickness of the fitting body is permitted to
change gradually from the one wall thickness to the other.
e. Wall thickness of the cover of the saddle branch shall be equal or greater than
emin of the applicable size and series (see Table 4 BS EN 1401-1:2009) of the
inlet.
f. Wall thickness of fabricated fittings, except for spigot and socket, may be
changed locally by the fabrication process, providing that the minimum wall
thickness of the body as given in Table 6 BS EN 1401-1:2009, as appropriate for
the SDR concerned.
3. Dimensions of Sockets and Spigots
a. Elastomeric ring seal sockets and spigots Diameters and lengths: - the diameters
and lengths of elastomeric ring seal sockets and spigots shall conform to Table 5
BS EN 1401-1:2009. Different designs of elastomeric ring seal sockets and
spigots are permitted, provided the joints conform to the requirements given in
Table 15 BS EN 1401-1:2009.
b. Wall thicknesses of sockets, the wall thicknesses of sockets, except the socket
mouth, shall conform to Table 6 BS EN 1401-1:2009
c. Dimensions for "O-ring type" sockets, the dimensions of "O-ring type" sockets
with a nominal diameter, shall conform to Table 7 BS EN 1401-1:2009
N. Mechanical Characteristics
1. Mechanical characteristics of pipes, the pipe shall have general mechanical

characteristics conforming to the requirements given in Table 9 in BS EN 1401-
1:2009
a. Test Characteristic: - Impact resistance (round-the clock method)

b. Test parameters Requirements: TIR ≤10 %
c. Test method: EN 744:1995
2. Mechanical characteristics of fittings, the fitting shall have mechanical

characteristics conforming to the requirements given in Table 11 BS EN 1401-
1:2009
a. Test Characteristic: Mechanical strength or flexibility

b. Test parameters Requirements: No sign of splitting, cracking, separation, and/or
leakage
c. Test method: EN 12256
d. Test Characteristic: Impact strength (drop test)
e. Test parameters Requirements: No damage
f. Test method: EN 12061
O. Physical Characteristics

1. Physical characteristics of pipes, the pipe shall have physical characteristics
conforming to the requirements given in Table 12 BS EN 1401-1:2009
a. Test Characteristic: Vicat softening temperature (VST)

b. Test parameters Requirements: ≥79 °C
d. Test Characteristic: Longitudinal reversion
e. Test parameters Requirements: ≤5 % The pipe shall exhibit no bubbles or cracks
f. Test method: EN ISO 2505: Liquid bath
g. Test Characteristic: Resistance to dichloromethane at a specified temperature
h. Test parameters Requirements: No attack
i. Test method: EN 580
2. Physical characteristics of fittings, he fitting shall have physical characteristics

conforming to the requirements given in Table 13 and/or Table 14 BS EN 1401-
1 2009, as applicable.
a. Test Characteristic: Vicat softening temperature (VST)

b. Test parameters Requirements: ≥ 77 °C
d. Test Characteristic: Effects of heating
e. Test parameters Requirements: the depth of cracks, delamination or blisters
shall not exceed 50 % of the wall thickness at the chosen test point;
f. Test method: EN ISO 580: Air oven
g. Test Characteristic: Water tightness
h. Test parameters Requirements: No leakage
i. Test method: EN 1053
P. Types of Fittings
1. The types of fittings shall conform to the requirements given in BS EN 1401-

1:2009 other designs of fittings are permitted.
a. Bends
b. Couplers and slip couplers
c. Reducers
d. Branches and reducing branches
e. Saddle branches
f. Plugs
Q. Sealing Rings
1. Sealing ring shall have no detrimental effects on the properties of the pipe and
the fitting and shall not cause the test assembly to fail to conform to Table 15
BS EN 1401-1:2009
2. Materials for sealing rings shall conform to EN 681-1 or EN 681-2, as applicable.
R. Adhesives

1. The adhesive shall be solvent cement and shall be as specified by the
manufacturer of pipes or fittings.
2. The adhesive shall have no detrimental effects on the properties of the pipe
and of the fitting and shall not cause the test assembly to fail to conform to
Table 15 BS EN 1401-1:2009
S. Classification of PIPES:
1. Pipes shall be manufactured in accordance with EN 1401-1:2009 capable to

withstand a working pressure of 6 kg/cm2 for gravity network depth up to 6 m
and 10 kg/cm2 for depth more than 6 m, Pipes used in gravity system shall be
Socket and spigot joints with elastomeric sealing.
2.7 DRAIANGE STRUCTURE
2.7.1 CAST IN-SITU MATERIAL
A. Fine Aggregate
1. The grading of fine aggregate shall be within the limits of Table (5) BS 882.
2. Fine aggregate shall be of such uniformity that the fineness modulus as defined
in AASHTO M6 or (ASTM C125) shall not vary more than 0.20 either way from
the fineness modulus of the representative samples used in the mix design.
3. The sand equivalent for fine aggregate (AASHTO T176) shall be a minimum of
70.
4. The water absorption of fine aggregates (ASTM C128) or (AASHTO T84) shall not
exceed 2 percent.
B. Coarse Aggregate
1. Coarse aggregate shall be prepared as single size aggregates and blended to

produce normal size grading. The combined grading of coarse aggregate shall be
within the limits given in Table (4) of BS 882 for nominal size of graded
aggregate 20 mm to 5 mm.
2. The 10 percent fineness values of coarse aggregate determined in accordance
with BS 812 shall not be less than 75 KN. The flakiness index and elongation
indices of coarse aggregate determined by the sieve method described in BS
812 shall not exceed 30, except that for aggregates used in Class E concrete no
limit shall apply. The abrasion loss when tested in accordance with ASTM C131
shall not exceed 25 percent.
3. The water absorption of coarse aggregate (ASTM C127) shall not exceed 2
percent.
C. Cement
1. Ordinary Portland Cement and rapid-hardening Portland cement shall comply

with the requirements of BS 12 or ASTM C150 Type II.

2. Sulphate Resisting Portland Cement shall comply with the requirements of BS
4027 or ASTM C 150 type V.
3. Super sulphated Cement shall comply with the requirements of BS 4248 or
ASTM C 150 type V.
D. Water
1. Water for concrete, mortar and curing shall comply to BS 3148.

2. All water used in concrete & mortar shall be clear, fresh water free from oil,
acids, alkali, sugar, vegetable substances, or any other contaminating agent.
3. If required by the Engineer, Contractor shall provide water quality test results.
4. Non-potable water shall not be used in concrete unless written approval to do
so is granted by the Engineer.
E. Concrete:
1. Shall conform to Section “Concrete and Reinforced Concrete”
F. Concrete Blocks
1. Concrete blocks shall be hard, durable, sound, clean, well defined edges and free
from cracks, flaws or other defects. They shall comply with the requirements of
ASTM C140.
2. All mortar shall consist of one-part masonry cement to three parts loose sand
complying with the following requirements.
a. Sand complying with ASTM C144, grading and coloring suitable for type of
masonry and as approved by the Engineer.
b. Sulphate Resisting Portland Cement shall comply with the requirements of BS
4027 or ASTM C150 type V.
c. Water Complying with water for Concrete Mixes and curing, of the
Specifications Section “Concrete and Reinforced Concrete”
G. Reinforcing
1. Reinforcing bars. Plain and deformed bars shall conform to BS 4449.

2. Mesh reinforcement shall conform to the specifications of ASTM designation A
185
3. Black annealed wire used as reinforcing steel, but not including tie wire, in
structures as shown on the plans, shall be commercial quality black annealed
wire of the gauge
4. Designated; the gauge shall be American steel and wire gauge.
5. All testing of reinforcing steel bars shall be carried out in accordance with BS
4449 and BS 4482.
2.7.2 STEP IRONS:
1. General

a. Steps shall conform to the requirements of this clause. Where a fixing system is
supplied as part of the step, the system shall conform to the requirements of EN
13101
b. Steps shall be installed in accordance with the manufacturer's instructions. For
the installation of the steps, national regulations shall be observed.
2. Materials
a. Metals, Steps shall be manufactured from the following metals:
1) Aluminum alloys according to designation 6 060 or 6 106 of EN 573-3:1994.
b. Cast Iron:
10) Malleable cast iron conforming to EN 1562;

11) Spheroidal graphite (ductile) cast iron conforming to EN 1563;
12) Flake graphite (grey) cast iron conforming to EN 1561.
c. Steel:
1) Steel conforming to EN 10025 or ENV 10080:1995;
3. Plastics encapsulation
a. The material for encapsulating steps in plastics shall be polyethylene of

minimum density 0,935 glcm3 (as tested in accordance with ISO 1183) or
equivalent qualities of polypropylene copolymer.
2.7.3 DROP CONNECTIONS AND Y CONNECTIONS
A. All manhole drop connections shall be outside drop. Outside drops shall be
provided with same pipe material as sewer main as indicated in the standard
drawings.
B. Pipes and fittings (Elbow, Tee, and Y connection) shall be provided with same
pipe material as sewer main as indicated in the standard drawings
2.7.4 DRAINAGE STRUCTURE COVERS AND FRAMES:
A. Manholes, Ductile iron kitemarked to BS EN124 solid top circular hinged access
cover and frame , opposite cover parts block at 90, the covers are removable
from the frame horizontally or vertically after removing the metal safety pins.
Circular frame over all flanged with anchoring holes that can be used to fix the
frame.
B. Inspection/Drainage/sedimentation chamber, ductile iron kitemarked to BS
EN124 solid top rectangular access cover and frame, the covers are removable
from the frame horizontally or vertically after removing the metal safety pins.
Rectangular frame over all flanged with anchoring holes that can be used to fix
the frame.

C. Catch Basin, Ductile iron kitemarked to BS EN124 grating top rectangular/or
square cover and frame, the covers are removable from the frame horizontally
or vertically after removing the metal safety pins. Rectangular frame over all
flanged with anchoring holes that can be used to fix the frame.
D. Drainage Channel Ductile Iron slotted grating kitemarked to BS EN124,
Innovative 4·point lock in the drainage channel body for a firm and stable seat
without loose or rattling parts, Securing the covers against longitudinal shifting,
no reduction of the drainage cross-section, because the complete drainage
channel cross section remains free, Quick and easily attach and release of the
grates with one hand without special-purpose tools.
E. Covers and frames shall be unvented and shall be made of spheroidal graphite
cast iron, ductile iron, to ISO 1083. They shall be supplied in one piece, unless
specified otherwise, to suit the clear openings shown on the drawings.
F. The cover should be freely removed from the frame at suitable opening angle.
The cover should be also equipped with a safety mechanism to maintain the
cover safely locked when opened at suitable vertical angle.
G. Unless otherwise shown on the drawings or instructed by the Engineer the class
of covers, gratings and frames shall be as follows:
a. Class D400 in areas subject to vehicular traffic.

b. Class C250 in areas accessible to traffic.
c. Class B125 in areas not subject to vehicular traffic.
1. Warm applied black bitumen coat (paint) to BS 3416 and special coats for
protecting covers.
2. All covers shall be non-rock preventing noise and vibration.
3. Clear opening dimensions shall be as indicated on drawings.
4. All covers, frames and supporting metal work shall be designed for loading to BS
5400-2.
5. One prying and lifting bar of approved design shall be provided with each 20
covers supplied with a minimum of one for each type of cover.
6. Covers shall be sampled at random by the Engineer and load tested under his
supervision according to BS EN 124 procedures. The sampling and testing rate
shall be 2%.
7. Each cover should be badged with:
a. The name and/or identification mark of the manufacturer

b. The marking of the standard
c. The appropriate class
d. The badge of the project and usage subject to engineer’s approval
8. Coatings to Covers, Gratings, Frames and Surface Boxes
e. All castings shall be inspected for defects. Castings with unacceptable defects
shall be rejected.
f. Minor blowholes and surface imperfections shall be filled in and repaired with
approved two component epoxy amine solvent free filler.
g. All castings shall be degreased, grit blasted to SA 2.5, near white metal
condition, primed with a metallic zinc primer and then coated with a black two

component solvent free epoxy polyamine cured coating material applied in two
coats, each coat having a minimum dry film thickness of 200 microns.
h. Coated castings shall not be handled and transported until full cure has been
achieved. An original of the approved coating specialist's quality control report
for each itemized component shall be provided with each delivery. The report
shall bear an original company stamp and signature.
PROTECTIVE COATING:
A. Concrete protection and waterproofing systems shall comply with the

requirements of “CORROSION PROTECTION AND ODOR CONTROL" section.
GROUT
A. Non shrink Cementations Grout
1. Non shrink cementations grouts shall meet or exceed the requirements of ASTM
C1107 Grades B or C and CRD-C 621. Grouts shall be Portland cement based,
contain a pre- proportioned blend of selected aggregates and shrinkage
compensating agents and shall require only the addition of water. Non shrink
cementations grouts shall not contain expansive cement or metallic particles.
The grouts shall exhibit no shrinkage when tested in conformity with ASTM
C827.
B. Non shrink Epoxy Grout
1. Non shrink epoxy-based grout shall be a pre-proportioned, three components,

100 percent solids system consisting of epoxy resin, hardener, and blended
aggregate. It shall have a compressive strength of 97 MPa in 7 days when tested
in conformity with ASTM D695 and have a maximum thermal expansion of 30 x
10-6 when tested in conformity with ASTM C531.
GRP PRODUCTS
A. Raw Materials
2. Materials used in the manufacture of GRP products shall be new stock and of
the best quality.
3. Materials shall be free from all defects and imperfections that might affect the
performance of the finished product.
4. Resins shall comply with the relevant provisions of BS 3532 Type B, unless
otherwise approved by the Engineer. Vinylester resins shall have an elongation
at break of 3 to 6%.
5. Glass shall comply with the relevant provisions of the following standards unless
otherwise approved by the Engineer. Surface tissues shall also comply with one
of the following standards:
a. BS EN 14020-1, BS EN 14020-2 and BS EN 14020-3 for roving’s.

b. BS 3396 for woven fabric.

c. BS EN 14118-1, BS EN 14118-2 and BS EN 14118-3 for chopped strand mat.
6. All glass shall be ECR or other corrosion resistant glass, unless otherwise
approved by the Engineer.
7. Roving size shall not exceed 2400 Tex.
8. Chopped strand mat shall not exceed 450g/m².
9. Sand aggregate used for non-slip surfaces shall be a clean graded silica sand,
nominal size 3mm.
10. General properties of GRP products shall be as follows: -
a. Axial tensile strength ISO 527 100N/mm2

b. Water absorption maximum ASTM D570 0.15% not short term boiling
method
c. Barcol hardness ASTM D2583 Min 35 prior to dispatch
11. The frequency of testing of GRP products for dimensional accuracy, the
properties given above and the load and deformation criteria given below shall
be as agreed with the Engineer.
12. GRP products exposed to a sewage environment shall be corrosion resistant to
raw sewage and associated gases.
13. GRP products exposed to weather shall contain an ultraviolet inhibitor and shall
additionally receive a 500 microns’ thick gel coat to shield the exposed surface
from ultra violet light.
B. GRP Sealing Plates for Sewage Manhole & Chambers
1. The sealing plate thickness shall be a minimum of 7mm and shall be designed to
support a minimum load of 7.5kN/m².
2. The sealing plate shall be manufactured from the required number of layers of
chopped strand mat 450g/m², “Advantex” powder bound corrosion resistance
or equivalent approved, impregnated with isophthalic or vinylester resin of
approved type. Resin to glass ratio shall be 75% to 25% by weight with a
tolerance of ± 5%. Fillers and aggregates shall not be used. The underside of the
plate shall be protected with a resin rich vinylester liner 1.5mm thick reinforced
with one layer of “C” glass tissue and two layers of chopped strand mat
300g/m².
3. The sealing plate shall be in the form of a plug with a flange to prevent the plate
dropping through the access opening.
4. The sealing plate shall incorporate a peripheral retained rubber ring such that
when the cover is closed a gas tight seal is formed. The rubber ring shall be
made from nitrile rubber, EPDM formulation, in compliance with BS EN 681 and
with joints vulcanised and not glued.
5. The plate shall be designed such that a gas tight seal is obtained without the use
of bolts.
6. The sealing plates shall have two securely laminated GRP lifting handles.
7. Cuts and/or drilled faces shall be sealed with resin only.
8. GRP sealing plates shall be seated on the lips of the frames without causing any
reduction to the dimensions of the specified openings

C. GRP Ladders and Safety Gages
1. GRP ladders shall be of an approved pattern, dimension and duty to suit the
location and shall be installed as shown on the drawings.
2. GRP ladders shall be hand laminated mouldings composed of seven layers of
chopped strand mat 450g/m² and one layer of glass surface veil 30g/m,
“Advantex” powder bound corrosion resistance or equivalent approved,
impregnated with vinylester resin of approved type. Resin to glass ratio shall be
75% to 25% by weight with a tolerance of ± 5%. Fillers and aggregates shall not
be used.
3. Hardwood stiffeners are to be provided inside both the rungs and the rails as a
former, and shall be fully encased in the GRP laminate which shall have a
minimum thickness of 5mm and there shall be no sharp edges.
4. The structural components shall possess Class I fire retardance, with an ASTM
E84 maximum flame spread rating of 25.
5. Fixing brackets shall be GRP integrally moulded into the ladder laminations and
they shall be not more than 500mm apart. The fixing brackets shall be designed
to be anchored securely in concrete having a roughened surface to provide a
good bond and shall project a minimum of 100mm into the concrete.
6. The rungs shall be 250mm apart with the upper faces finished to a non-slip
surface.
7. Intermediate landing shall be provided where the rise exceeds 6m.
8. Nuts and bolts shall not be used either in the construction, assembly or fixing of
the ladder.
9. Each rung shall be able to withstand a point load of 5000N when applied at the
center of the rung and when applied close to one end.
10. When supported horizontally over a span of 1m with the climbing face
uppermost and with a load of 1000N applied at the center of the span there
shall not be a deflection greater than 10mm at the point of application of the
load and there shall be no permanent deformation after removal of the load.
The loads shall remain in place for 24hours after which the ladder shall be
inspected for defects.
11. Each ladder fixing shall be capable of withstanding shear and pullout loads of
5000N.
12. GRP safety cages shall be as shown on the drawings and shall be manufactured
in the same manner as GRP ladders but without the hardwood core.
13. Safety cages shall be provided where the distance between the ladder landings
exceeds 4.5m.
14. Safety cages shall be constructed of three flat vertical members supported by
flat hoops with diameter of 750mm. The hoops shall be at a maximum of
700mm centers and the first hoop shall be 2.4m above ground or platform level.
15. Each hoop shall be able to withstand a tangential point load of 740N and a
vertical point load of 1200N applied at any point on the hoop. The maximum
allowable deflection at the point of application of the load shall not exceed
25mm and there shall be no permanent deformation of the hoops after removal
of the load after 24 hrs.
D. GRP Hand railing

1. GRP hand railing shall be as shown on the drawings and shall be manufactured
in the same manner as GRP ladders.
2. GRP hand railing shall be in prefabricated lengths complete with fittings. The
Contractor shall ensure that unless otherwise specified, all hand railing shall be
of uniform appearance and manufacture.
3. GRP hand railing shall be 1000mm high and be provided with an intermediate
rail 500mm high. Standards shall be set at not more than 1.50m centers.
4. Hand railing and fixings shall be designed to withstand a lateral horizontal force
at upper handrail level of 740N/m run. The deflection of rails shall not exceed
0.8% of their span between standards and the deflection of standards shall not
exceed 0.8% of their height.
E. GRP Liners
1. GRP liners shall be minimum 6.5mm thick or as shown on the drawings.

2. Raw materials and properties of the final product shall be as in Section 2.5
3. Site lamination shall start only after concrete reach its 28-day strength.
F. GRAB Handles
1. Grab handles shall be constructed from 20mm diameter formed mild steel bars
and coated with a vinylester resin rich GRP laminate. Handles shall have 150mm
x 150mm square openings in their final position.
STEEL PRODUCTS
A. Material
1. Steel, hand railing, ladders, stairs and flooring shall comply with the following:
a. Steel tubes and tubulars suitable for screwing to BS 21 pipe
1) Threads BS 1387
2) Hot rolled sections BS 4: Part 1 Hot
b. Hot rolled structural steel Sections
1) Equal and unequal angles BS 4848: Part 4

2) Hollow sections BS 4848: Part 2
c. Wieldable structural steels BS 4360.
2. Stainless steel, hand railing, ladders, stairs and flooring
a. Grade 304 S BS 970: Part 1.

b. longitudinally welded tubes BS 6323: Part 8. Tubes for handrails polished.
3. Aluminum, hand railing, ladders, stairs and flooring shall comply with the
following:

a. Wrought aluminum and aluminum alloys for general engineering purposes
1) Plate, sheet and strip BS 1470

2) Drawn tube BS 1471
3) Bars, extruded round tubes and sections BS 1474
b. Aluminum shall be anodized to Grade AA 25 in accordance with BS 1615.
1. Bolts, nuts, screws, washers and rivets
a. Bolts, nuts, screws, washers and rivets, shall comply with the and following:
1) ISO metric black hexagon bolts, screws and nuts BS 4190
2) ISO metric black cup and countersunk head bolts and BS 4933
screws with hexagon nuts
3) Metal washers for general engineering purposes BS 4320
4) Rivets for general engineering purposes BS 4620
5) Wrought aluminum and aluminum alloys for general BS 1473

engineering purposes - rivet, bolt and screw stock
6) Stainless steel fasteners BS 6105
b. The length of bolts shall be such that the threaded portion of each bolt projects
through the nut by at least one thread and by not more than four threads.
c. Rag, indented bolts, expansion bolts and resin bonded bolts shall be of a
proprietary type approved by the Engineer and shall be capable of withstanding
the design working load.
d. Hot dip galvanized bolts, nuts, screws, washers and rivets shall be used with hot
dip galvanized hand railing, ladders, stairs and flooring. Aluminum bolts, nuts,
screws, washers and rivets shall be used with aluminum hand railing, ladders,
stairs and flooring. Stainless steel bolts, nuts, screws, washers and rivets shall be
used with other types of hand railing, ladders, stairs and flooring. Bolts, nuts,
screws and washers shall be insulated from aluminum by non-metallic washers
and sleeves.
e. The length of bolts shall be such that the threaded portion of each bolt projects
through the nut by at least one thread and by not more than four threads.
B. Designed by Contractor

1. Hand railing, ladders, stairs and flooring which are to be designed by the
Contractor shall comply with the following requirements:
a. Hand railing shall be capable of withstanding a horizontal loading of 740 N/m.

The deflection of hand railing shall not exceed 1 in 200 at mid-span.
b. Stairs shall be designed for a live loading of 5 kPa.
c. Flooring shall be designed for a live loading of 5 kPa. The deflection of flooring
shall not exceed 1/200 of the span.
C. Fabrication of Hand railing, Ladders, Stairs and Flooring
1. General
a. Steelwork for hand railing, ladders, stairs and flooring shall be fabricated in
accordance with BS 5950: Part 2.
2. Galvanizing to steel
a. All steel that is to be galvanized shall be hot dip galvanized in accordance with
BS EN ISO 1461:1999.
b. Galvanizing to steel shall be applied after welding, drilling and cutting are
complete.
3. Welding steel
a. Welds to steel for hand railing, ladders, stairs and flooring shall be full depth
fillet welds. The welded surface shall be clean and flush before application of
the protective coating.
b. Steel shall not be welded after hot dip galvanizing unless permitted by the
Engineer and if permitted, the welded areas shall be free from scale and slag
and shall be treated with appropriate coating system approved by the Engineer,
which is compatible with the protective system of the parent material.
4. Fabrication
a. Hand railing
1) Hand railing, shall be discontinued at movement joints in structures. The

spacing between standards shall be regular and shall not exceed 1.6 m. Curved
hand railing shall not be made up of a series of straights.
b. ladders
1) Ladders shall comply with BS 4211

2) Steel ladders shall be hot-dip galvanized.
3) Aluminum ladders shall be Grade 6082 aluminum.
4) Rungs, extended stringers, safety cages and brackets shall be welded to the
stringers of ladders.

5) Rungs on aluminum ladders shall have longitudinal grooves and pressed
aluminum alloy caps shall be fixed to open ends.
c. Stairs
1) Stairs shall comply with BS 5395: Part 1.
d. Flooring
1) The shape of each panel of flooring shall be such that the panel can be easily
removed. The mass of each panel shall not exceed 40 kg. Where intermediate
supports are provided to support flooring they shall be capable of being
removed to provide the specified clear opening.
2) Curbs shall be provided in concrete surfaces for flooring.
3) Cut-outs in flooring shall be neatly shaped and shall be provided with toe plates.
Cut-outs in open mesh flooring shall be trimmed with edge bars welded to the
bearing bars. The clearance between the edge of cut-outs and the component
passing through the cut-out shall not exceed 30 mm.
4) The bearing bars in open mesh flooring shall be welded to the nosing bars. The
transverse bars shall be riveted or welded to the bearing bars. Panels of open
mesh flooring shall be secured with adjustable fixing clips.
5) Chequer plate flooring shall have a non-slip pattern of a type approved by the
Engineer and shall be provided with lifting holes. The flooring shall be secured to
curbs by countersunk screws.
e. Toe plates
1) Toe plates shall be fixed to handrail standards by brackets and shall be bolted or
welded to stairs and flooring.
f. Safety Chains
1) Pipes over DN600mm should be provided with safety chains for placing at the
mouth of the outgoing sewer, BS EN 752-3:1997
2) Safety chains shall comply with BS 4942 and shall be capable of withstanding a
breaking force of 30 kN and a proof force of 15 kN.
3) Steel safety chains shall be 8 mm nominal size, Grade M4 non-calibrated chain
Type 1 and shall be hot-dip galvanized.
4) The links of stainless steel safety chains shall be welded and shall have an
internal length exceeding 45 mm and an internal width of between 12 mm and
18 mm. Fins caused by welding shall be removed.
5) Hot dip galvanized hooks on chains shall be fitted with a sprung securing device.
PART 3 EXECUTION
3.1 SPECIALISTS, INSPECTION AND TESTING
A. The Employer may employ the services of a specialist firm to assist the Engineer

as he may require in any matter connected with pipes, and fitting including the
inspection of materials and workmanship and the witnessing of tests at any
stage during the execution and maintenance of the Works.
B. Such independent tests may be carried out at any stage during the execution
and maintenance of the Works, but they shall not relieve the Contractor of his
obligations under the Contract.
C. To the extent ordered by the Engineer, the Contractor shall provide labour,
plant, tools and materials (but not special testing equipment) for direct
assistance to the specialist firm in their inspection and independent testing and
for any further work, investigations, and repairs which the Engineer considers
necessary as a result of such inspection or testing.
D. The provision of labour, plant and materials a s aforesaid shall be an obligation
of the Contractor where in the Engineer’s opinion the inspection test or further
investigation shows that materials and workmanship provided by the Contractor
do not comply with the designated requirements.
E. The Contractor shall supply all necessary tools for cutting, chamfering, jointing,
and testing and for any other requirement for satisfactory installing the
pipelines.
3.2 SOIL CORROSIVITY STUDY
A. Where designated in the Project Specification, the Contractor shall carry out a
soil corrosivity study along the route of proposed ferrous pipelines as directed
by the Engineer and mark the results on the pipeline layout plans.
B. Soil resistivities shall be undertaken using a low resistance, null -balance earth
tester and a four pin array, or any other equipment approved by the Engineer.
Readings shall be recorded in ohm-cm and shall be taken at 1.0 m incremental
depths to a depth 1 m below the pipeline invert levels. Readings shall be taken
at a spacing along the route of the proposed pipelines as required to reflect the
changing soil conditions, but in no case shall the spacing exceed 500 m.
C. Soil samples shall be taken as directed by the Engineer along the route of the
proposed pipelines at a maximum spacing of 500 m. Soil samples shall be
tested for sulphates, sulphides, chlorides, pH, moisture content, and
carbonates.
3.3 EARTH WORK
EXCAVATION
A. General
2. The trenches shall be excavated to the required line and level as shown on the
drawings or as approved by ENGINEER, and shall, at all times, be drained and
braced to ensure safe and efficient pipe laying. In locations where services,
ruins, or other structures are near the pipeline route, only hand excavation will
be permitted.

3. Excavate trench to accommodate drain system. Excavations must be made
about the center line of proposed drainage run
4. Make sure the extent of all trenches in open cut is the minimum necessary or
practicable for the construction of the Works.
5. Do not exceed the maximum total length of 500m for continuously open
trenches for pipelines.
6. Do not make battered trenches in public highways, private gardens or within
30m of any building or other structure unless otherwise approved by the
Engineer.
7. Do not impinge on 45 degree bearing splay of foundations.
8. Form that portion of the trench which extends from the formation to a point
300mm above the crown of the pipe when laid in its correct position, with
vertical sides the minimum practicable distance apart, unless otherwise
specified by the pipe manufacturer and/or accepted by the Engineer.
9. Make the top edge of the trench as straight as practicable.
10. Deposit excavated material in the designated area on site for backfilling or any
other purpose in such a manner that will avoid damage or inconvenience and
away from the trench so as not to overload trench sides. Remove excess
material, not being used, from site.
11. Take every precaution to prevent slips and falls of earth and other materials in
the trenches.
12. The Contractor shall take precautions to prevent flotation of pipes in locations
where open trench excavations may become flooded. If flotation has occurred
the Contractor shall remove the pipes, bedding and surround if placed and
reinstate the Works to the satisfaction of the Engineer.
13. Do not use blasting or explosives to carry out the Works.
14. Contractor shall carry out further excavation as necessary to accommodate
manholes, chambers and thrust blocks.
15. Where the trench excavation crosses permanent barriers such as fences and
walls the Contractor shall provide temporary barriers where these have to be
removed and reinstate the permanent barriers to the approval of the Engineer
on completion of the backfilling.
16. Unless otherwise directed by the Engineer all open excavations and other
hazardous areas shall be enclosed from all sides by temporary fencing. All
damaged sections of temporary fencing shall be repaired or replaced.
Temporary fencing shall not be removed from any location without the
Engineer’s approval.
17. Buried marker tape shall be placed above all utilities at a depth of 300mm below
final grade level.
18. Pipeline marker plates and posts shall be placed over pumping and pressure
mains as shown on the drawings.
19. Do not commence any permanent works until the Engineer has inspected and
accepted the excavation.
20. Engineer reserves the right to stop the works at any time if in its opinion it is
considered that methods of work are not safe.
21. Where dewatering is required, provide a qualified and experienced crew to
perform the dewatering operation, or furnish the services of a dewatering
subcontractor approved by the Engineer to design and operate the dewatering
works in accordance with the requirements of this specifications.

B. Preparation
1. The Engineer shall provide the Contractor with benchmark, base line and points
of reference to be used by the Contractor in laying out the work. From the
benchmark, base line and points of reference the Contractor shall do his own
layout. The Contractor shall notify the Engineer if for any reason these
benchmarks, base line and pints of reference are disturbed, lost or destroyed.
The Contractor shall be charged the cost necessary to replace and relocate all
bench marks, base line and points of reference so disturbed, lost or destroyed.
2. The Contractor shall be responsible for true and proper laying out of the work
and for the correctness of position, levels, dimensions and alignment of all parts
of the work and for the provision of all necessary survey instruments,
equipment, labor, stakes, templates, batter boards, material and supplies
necessary for the laying out of the work and maintenance thereof.
3. Run string line, or laser, at finished surface level along full length of proposed
trench run to ensure trench is installed at grade.
4. If at any time during the progress of the work any error shall appear or arise in
the position, levels, dimensions or alignment of any part of the work the
Contractor shall, at his own expense, rectify such error to the satisfaction of the
Engineer.
5. The checking of any layout or of any line or level by the Engineer shall in no way
relieve the Contractor of his responsibility for the correctness thereof.
6. All sewers shall be laid accurately to the lines, and levels gradients shown on the
approved drawings so that the pipeline is straight between successive manholes
in the vertical and horizontal planes.
7. Take and record levels in the manner specified or agreed with the Engineer
before disturbing any part of the site or beginning the Works thereon.
8. Protect plant life, lawns and other features remaining as a portion of final
landscaping.
9. Protect bench marks, existing structures, fences, sidewalks, paving, and curbs
from excavating equipment and vehicular traffic.
10. Carefully strip and set aside the surface materials for re-use as directed by the
Engineer.
11. Break up and dispose of the concrete of concrete roads and foundations as the
Engineer directs
C. Maintaining and Supporting Services and Structures

1. Ascertain the actual locations of all existing services and obstructions before
commencing any part of the Works.
2. After obtaining approvals from all concerned Authorities, the Contractor shall
carefully excavate all necessary trial pits by hand to locate all services and
obstructions.
3. Do not exceed a maximum distance of 25m between trial pits.
4. Submit to the Engineer detailed drawings showing the services and/or
obstructions in relation to the permanent and temporary works.
5. If the proposed method of working will damage, expose or affect these services
etc. in any way, obtain written acceptance from the appropriate Authority and
the Engineer for this method of working before commencing work. Such

acceptance will in no way relieve the Contractor from any part of his
responsibilities under the Contract.
6. When excavation is to be undertaken within 10m of an existing flexible pipeline
the Contractor shall undertake a Closed Circuit Television Survey (CCTV) and
deflection survey of the pipeline before commencing any dewatering works.
Vertical and horizontal pipe deflections shall be measured at 2m intervals and at
each side of a pipe joint. On completion of the Work and removal of the
dewatering installation repeat the deflection survey. If the method of working
has resulted in changes to the deflection of the existing pipeline the Contractor
shall reinstate the existing pipeline to the satisfaction of the Engineer at no cost
7. Call the attention of the Engineer and the appropriate Authority as soon as any
existing service is encountered in the excavation. Take photographs to illustrate
the existing damage or conditions.
8. Safeguard and maintain all watercourses, sewers, drains, gas pipes, water pipes,
electricity and telecommunication cables and all other services and structures
encountered during the construction of the Works and take any remedial
measures necessary to make good immediately any damage arising out of the
construction of the Works.
9. Support and divert all such services and structures to the satisfaction of the
appropriate Authority and the Engineer, all in accordance with the accepted
method of working and without delay.
10. Replace all diverted and supported services and structures on completion of the
Works.
11. If the appropriate Authority chooses to carry out repairs to damaged services
themselves or by using their own nominated subcontractors the Contractor
shall reimburse all the costs incurred for such works and if he fails to do so such
monies may be deducted from any monies due or which shall become due from
appropriate Authority to the Contractor. In addition to any reimbursement of
costs the Contractor will be required to pay the appropriate Authority a sum of
money as a penalty for damage caused to any of that Authority’s services.
D. Keeping the Excavations in Dry Condition and Dewatering

1. Keep all excavations free from water and sewage whether affected by tides,
floods storms or otherwise. Ensure that the work is constructed in dry
conditions.
2. Do not leave in any sub-drainage pipes, unless they are filled with concrete
Grade C20 or other accepted material.
3. Completely wrap any sub-drainage left in below the permanent works in an
approved geotextile filter fabric.
4. Make sure that the subgrade left in place provides support at least equal to that
which would have been available if the sub-drain was not present.
5. Obtain discharge approval from the relevant authority for any water discharge
into an existing facility. Ground water shall be pumped away and disposed of as
directed in the discharge license. Pump water removed from excavations,
wherever practicable, directly to the sea or to storm sewers if accepted via an
efficient system of discharge lines. Do not discharge any water into any sewer
including those sewers laid under this Contract, into the Works or onto open
spaces.

6. Make sure that at all times during construction, no groundwater comes into
contact with any concrete surface or reinforcement and that any structure is
capable of withstanding any hydrostatic pressure to which it may be subjected
during construction and until completed.
7. Make sure that at all times during construction, no groundwater comes into
contact with any concrete surface or reinforcement and that any structure is
capable of withstanding any hydrostatic pressure to which it may be subjected
during construction and until completed. Fully comply with the requirements of
the Engineer in regard to the Works for maintaining excavations, dewatering
and the discharge of groundwater arising from dewatering, Include for the
diversion of all watercourses encountered in the Work until the complete
drainage scheme for the site is completed and put into operation.
8. Draw the static water level down to a minimum of 300mm below the formation
level of the excavation so as to maintain the undisturbed state of the
foundation soils and to allow the placement of any fill or backfill to the required
density.
9. Install and operate the dewatering system so that the groundwater level outside
the excavation is not reduced to the extent that would damage or endanger
adjacent roads, structures, utilities or property.
10. Establish at several site locations, approved by the Engineer groundwater level
monitoring stations using open tube piezometers that can be observed during
the work. Also, provide settlement gauges as directed, accepted and designated
by the Engineer at several locations to monitor settlement of new and existing
facilities.
11. Perform dewatering so that no flow of water occurs along the pipe zone
material. Use where applicable cut-off walls to reduce the potential
groundwater flow along pipe trenches. Submit to the Engineer for his approval
details of the proposed method of working and temporary works installations to
achieve this.
12. Perform the restoration of groundwater to its original static level so as to
maintain the undisturbed state of the natural foundation soils, prevent
disturbance of compacted fill or backfill and prevent flotation or movement of
structures and underground utilities.
13. Do not remove any dewatering systems without the Engineer’s acceptance.
Maintain monitoring and settlement measurement systems in operation until
removal is accepted by the Engineer. Where necessary, maintain until final
compaction is completed. Well points and like items may be abandoned to the
extent accepted by the Engineer Fully comply with the requirements of Abu
Dhabi Municipality or any other Government Department in regard to the
Works for maintaining excavations, dewatering and the discharge of
groundwater arising from dewatering.
E. Support of Trenches
1. Fix timbering, steel sheeting, shuttering and sheet piling for the support of
excavation in accordance with BS 6031 taking into account the nature of the
ground to be excavated, the level of water table at the site and the proximity of
buildings and roads.
2. Where the depth of trenches exceeds 1.2m do the following.

a. Batter back the sides of the trenches to a gradient compatible with the angle of
repose of the soil or,
b. Support the sides of the trenches with a system of sheeting and shoring or,
c. Adopt a combination of these.
3. Do not remove temporary works supporting the excavations until in the opinion
of the Engineer the permanent work is sufficiently advanced to permit such
removal. Execute removal of temporary works under the personal supervision
of a competent foreman. Any advice, permission, acceptance or instruction
given by the Engineer relative to such support or its removal will not relieve the
Contractor from his responsibilities under the Contract.
4. Remove all temporary works supporting the trenches during backfilling, unless
previous acceptance has been obtained from the Engineer.
F. Removal of Unsound Foundations and Soft Spots

1. Excavate further on directions from the Engineer if on reaching the specified
levels of trench or structure, the inspected exposed ground, or part of the
ground is considered naturally unstable by the Engineer or became
unacceptable due to exposure to weather conditions or due to flooding or has
become puddled, soft or loose during the progress of work. Backfill the further
excavation with concrete Grade C20 or with such materials as the Engineer may
direct.
2. Remove the backfill over its full depth and for the full width of the pipe trench
shown on the drawings, where a pipe is being laid into a port in an existing
structure manhole chamber or thrust block, and where the backfill material to
the previous excavation beneath the pipe formation is not concrete. Fill the
resulting void with concrete Grade C20 to a level approved by the Engineer.
3. The omission by the Engineer to give an instruction under this Clause will not
relieve the Contractor from any responsibility for defects in the Works due to
the construction being placed upon an unsuitable formation if prior to the
construction of the work the Contractor failed to advise the Engineer in writing.
G. General Trench Excavation

1. Excavate subsoil required by design drawings.
2. Cut trenches sufficiently wide to enable installation and allow inspection. For
flexible pipelines excavate trenches to a width as shown on the drawings
3. Excavate trench to accommodate drain system. Excavations must be made
about the center line of proposed drainage run
4. The trench width is dependent on the nature of the ground, depth, and pipe
size. The clear width of the trench at any level shall be minimum of one pipe
outside diameter, plus 300mm clearance on either side. In all cases the trench
shall be excavated sufficiently wide to ensure efficient laying and jointing of the
pipes.
5. Trench must be big enough to accommodate each of the following:
a. Manhole/catch basin/drainage structure width and depth dimensions.

b. Concrete surround dimensions

6. Trench formation shall be free of stones and other protrusions.
7. If the Contractor excavates below the formation level, he shall restore to the
correct level with Grade C20 concrete.
8. Excavation in rock shall be made to provide a minimum of 150mm clearance on
each side of and below all pipes or fittings. Blasting shall not be carried out in
any part of the WORKS without the permission in writing of the ENGINEER
9. Wherever practical, mechanical excavation methods shall be used, except
where such methods may cause damage to existing structures, services or ruins.
In such locations, the CONTRACTOR shall hand excavate only.
10. The trench formation shall be compacted to obtain minimum 90% compaction
of the relevant maximum dry density of the material in accordance with BS 1377
Part 4. In-situ density tests shall be carried out to BS 1377 Part 9.
11. For the soils considered as unstable the safe width of trench should be
considered based on the repose angle of the soil material and the minimum
working space inside the trench, alternatively the trench wall support systems
should be provided
H. Trench Excavation in Roads

1. Where open excavation is allowed, all trench excavation and other work carried
out within the limits of any existing road, highway or paved parking area shall be
completed as rapidly as possible.
a. Road cutting permit to be obtained prior to commencement of any work.

b. If the roads are capable of carrying two or more lanes of traffic, not more than
half of the width of the carriageway shall be obstructed at any one time.
c. In single carriageway roads, the Contractor shall program his work in such a
manner that minimum inconvenience is caused to those persons who have
reasonable grounds for using the road.
2. Traffic management measures shall be approved by the Engineer.

3. Where trenches are open cut in asphalt or concrete roads, the roads shall be
saw cut along the edges of the trench prior to excavation.
4. Road drains and channels shall be kept free from obstruction at all times.
5. Where trench excavation or any part of the works obstructs any footpath or
right of way, the Contractor shall provide a temporary footpath around the
obstruction to the satisfaction of the Engineer.
PLACING PIPE BEDDING AND SURROUND
A. Granular bedding and surround.

1. Prior to placement of the bedding and surround the trench formation and sides
shall be lined with an approved geotextile filter fabric. The filter fabric shall be
placed completely around the bedding and surround and shall be lapped by a
minimum of 300mm.
2. Width and depth of bedding and surround shall be as detailed on the drawings.
3. Bedding and surround shall be deposited in layers not greater than 150mm
compacted thickness and shall be compacted to obtain minimum 90%

compaction of the relevant maximum dry density of the material in accordance
with BS 1377 Part 4.
4. Prior to pipe laying suitable depressions shall be formed in the pipe bedding to
accommodate the pipe joints.
5. Following pipe laying the depressions for the pipe joints shall be completely
filled and the granular material well compacted under the pipe for the complete
length of the pipe.
6. Particular care shall be taken to avoid any damage to pipe or geotextile filter
fabric.
7. In narrow trenches where the Contractor’s method of working involves the use
of trench sheets or other forms of trench support it is imperative that, unless
the Contractor is instructed to leave them in place and burn or cut off the tops,
the trench supports shall be carefully withdrawn to above the crown of the pipe
as the surround is placed to ensure that voids between the surround and the
trench sides are eliminated.
8. If the Contractor is consistently unable to achieve the required degree of
compaction or proves unable to keep flexible pipe deflection to within specified
limits the Contractor shall change his method of working or use a better class
bedding material.
9. After excavations have been completed to the designated levels and, trench
formation compacted, the Contractor shall issue a formal notice to the Engineer
that the trench formation is ready between designated points for inspection.
The Engineer will without unreasonable delay inspect the said trench formation,
unless he considers it unnecessary and advises the Contractor accordingly. Any
rejection of trench formation will be confirmed in writing by the Engineer.
B. Concrete bedding and surround.

1. Where indicated on the drawings, or ordered by the Engineer, pipe shall be
either provided with concrete Grade C20 bedding or bedding and surround.
2. Pipes shall be supported on precast setting blocks spaced at 2m maximum
centers. The top face of each block shall be covered with a separation layer.
3. Concrete shall not be placed until the joints at each end of the pipe have been
completed.
4. Concrete bedding and surround shall be placed in a sufficient number of lifts in
order to prevent pipes from floating or moving.
5. If the bedding and surround is cast in one operation, measures, which shall be
approved by the Engineer, shall be taken to secure the pipe from floating or
moving.
6. The continuity of the concrete surround shall be broken at each joint, unless
otherwise approved by the Engineer.
7. Discontinuities in the concrete surround shall be formed with fibre board as
shown on the drawings.
8. Where concrete bedding and surround to flexible pipes is to be provided the
distance between pipe joints shall not be greater than 3m.
9. Where concrete bedding and surround to rigid pipes is to be provided the
distance between pipe joints shall not be greater than 8m.
10. When trench support is provided place building paper against the support
before concreting to facilitate withdrawal of the support

STANK
A. Concrete stank shall be formed in the granular surround as follows.

1. Unless noted otherwise concrete stanks shall be provided at a maximum spacing
of 50m with one at each appurtenant structure and at least one located midway
between two adjacent appurtenant structures.
2. Concrete stanks shall be of concrete Grade C20.
3. Stanks shall be installed across the full cross section of the granular surround
and into the trench walls as shown on the drawings and shall be at least 300mm
in length.
BACKFILLING
A. Backfill trenches to contours and elevations with fill materials as specified in this
specification and accepted by the Engineer.
B. In the case of trenches other than in roads and tiled/paved areas backfill the
trench excavation with approved material in layers not exceeding 250mm to
obtain minimum 90% compaction of the relevant maximum dry density of the
material in accordance with BS 1377 Part 9.
C. Backfill trenches in roads and paved/tiled areas, including areas designated as
future roads and paved/tiled areas as directed by the Engineer, in accordance
with the Abu Dhabi Municipality specification for backfilling of trenches and
excavations in asphalt roads, tiled/paved parking areas and sidewalks.
D. Employ a placement method that does not disturb or damage foundation
perimeter drainage and utilities in trench.
E. Maintain optimum moisture content of fill materials to attain required
compaction density.
F. Where concrete slab protection to pipelines is required extend such protection
to a minimum of 200mm onto undisturbed ground on either side of the pipe
trench to the details shown on the drawings. Place a compressible layer of
expanded polystyrene of width equal to the diameter of the pipe directly above
the pipe and immediately below the slab for the full length of the pipe. Take
care that the compressible layer is not disturbed when the slab is placed.
G. Remove surplus fill materials from site.
H. Leave fill material stockpile areas completely free of excess fill materials.
I. The finished level shall be within plus or minus 25mm of the specified level.
J. All trenches shall be marked with a high quality acid and alkali - resistant red
non bio-degradable plastic tape with a minimum width of 150 mm placed during
backfilling 300 mm below finished surface or as directed by the Engineer.
K. All tapes shall be clearly marked in black lettering with “SEWAGE WATER” All
non-ferrous pipelines shall have marker tape with tracer wire.

FILED TESTING
A. In Situ Field Density Tests Shall Be Carried Out to BS 1377 Part 9

1. At least one test shall be conducted for each layer for every 100m of pipe trench
backfilled.
2. At least one test shall be conducted for each layer adjacent to any structure,
chamber and thrust block
B. Dry Density/Moisture Content Relationship Shall Be Determined In Accordance

With BS 1377 PART 4
1. At least one test shall be conducted for every 30 field density tests carried out
or as directed by the Engineer due to changes in soil conditions.
2. Were instructed by the Engineer, arrange for an approved independent testing
laboratory to carry out tests to determine the in-situ density of the backfill
material.
3. If tests indicate work does not meet specified requirements, remove work,
replace and retest to the satisfaction of the Engineer.
COMPLETION OF FINISHED WORK
A. Upon completion of the work of this section, all rubbish debris and excess or
waste material shall be removed from the site.
B. All areas subject to vehicular traffic during construction shall be reinstated to
their original condition.
3.4 PIPE LAYING
STRINGING OF PIPES
A. Pipes shall be distributed to installation site only in such quantities as can be

installed in one working day or as allowed by the Engineer.
B. The Contractor shall take pipes from the storage areas, unload and string along
the route of the proposed pipeline. Pipes shall be so strung as to cause the least
practicable interference with the use of the land.
C. Distribute material on the job no faster than it can be used to good advantage.
Unload pipe, which cannot be physically lifted by workers from the trucks, by a
forklift or other approved means. Do not drop pipe of any size from the bed of
week’s supply of material in advance of laying, unless otherwise approved by
the Engineer.
D. After a pipe has been strung and immediately before being laid, it shall be
cleaned out and inspected for defects. Other pipes shall be visually inspected.
Any defective, damaged or unsound pipe shall be rejected.
PIPE PREPARATION AND HANDLING
A. Inspect all pipe and fittings prior to lowering into trench to ensure no cracked,
broken or otherwise defective materials are being used. Clean ends of pipe
thoroughly. Remove foreign matter and dirt from inside of pipe and keep clean

during and after laying.
B. Pipe and accessories that are chipped, cracked or contain other imperfection or
do not meet the test requirements shall be marked with a permanent marking
as rejected and shall be promptly removed from the Site.
INSPECTION DURING INSTALLATION
A. Pipes and fittings including any sheathing, shall be inspected by the Contractor
immediately before and after installation, and damage or other imperfection
shall be repaired by the Contractor as directed by the Engineer before
installation and in accordance with the following:
1. Without relieving the Contractor of any of his obligations, the Engineer may
inspect and test the pipe and appurtenances by any appropriate means, and
damage discovered by such inspection shall be repaired by the Contractor
2. The Contractor shall remove from Site any pipe or appurtenance which in the
opinion of the Engineer is so damaged as to be unfit for incorporation in the
Works. The obtaining of replacements for damaged pipes and fittings to the
approval of the Engineer shall be an obligation of the Contractor.
LAYING OF FLEXIBLE PIPES
A. General
1. All operations involving the laying, bedding, jointing, backfilling etc. of pipes of
plastic materials shall be strictly in accordance with the manufacturer’s
recommendations subject to the approval of the Engineer.
2. The pipes shall be laid and bedded in granular bedding material except where
concrete bedding or protection is required. The granular material shall extend
from not less than l50 millimeters beneath the pipes to l50 millimeters above
the crown of the pipes or as approved by the Engineer. Subsequent filling of the
pipe trench shall be carried out as detailed in this Section of the Specification.
3. Except as otherwise specified in this Clause, pipe bedding shall conform to the
requirements specified in EARTHWORK sections. The Contractor shall, after
excavating the trench and preparing the proper bedding, furnish all necessary
facilities for properly lowering and placing sections of the pipe in the trench
without damage and shall properly install the pipe.
4. Each pipe shall be carefully lowered onto its prepared bed by means of
appropriate slings and tackle. A recess shall be left in the prepared bed to
permit the sling to be withdrawn. If the prepared bed is damaged, the pipe shall
be raised and the bed made good before pipe laying is continued.
5. No pipe shall be rolled into place for lowering into the trench except over
suitable timber planking free from roughness likely to damage any coatings.
6. The section of pipe shall be fitted together correctly and shall be laid true to line
and grade in accordance with the bench marks established by the Contractor.
The bench marks shall be approved by the Engineer.
7. The full length of the barrel of the pipe shall have a uniform bearing upon the
bedding material and if the pipe has a projecting socket, suitable excavation
shall be made to receive the socket which shall not bear on the subgrade.

8. Pipes shall be laid with the class identification marks or the jointing marks
shown by the manufacturer in the uppermost position. Pipe sections shall be so
laid and fitted together that the pipeline will have a smooth and uniform
interior. The pipeline shall be clean and unobstructed at the time of its
installation and shall be true to the required line and levels.
9. Spigot and socket pipes shall generally be laid upgrade without break from
structure to structure and with the socket end upgrade. Back laying may be
permitted as deemed necessary and approved by the Engineer.
10. Whenever work ceases on any pipeline the unfinished end of the pipeline shall
be securely closed with tight fitting plug or cover.
11. Before any pipe is lowered into place, the bedding shall be prepared and well
compacted so that each length of pipe shall have a firm and uniform bearing
over the entire length of the barrel.
12. Pipes shall be laid in straight lines, both in the horizontal and vertical planes,
between manholes or, where directed in the case of pressure pipelines and
larger diameter sewers to regular curves. The placement of pipes shall comply
with the following requirements:
13. Each pipe shall be plumbed to its correct line and directly and accurately sighted
by means of a laser positioning system or boning rods and sight rails fixed to
secure posts which shall be set up and maintained at each end of the sewer to
be laid and not more than 20 m apart. Sight rails shall be clearly painted in
contrasting colours and be not less than l50 mm deep, straight and level
14. Boning rods shall be of robust construction clearly painted and accurately made
to the various lengths required, the lower end being provided with a flat edged
shoe of sufficient projection to rest on the invert of the pipes as laid. The
boning rod shall be complete with a vertical spirit level
15. Boning rods and sight rails shall not be removed until the pipeline has been
checked and approved by the Engineer
16. Alternative methods of locating and levelling pipelines may be allowed subject
to the approval of the Engineer
17. Any pipe which is not in true alignment, both vertically and horizontally, or
shows any undue settlement after laying, shall be taken up and re-laid correctly
by the Contractor
18. All adjustments in line and grade shall be made by scraping away or filling and
tamping in under the barrel of the pipe and not by wedging or blocking
19. The trench shall be kept completely dry
20. In no case shall pipes be jointed before being lowered into position , The gasket
should be positioned and lubricated
B. Joints
1. Push fit Joints
a. Immediately before assembling each joint incorporating a rubber ring seal, the
rubber shall be inspected for cracks, every part of the ring being deformed by
hand to about l50 mm radius. If under this deformation any cracks are either
revealed or initiated the ring shall be rejected, cut through completely to
prevent inadvertent use, and the matter reported forthwith to the Engineer. If
more than three successive rings inspected in this way are rejected the

Contractor shall on the instruction of the Engineer stop all pipe jointing until the
cause of the defect has been proved and remedied to his satisfaction.
b. The rubber ring shall be placed in the groove on the socket or spigot ring. The
groove shall be free of deleterious material; e.g., dirt, moisture, oil, and grease.
The inside surface of the socket shall be lubricated with a compound
recommended by the manufacturer which will facilitate the telescoping of the
joint. The spigot end of the pipe shall then be inserted into the socket of the
adjoining pipe using a suitable tool to push the spigot into the socket. The
position of the pipe and the gasket in the joint shall then be checked using a
feeler gauge to demonstrate proper jointing. When joints are not properly
made, pipes shall be adjusted, or removed and rejointed as necessary to ensure
proper jointing. Care shall be taken to avoid twisting or cutting the ring when
jointing the pipe.
2. Mechanical Joints
a. Where mechanical joints are approved, installation shall be in accordance with

the manufacturer’s recommendations. The Contractor shall render the end of
each pipe perfectly smooth so as to allow the joint sleeve to slide freely and
where necessary shall coat the pipe ends with two coats of an approved quick
drying sealing and protective compound. Where directed by the Engineer, end
movement of pipes jointed by the coupling shall be restrained by a steel work
harness, which shall be cleaned and painted with two coats of bituminous paint.
Buried joints shall be wrapped using protective tape.
3. Closures and Short Sections
a. For the purpose of reducing the angular deflections at pipe joints, and for
closure sections, the Contractor will be permitted to install pipe sections of less
than standard length. Closing lengths and short sections of pipes of all types
shall be fabricated and installed by the Contractor as found necessary at Site.
Where closing pieces are required, the Contractor shall make all necessary
measurements and shall be responsible for the correctness thereof. The
Contractor shall be responsible for taking the measurements required to
determine the lengths of cut portions of pipes for insertion as closing lengths in
pipelines.
C. Cutting of Pipes
1. Where pipes are required to be cut on the Site the cutting shall be done by the
Contractor in accordance with the manufacturer’s recommendations and in a
manner approved by the Engineer.
2. The pipe and methods of jointing shall be such that the locations of fittings and
lengths of pipe can be adjusted to suit Site conditions.
3. Cutting of reinforced concrete pipes will not be allowed. Special lengths of
pipes shall be manufactured for closures as required. Other pipes such as GRP,
ductile iron and cast iron pipes shall only be cut if approved by the Engineer.
4. The cutting of ductile iron pipes for inserting specials, fittings or closure pieces
shall be carried out as follows:

a. Cutting shall be carried out in a neat and workmanlike manner with an approved
cutting machine without damage to the pipe and so as to leave a smooth end at
right angles to the axis of the pipe
b. Cutting by hacksaw shall not be permitted unless approved by the Engineer.
c. Only experienced men shall be employed by the Contractor on this work
d. The Contractor shall take every precaution to ensure that both the
measurement tolerances and the cutting of pipes are to the accuracy required.
Should any errors occur the Contractor shall correct the defects to the approval
of the Engineer.
LAYING OF UPVC PIPE
A. General
1. All pipe and fittings shall be thoroughly cleaned before laying, shall be kept
clean until they are used in the work, and when laid, shall conform to the lines
and grades required. PVC pipe and fittings shall be installed in accordance with
requirements of the manufacturer except as otherwise provided herein. As
soon as the excavation is complete to normal grade of the bottom of the
trench, sand shall be placed as shown on the drawings, compacted and graded
to provide firm, uniform and continuous support for the pipe. Bell holes shall
be excavated so that only the barrel of the pipe bears upon the bedding. The
pipe shall be laid accurately to the lines and grades indicated on the Drawings.
Blocking under the pipe will not be permitted. Sand shall be placed evenly on
each side of the pipe to mid-diameter and hand tools shall be used to force the
sand bedding material under the haunches of the pipe and into the bell holes to
give firm continuous support for the pipe. Sand shall then be placed to 300
mm above the top of the pipe. The initial 900 mm of backfill above the
bedding material shall be placed in 300 mm layers and carefully compacted.
Generally, the compaction shall be done evenly on each side of the pipe and
compaction equipment shall not be operated directly over the pipe until
sufficient backfill has been placed to ensure that such compaction equipment
will not have a damaging effect on the pipe. Equipment used in compacting the
initial 900mm of backfill shall be approved by the pipe manufacturer's
representative prior to use.
2. All pipes shall be sound and clean before laying. When laying is not in progress,
including lunchtime, the open ends of the pipe shall be closed by watertight
plug or other approved means. Good alignment shall be preserved in laying.
The deflection at joints shall not exceed that recommended by manufacturer.
3. When cutting pipe is required, the cutting shall be done by machine, leaving a
smooth cut at right angles to the axis of the pipe. Cut ends of pipe to be used
with a bell shall be beveled to conform to the manufactured spigot end.
4. The Contractor shall construct anchor and thrust blocks at every bend and
junction on pressure pipelines and where otherwise shown on the Contract
Drawings or instructed by the Engineer. Each thrust block shall to have a
sufficient bearing area and shall be placed to safely transmit thrust to the
surrounding original ground. If soft, spongy, unstable or similar material is
encountered upon which the thrust block is to bear this unsuitable material
shall be removed and replaced with Grade 20 SRC mass concrete as directed by

the Engineer.
5. Thrust blocks shall be in-situ concrete, cast on undisturbed soil, and unless
otherwise designated, shall be constructed of Grade 25 SRC concrete. Thrust
blocks shall be placed between fitting and trench wall or trench bottom, as the
case may be. The bearing faces of the block shall be placed against freshly, cut
and undisturbed. A deboriding sheet shall be fitted around the pipe/fitting. All
concrete shall be kept behind the sockets of fittings. Formwork shall be
constructed wherever necessary to confine the concrete to the prescribed
dimensions for the block. All form lumber shall be removed before testing.
6. No pressure shall be applied to thrust blocks until the concrete has matured for
at least seven days.
B. Jointing PVC Pipe:
1. The joint is engineered to provide problem-free service for the life of the pipe,
but proper procedures must be followed to ensure its effectiveness:
a. Clean the gasket area. Remove sand, dirt, grease, and debris. Do not remove
gaskets from bells, removal could cause improper reinstallation.
b. Check the gasket. Make sure the gasket is seated uniformly in the groove by
running your finger around the inner edge of the gasket.
c. Clean the spigot. Use a rag to wipe the spigot clean.
d. Lower the pipe into the trench. Lower carefully to avoid getting dirt into the
bell or spigot.
e. Lubricate. Apply lubricant to the bevel of the spigot end and approximately
midway back to the stop line. A thin layer of lubricant may be applied to the
face of the gasket, but be careful not to get lubricant behind or under the
gasket.
f. Keep lubricated areas clean. If dirt or sand adhere to lubricated areas, clean
and re-lubricate.
g. Assemble pipe. Insert the spigot end into the bell until it contacts the gasket
uniformly. Straight alignment is essential for ease of assembly. Apply steady
pressure by hand or by mechanical means (bar and block, come along,
hydraulic jack) until the spigot slips through the gasket. Insert the pipe until the
stop line is flush with the bell end. For some job conditions and sizes of pipe,
use of heavy equipment (such as a backhoe bucket) may be necessary for
assembling the pipe. When this equipment is used, extra care must be taken
because the installer loses the “feel” of the assembly. Conditions such as
improper spigot alignment, rolled gaskets, or over insertion (over belling) could
go unnoticed during assembly because of the large force generated by the
equipment.
2. The following precautions should be followed:
a. Position the spigot carefully in the bell to ensure straight alignment both
horizontally and vertically.
b. Exercise caution to prevent damage of the bell lip due to rough contact by the
equipment.
c. Be careful that the action of the equipment does not move the pipe out of

straight alignment.
d. Do not insert the spigot past the stop line. When the equipment has pushed
the spigot far enough to overcome the initial resistance of the gasket, use a bar
and block to finish pushing the pipe to the stop line. This procedure not only
prevents over insertion but also identifies rolled (fish mouthed) gaskets at a
time when they can still be easily corrected.
e. If undue resistance to pipe insertion is encountered or if the pipe cannot be
inserted to the reference mark, disassemble the joint and check the position of
the gasket.
1) If the gasket has been dislodged from the race, inspect the pipe and gasket for
damage, replace damaged items, clean the components, and repeat the
assembly steps, assuring straight alignment.
2) If the gasket is still properly positioned, verify proper positioning of the
reference mark. Relocate the mark if it is not correctly positioned. In general,
fittings allow less pipe insertion than do pipe bells. If the pipe still cannot be
inserted properly, call Supplier for assistance.
f. If the pipe must be field-cut, mark the entire circumference of the pipe to
ensure a square cut. The pipe can be cut with a hacksaw, handsaw, or portable
power saw with a steel blade or abrasive disc.
g. Bevel the cut end using a pipe beveling tool or a portable sander or abrasive
disc. Round off any sharp edges on the leading edge of the bevel with a pocket
knife or a file. Mark cut end with an insertion line similar to uncut pipe.
h. Bevel requirements may vary with different joint types:
1) Joint Bevel
2) PVC pipe Bell Same as factory bevel
3) PVC push-on fitting Same as factory bevel
4) Other pipe bell/push on fitting Shorter bevel length
5) Mechanical joint fitting No bevel
UNDERGROUND WARNING TAPES
A. Warning tapes shall be laid above all utility pipes. Tapes shall be durable and
detectable by electro-magnetic means using low output generator equipment.
They shall remain legible and color fast in all soil conditions at pH values of 2.5
to 11.0 inclusive.
B. Warning tapes shall be placed in compacted backfill material, approximately
300 mm below finish grade and as indicated on drawings.
C. The tapes shall be flexible and subject to the Engineer’s approval. Width of the
tape shall be at least 6” (150 mm).
D. Tapes shall have different colors for different utilities and with black text in
Arabic and English as “CAUTION WATER PRESSURE MAIN BELOW” for water
mains, etc. The text on the tape shall be permanent ink bounded to resist
prolonged chemical attack by corrosive acids and alkaline with message
repeated at a maximum interval of two (2) meters.

E. The tape shall be laid continuous over pipelines and at joints there shall be a
minimum of one (1) meter overlapping. Tape shall be terminated inside valve
boxes to allow clipping of detector equipment to the tape.
F. Warning tape shall not be separately measured or paid for, but shall be
considered as a subsidiary obligation under the respective items included in the
Bill of Quantities.
DEFLECTION CRITERIA FOR FLEXIBLE PIPELINES
A. All flexible pipelines will be subjected to deflection measurements at Site.

Sections of pipe failing to meet the specified deflection criteria shall be
removed from the trench and re-laid provided the pipe is not damaged. This
procedure shall be repeated until the pipeline is found to be satisfactory.
Removal from the trench and relaying shall be an obligation of the Contractor.
lf the permanent set or deflection, after removal, exceeds the limits set out
below, the pipes shall be deemed to be damaged and will therefore be
condemned. Pipes so condemned shall be indelibly marked, removed from the
Site, and replaced by the Contractor.
B. At all times, backfilling shall be carefully carried out to ensure that no voids or
pockets of unconsolidated material are present. The Contractor shall monitor
the vertical deflection of the pipes throughout the backfilling operation. No
pipe shall exhibit more than 1.5 % deflection after placing and compaction of
the granular bed and surround. In addition, after completion of trench
backfilling, the average deflection of a length of pipes shall not exceed 1.5 %,
and every pipe shall be demonstrated to exhibit no more than the
manufacturer’s calculated allowable initial deflection, or 3.5 % deflection,
whichever is the smaller. If any of these values is exceeded, the affected pipes
shall be dismantled and relaid.
C. The deflection shall also be checked on each length between manholes before
commissioning to determine whether longer -term deflections are within the
specified limits. The average deflection of a length of pipes shall not exceed 3
%, and every pipe shall be shown to exhibit a deflection no greater than 5%,
whichever is the smaller, at any point. Pipes exhibiting greater deflections shall
be exhumed and relaid.
D. Pipes exhibiting a deflection greater than 8% or 1.6 times the calculated
allowable long term deflection, shall be exhumed, indelibly marked
“REJECTED”, removed from site and not reused.
TESTING AND INSPECTION
A. General
1. The Contractor shall submit for the Engineer’s approval details of his proposed
methods and program for testing (including details of test equipment) and shall
arrange for all test to be witnessed by the Engineer or other person appointed
by the Engineer. Test equipment shall be approved by the Engineer and
calibration certificates when requested by the Engineer shall be submitted.
The Contractor shall provide all equipment necessary for carrying out testing

and cleaning including pumps, gauges, piped connections, stop ends, and all
other temporary works. All water required for testing and cleaning the
pipelines shall be from a source approved by the Engineer.
2. Pipelines shall be adequately restrained before being put under test except as
hereinafter detailed. No testing will be permitted until seven days after thrust
blocks and other holding down works have been completed. Trenches may not
be left open at joints before testing pipelines except as permitted by the
Engineer who may lay down certain restricting conditions. In addition to any
tests of individual joints or other interim tests which may be designated
elsewhere, the Contractor shall submit all parts of the pipelines to a final test.
3. All pipelines shall be tested between manholes or valve chambers not
exceeding 400 m.
4. On completion of testing the section of pipeline shall be properly sealed to
prevent the intrusion of any extraneous matter, until connected to the pipeline
network. The seal should be fitted with a valued vent to allow equalization of
pressure before removal.
5. All flexible pipelines shall be tested for deflection as per this specification.
B. Inspection of Sewers:
1. Inspect and obtain the Resident Engineer's approval. Thoroughly flush out
before inspection. Lamp test between structures and show full bore indicating
sewer is true to line and grade. Lip at joints on the inside of gravity sewer lines
is not acceptable.
C. Television Inspection:
1. The video inspection shall be conducted and paid for by the contractor. The
Contractor shall video inspect all sections of lines from manhole to manhole or
other structures. Video inspection shall not be done until the pipe is laid and
has passed the required leakage test and deflection test.
2. Preparation for Video Inspection: After cleaning of the line and just prior to
performing the video inspection, water will be introduced in the upstream
manhole until observed at the most downstream manhole to be videoed. This
shall ensure that any area where ponding is possible will be filled with water.
3. Video Camera and Video Tape Equipment:
a. The video cameras and video cassette's recorder shall record VHS format in
color. Lighting and camera quality shall be suitable to allow a clear, in-focus
picture for the entire inside periphery of pipelines. To ensure peak picture
quality throughout all conditions encountered during the survey, a variable
intensity control of the camera lights shall be located at a studio. The replay of
the recorded video information shall be free of electrical interference and shall
provide a clear stable image.
b. The camera monitor shall be located within a studio which will allow seating of
two authorized viewing personnel in addition to the operating technician.
Simultaneously displayed on the monitor as part of the video presentation shall
be a continuous forward readout of the camera distance from the start of each

survey. Prior to the beginning of each video inspection from manhole to
manhole, and as part of the video presentation, manhole identification
numbers will be displayed, and shall become a part of the video cassette
record. These manhole identification numbers shall correspond to the
numbers shown on the plans.
c. The videotaping and monitoring equipment shall have the capability to
instantly review video quality of the video tape production at all times, with
still picture reproduction also available. The video tapes shall be furnished by
the Contractor and shall become the property of the Client.
4. Operations:
a. The operating technician shall have control of the movement of the television
camera at all times. The travel speed of the camera shall be variable but
uniform, and shall not exceed 45 feet per minute while viewing. Any means of
propelling the camera through the sewer lines which would produce
nonuniform or jerky movements will not be acceptable. The television system
shall be capable of doing increments of 900 feet (274 m) with one setup. As
directed by the Engineer, the camera shall be stopped to view and analyze
conditions that appear unusual or uncommon. The operating technicians shall
at all times be able to move the camera through the lines in either direction
without the loss of quality in the video presentation on the monitor.
b. Footage shall appear on the screen as well as the picture of the interior of the
pipe and shall become a part of the video cassette record.
5. Inspection Records:
a. In addition to the video cassette tape, a certified inspection report detailing the
physical condition of each of the sewer mains scheduled for inspection shall be
submitted to the Engineer. Each main shall be reported individually providing
the following information:
1) The log shall contain the project name, inspector's name, date of inspection,
client's name, pipe size, type of pipe, and tape footage reference number.
2) Location of sewer main - the street name where the main is located together
with the upstream and downstream cross streets, where applicable.
3) The direction of flow and the direction of the camera shall be indicated as well
as the section length.
4) Reach shall be defined by the manhole and cleanout numbers and line
designations which appear on the drawings and in the below stated lines to be
cleaned and televised.
5) Defective or abnormal segments of each reach shall be defined by the beginning
and end stations when stationing is used, or footage from the center of the
manhole immediately upstream of any particular reach if reach is defined by
code numbers. The type of defect or abnormality shall be accurately described
indicating the degree of severity using a systematic rating system. Infiltrations,

leaks at joints, ponding, and offset joints shall be identified and located. Depth
of ponding will be recorded in 1/4-inch (6 mm) increments.
6. Acceptance:
a. Any of the following observations shall be considered defects that will require
corrections prior to acceptance.
1) Ponding greater than 10 percent of the nominal pipe inside diameter or over 25
feet in length will be cause for rejection of the pipe segment.
2) Joint separations - over 3/4 inch (18 mm).
3) Offset joints.
4) Chips in pipe ends - none more than 1/4 inch (6 mm) deep;
5) Cracked or damaged pipe or evidence of the presence of an external object
bearing upon the pipe (rocks, roots, etc.).
6) Infiltration.
7) Debris or other foreign objects.
8) Other obvious deficiencies when compared to Approved Plans and
Specifications and Standard Drawings.
b. The Contractor shall be notified in writing of any deficiencies revealed by the

television inspection that will require repair, following which the Contractor
shall excavate and make the necessary repairs and request a television re-
inspection. Television re-inspection shall be at the Contractor's expense.
D. Air Test:
1. The Contractor shall plug all pipe outlets with suitable plugs, and brace each
plug securely where needed
2. Air shall be pumped in slowly to the pipe until a pressure of 100 mm water
gauge is indicated on a manometer connected to the system. After the internal
pressure of 100 mm water gauge is obtained, 5 min shall be allowed for the air
temperature to stabilize within the pipe
3. Air may be added to restore the pressure to 100 mm water gauge. During a
further period of 5 min, the pressure shall not fall below 75 mm water gauge
without further pumping.
E. Water Test:
1. All the joints of the pipeline shall be able to withstand a pressure of a minimum
5 m head of water, above the crown of pipe at the highest point of pipeline
without leakage. A layer of embedding soil equal to the diameter of pipe shall
be laid over the pipe to prevent the lifting of pipe while applying test pressure.
However, all the joints shall be left open for the purpose of inspection for
leakage if any. All branches and open ends shall be closed with stoppers,
secured with longitudinal braces/ thrust block, before testing begins

2. Water shall be filled from the lowest point and air allowed to escape through
an air vent fixed for the purpose at the high points of the pipeline section under
test. The diameter of air vent shall be about one and ha lf times the diameter
of water inlet pipe to allow easy escape of air. No entrapped air shall remain in
the pipeline while testing
3. A pressure of 5 m head of water shall be maintained for one hour to allow
initial absorption of water. After that the test pressure shall be maintained for
15 min and water added shall be measured. If water consumption in 15 min
does not exceed 0.1 l/m 2 of wetted inner pipe surface and if there are no
visible leakage through joints, the pipeline shall be treated as passed.
F. Infiltration Test:
1. The upper ends of the sewer and service connections shall be closed
sufficiently to prevent the entry of water and pumping of groundwater shall be
discontinued until the groundwater surface reaches its natural level before
beginning the infiltration test
2. The dewatering system shall be stopped, but not be removed until the
infiltration test has been successfully completed or as otherwise permitted by
the Engineer
3. The infiltration shall not exceed 6 liters per millimeter diameter per kilo meter
per day of the portion of sewer being tested, including the length of service
connection entering that section
4. The total length tested in one section shall not exceed 400 m in length. This
length is dependent upon the type of deflection measuring equipment
proposed by the Contractor if flexible pipes are used
5. No gravity pipeline will be accepted if the total infiltration exceeds the above
mentioned limit and joints will not be accepted if during an internal inspection,
any infiltration is visible.
3.5 DRAINAGE STRUCTURE
GENERAL
A. Manholes shall be installed in places indicated on drawings and at every change

in diameter, horizontal and/or vertical alignment, at the maximum spacing for
maintenance requirements as per Egyptian Code of Practice and as indicated in
the drawings.
B. Inspection chamber shall be placed in locations indicated on drawings at the
each building drainage outlets.
C. Drainage chamber shall be placed in locations indicated on drawings at the each
building roof outlets.
D. Slow Down Chamber shall be placed in locations indicated on drawings at each
building pressure line outlet
E. Prior to construction activities, detailed shop drawings shall be submitted by the
contractor for engineer approval

SPECIALISTS, INSPECTION AND TESTING:
A. The Employer may employ the services of a specialist firm to assist the Engineer
as he may require in any matter concerning Drainage Structure including the
inspection of materials and workmanship and the witnessing of tests at any
stage during the execution and maintenance of the Works.
B. Such independent tests may be carried out at any stage during the execution
and maintenance of the Works, but they shall not relieve the Contractor of his
obligations under the Contract.
C. To the extent ordered by the Engineer, the Contractor shall provide labour,
plant, tools and materials (but not special testing equipment) for direct
assistance to the specialist firm in their inspection and independent testing and
for any further work, investigations, and repairs which the Engineer considers
necessary as a result of such inspection or testing.
D. The provision of labour, plant and materials as aforesaid shall be an obligation
of the Contractor where in the Engineer’s opinion the inspection test or further
investigation shows that materials and workmanship provided by the Contractor
do not comply with the designated requirements.
EXCAVATION & BEDDING PREPARATION
A. Shop Drawing: Proposed Location for Chambers will be surveyed based on

approved drawings.
B. Setting Out: Setting out of manhole shall be done as per the approved shop
drawings, excavation will be carried out along with the pipeline trenches.
C. Dewatering: Depending on the location of drainage chambers and ground water
presence, dewatering is required, shall be carried out as per approved
contractor method statement. All drainage chambers installation work shall be
carried out in the dry.
D. Prior starting the work the contractor shall review all proposed drainage
structure installation locations on the project with the design engineer and
identify any potential conflicts or reasons for movement of the drainage
structure to a more appropriate location. If a conflict is identified onsite prior to
excavation or while performing layout, the engineer shall be notified
immediately to propose alternative location
E. Shoring if utilized for construction shall be in accordance with all national, and
local regulations.
F. If shoring is to be removed it shall be done in accordance with the shoring
manufacturer’s recommendations or approved safe construction practices. The
contractor shall use the appropriate lifting equipment to safely remove the
shoring and to prevent any disturbance or damage to the drainage structure.
G. Voids in the side fill that are created by movement of the shoring shall be filled
and compacted in accordance with national and local regulations.
H. The foundation shall be moderately firm to hard in situ material, stabilized soil,

or compacted fill material with adequate bearing capacity to support the
manhole structure as specified by the engineer or project requirements.
I. When unsuitable or unstable material is encountered, the foundation shall be
stabilized or removed and replaced with firm and stable foundation material
with adequate bearing capacity to support the manhole structure.
J. A minimum 3 inches [75 mm] thick leveling course in an area not less than
manhole base area but preferably 6 inches [150mm] of approved bedding
material compacted to 90% proctor in an area not less than the base area but
preferably 6 inches beyond the outside radius of the manhole base. e. The
nominal maximum aggregate size within the leveling course shall not be greater
than 1 inch.
K. Drainage Structure sections installed over an unyielding foundation, including
concrete, shall be cushioned so as to prevent non-uniform bearing.
L. The soil levelling area under the drainage structure shall be of uniform stiffness
and thickness to the project specifications with even compaction throughout.
Local ground conditions may require additional leveling course thickness per
project specifications, the engineer’s recommendations, or the installers
judgment.
M. The soil foundation area or bedding under incoming and outgoing pipes should
be treated the same as the drainage structure base section to prevent
settlement or shearing of pipes and to provide proper alignment for the
watertight connector/pipe interface if resilient rubber connectors are being
used.
DRAINAGE STRUCTURE
CAST IN SITU
A. Manholes, chambers and drainage structure shall be cast-in-situ reinforced

concrete / or plain concrete of dimensions and depths as indicated on Drawings,
complying with the Egyptian Code if not shown.
B. Construct plain concrete conforming to Section “Cast-in-Place Concrete" and
reinforced concrete conforming to Section “Concrete and Reinforced Concrete
C. Mechanical vibrators shall be used for the compaction of all concrete used to
construct manholes.
D. After obtaining approval from the Engineer for the formation, blinding concrete
shall be laid to a minimum of 75 mm. The ‘torch-applied’ Water-proofing
Membrane (5mm) will be placed in accordance with the manufacturer’s
instructions. The membrane will be protected with 50 mm screed.
E. All drainage structures shall have Plain / or reinforced-concrete bases as
detailed on the drawings. Drainage structure bases for pipe less than 600 mm
may be precast or cast in place at the Contractor's option and as approved by
the Engineer. For precast reinforced-concrete manhole/chamber bases,
openings for pipes shall be cast in the base at the required location during its
manufacture. Field cut openings will not be permitted. All other drainage

structure bases shall be cast in place as indicated on the drawings. The Engineer
shall inspect all formworks, reinforcement and water bar in wall kicker before
placing the concrete. Shuttering will be removed after concrete has gained
sufficient strength to carry its own weight and imposed loads. Curing of
concrete will start after initial setting of concrete.
F. All drainage structures shall have Plain / or reinforced-concrete walls as detailed
on the drawings. Construction of wall will be done to the entire height of the
wall in a single pour. Internal & external shutter work will be carried out and
proper support will be given to the shutter to avoid any deformation. Formwork
material to give a fair faced finish. Shuttering will be removed after concrete has
gained sufficient strength to carry its own weight and imposed loads. Curing of
concrete will start after initial setting of concrete.
G. The concrete cover slab will be constructed separately with respect to road
levels. Drainage Chambers cover slabs shall be cast in place reinforced concrete
as marked on the drawings. Reinforced concrete cover slab shall be seated on
the walls using sand/ cement mortar. The joint shall be raked out 15 mm deep
on the inside face and pointed with an approved pitch extended polyurethane
sealant.
H. Manhole and junction chamber bases (all types) shall have benches and shall be
carefully formed to shapes and drops as indicated on the drawings. The
benching’s shall be sloped towards the channel at a gradient of 1 in 10 or as
otherwise detailed on the Drawings.
I. All construction joints to manholes, chambers and special structures shall be
perfectly watertight. Water stop across joints in structures as specified shall be
provided where detailed in the drawings or as directed. Joints shall be fully
scrabbled.
J. All manholes shall be watertight on completion and where leakage is discovered
the Contractor shall perform such work and provide all materials as are
necessary to render such faulty work watertight. The Contractor is warned that
he should expect rubbish and debris to be deposited in the manholes during the
course of construction and he should take the necessary measures to ensure
that the manholes clean.
K. The internal surfaces shall be protected in accordance with Corrosion Protection
and Odor Control Section either GRP, and PVC lining / or with a brush-applied
bituminous emulsion as indicated in the drawing. Lining shall incorporate lugs
molded onto the outside face at 500 mm centers to allow bonding to the
concrete surround. The lining shall have adequate strength to withstand
handling, and shall not buckle or distort during pouring of the concrete
surround. Internal bracing may be used during pouring of the concrete
surround. Internal bracing may be used during pouring to maintain circularity
and verticality.
L. The external (buried) surfaces shall be protected in accordance with Corrosion
Protection and Odor Control Section either with water-proof membrane with
protection board or with a brush-applied bituminous emulsion as indicated in
the drawing.

M. The ductile iron frames, grates and covers shall be to the BS EN 124 standard
frame, solid / or grate covers as indicated on the drawings. The ductile iron
frames and covers for drainage chambers shall be brought to grade by the
number of courses of concrete blocks shown on the drawings or as instructed by
the Engineer and a reinforced concrete frame into which the ductile iron frame
is embedded.
N. Covers in paved areas shall be set accurately on a course of concrete blockwork
to the level and slopes of the surrounding surface. The blockwork, cover and
frame shall have a bed of 15mm thick cement mortar and shall be surrounded
by concrete Grade C20 up to the underside of the base course of the paved area
and to the extent indicated on the drawings.
O. Covers in unpaved areas shall be set accurately on a course of concrete
blockwork. The blockwork, cover and frame shall have a bed of 15mm thick
cement mortar and shall be surrounded by concrete Grade C20 to 100mm
above the level of the surrounding surfaces and to the extent indicated on the
drawings or as instructed by the Engineer.
P. Pipes entering and leaving manholes, chambers and special structures shall be
laid soffit to soffit unless otherwise shown on the drawings.
Q. Use epoxy compound as interface between concrete and piping materials.
R. Compact backfill adjacent to concrete walls with hand-operated Dampers or
other equipment that will not damage manholes.
S. Unless otherwise indicated on Drawings, two pipe spigots and socket and one
double spigot on downstream rocker pipe connections shall be provided for
each pipe connected to the manhole or chambers.
AUXILIARY’S COMPONENTS
A. Reliner Inside DROP SYSTEM

1. Unless otherwise indicated on Drawings, each pressure line entering the
manhole shall be equipped with RELINER INSIDE DROP SYSTEM which is plastic
composite collection device that facilitates the controlled drop of effluent into
the main stream flow of a sanitary manhole as follow: -
a. Select Drop Bowl of size appropriate to flow rate and pipe diameter, a pipe
downsize is possible in most applications.
b. Trim incoming pipe so that only 2" maximum protrudes into manhole, for
improved flow control, cut a "V" shaped notch at bottom edge of incoming pipe.
c. Center Drop Bowl directly under incoming pipe, allow approximately 1"
clearance between pipe and bowl.
d. Attach Drop Bowl to manhole wall with 3/8" diameter stainless steel anchors
(between 4 & 6 expansion anchors) / or (3” Wedge Anchors) according to
manufacture installation instruction.
e. Cut and mount PVC drop pipe of diameter appropriate to Drop Bowl size and
flow, using RELINER adjustable stainless steel clamping brackets. Use a
minimum of 2 brackets with a maximum spacing of 4 feet (RELINER clamping
brackets will adjust to allow drop pipe to maintain correct stand off from wall).

f. Connection from Drop Bowl to drop pipe shall be by flexible external pipe
connector
g. Install appropriate pipe elbow to provide smooth transition into channel flow.
(recommend a 45-degree elbow.)
B. Removable Snout Oil – water Debris

1. Unless otherwise indicated on Drawings, each catch basin, drainage chamber,
and sedimentation chamber pipe outlet shall be equipped with Removable
Snout Oil – water Debris Separator, as follows: -
a. Select the SNOUT Oil-Water-Debris Separator of size and configuration to fit

application. (SNOUTS will fit over a pipe with an outside pipe diameter)
b. Center the SNOUT directly over the exit pipe so that the entire pipe is covered
and so that the lower edge of the hood is at least 1/2 the pipe diameter below
the lowest inside point of the pipe (deeper is even better.)
c. Drill equally spaced holes through the SNOUT flange. (*Number of holes will
vary depending on the type used.)
d. Mark and drill catch basin and install the tamp-in lead anchors.
1) Drill a hole into the base material to the required depth

2) Blow the hole clean of dust and other material.
3) Insert the anchor into the hole. Narrow end of cone must point out, lead shield
slides over cone.
4) Position the setting tool or a socket against the anchor outer cone. (The outer
rim of the tool or socket should seat onto the lead shield rim.) Set the anchor by
driving the lead sleeve over the cone using several sharp hammer blows. Be
sure the anchor is at the required embedment depth (flush or slightly below
face of concrete)
e. Attach the vent pipe adapter in the pre-drilled hole in the top of the SNOUT
using the 2 flat O-ring gaskets and PVC lock-nut supplied in the kit. Install with
female slip adapter up and a washer on each side of the SNOUT shell. Tighten
lock-nut hand tight.
f. Remove backing and with firm pressure, attach gasket strip(s) to back of flange
and trim excess.
g. Attach the SNOUT to the catch basin wall with 3/8" diameter stainless steel
bolts in lead expansion anchors. Do not over tighten; 10-15 foot-pounds should
be sufficient.
h. Cut the anti-siphon vent stack to length and attach to hood at slip adapter with
PVC cement.
i. Attach 90 degree fitting to vent stack with PVC cement. Ensure that fitting
opening is accessible for maintenance and inspection.
BUILDING IN PIPES TO STRUCTURES:
A. Pipes constructed into a concrete wall or structure shall be protected with a

concrete surround integral with the external face of the structure as shown on

the Drawings.
B. All internal and external protection membranes to the concrete shall be sealed
around the pipe openings as recommended by the Engineer. When the pipe is
later fixed, the remaining hole shall be re-formed and filled with non-shrink
grout.
C. Any over-excavation adjacent to a structure or beneath the formation level of a
pipeline, either to be constructed under the Contract or in a future contract,
shall be backfilled with Grade 20 SRC concrete.
D. Pipes and pipe specials through concrete walls and floors shall as far as possible
be positioned and built in during construction. They shall be located exactly in
the positions shown in the Contract Drawings and shall be true to line and level.
The Contractor shall take particular care to ensure that fully compacted
concrete is in contact with the pipe at all points.
E. Where it is impracticable to cast pipes and specials in the concrete, form box
holes in the shuttering. Form boxes of six or eight sides, depending on the pipe
diameter. Form boxes no larger in size than will give adequate clearance for the
subsequent positioning and grouting in of the pipe. Provide the sides of the box
holes with a tapered central annular recess to provide a positive key. Provide
the box holes with a grout hole and, at the top of the central annular recesses
with vent holes. Strip the box holes from the main shuttering and thoroughly
clean and roughen the concrete surface.
F. When the pipe or special to be installed is cast in, a suitable bonding agent and
non-shrink grout shall be used.
G. Unless otherwise shown on the drawings, protect the pipes passing through a
concrete wall or structure with a surround of concrete Grade C20 integral with
the external faces of the structure.
1. For pipes of less than 500mm diameter, extend the surround from the wall or
structure by 300mm, and extend the width and depth of the surround beyond
the outside face of the pipe at its horizontal and vertical diameters by a
minimum of 300mm or as otherwise indicated on the drawings.
2. For pipes of 500mm diameter or greater, extend the surround from the wall or
structure by 500mm, and extend the width and depth of the surround beyond
the outside face of the pipe at its horizontal and vertical diameters by 500mm
or as otherwise indicated on the drawings.
FLOW CHANNELS AND BENCH WALLS
A. Benching and channels shall be made to conform accurately to the pipe grades
and openings, and shall be brought together smoothly and in alignment with the
pipe at the ends of curved benching’s, with well-rounded junctions, thoroughly
clean the walls and base slab and apply a bonding agent prior to pouring
concrete of benching. Main drain channel shall be formed of Class C 30
reinforced concrete benching at inverts designated on Drawings at bottom of
manholes. Top surface of benching shall get 12 mm thick corrosion resistant
screed with non-skid finish and shall be given steep slopes towards the drain
channel. Remove all sharp edges or rough sections, which tend to obstruct flow

satisfactory to the Engineer, and in compliance with details shown on the
Drawings and as per the approved shop drawings for each manhole.
B. The bench should provide good footing for a worker and a place where tools
and equipment can be laid and must have adequate slope to drain.
1. The bench to have a minimum of 12-inch on each side of the channel. If the
width of the bench is not adequate, increase the diameter of the manhole.
2. Where space permits, the sewer can be offset to provide a wider bench on the
side of the manhole that the steps are located on.
3. In cases when the manhole is existing and the design requires the channel to be
increased, provide details on the drawings showing design of the modified
channel
C. Top of Bench Elevation.
1. When both the incoming and outgoing pipes are the same diameter, set the top
of bench at same as the top of pipe.
2. When the incoming and outgoing pipes have different diameters, set the top of
bench at the top of pipe elevation of the highest pipe within the manhole,
except when a manhole drop connection is designed. When a Sewer Service
(House) Connection SHC entering the manhole is significantly higher than the
mainline sewer, the bench on the side where the SHC enters may be elevated,
and the bench on the opposite side may match the top of the mainline sewer
for more convenient access.
3. If the HGL in the manhole is higher than the top of pipe within the manhole, set
the top of the bench at an elevation of 3-inch above the HGL.
4. If the top of bench needs to be higher than the incoming or outgoing pipes, the
top of bench elevation must be shown at the manhole on the profile.
D. Construct in conformance with standard drawings

E. The Contractor has the option to pour the flow channels or to have them
precast by the manhole manufacturer.
DROP MANHOLES
A. The backdrop lower connection to manhole shall be fixed and cast along with
the manhole base.
B. While casting manhole shaft, a plywood box frame shall be fixed at the
backdrop upper connection level.
C. Backdrop construction shall start after finishing shaft construction; as per the
following steps:
D. An opening in the shaft liner, with a size as per backdrop pipe size shall be
prepared at the backdrop higher connection point.
E. The backdrop pipe shall be fixed and connected, by lamination.
F. Due to practicality, back drop concrete is done after shaft.
G. Shutter shall be fixed around the pipe as per the required size and concrete will

be poured.
H. Precast base should include a 90-degree bend precasted into the base section
and protect the vertical pipe with precast Drop Collars.
I. Inside drop piping to be secured by expansion bolts and stainless steel bands.
DRAINAGE CHAMBER COVERS AND FRAMES
A. General
1. Chamber covers shall be ductile iron and comply with EN 124. Production
facilities shall be quality assessed in accordance with ISO 9000 or EN 29002 BS
5750).
2. The Contractor shall supply one pair of manhole keys or prying and lifting bar, as
appropriate with each 30 covers provided with a minimum of one tool for each
type cover. Keys and prying and lifting bars shall be of approved appropriate
design to match the different cover configurations. Keyways in chamber covers
shall be of the closed type.
3. Install frames and covers on top of drainage structure to positively prevent all
infiltration of surface or ground water into manholes. Frames shall be set in a
bed of mortar with the mortar carried over the flange of the ring. Set frames so
tops of covers are flush with surface of adjoining finish pavement surface.
Elsewhere set 50 mm above ground surface, unless otherwise shown or
directed.
4. The covers in paved areas shall be accurately set on precast concrete brickwork
to the level and slopes of the roads or pavements, to adjust cover level as
required.
5. The covers in landscape area areas shall be accurately set on precast concrete
brickwork to the level above the landscape by at least 100 mm above the
landscape level.
B. Installation
1. Ensure the Clear Area of the access cover or gully grating frame component is
the same or larger than the chamber top opening but does not result in any
cover or grating support ribs fouling on the chamber top. An exception may be
made when;
j. Proprietary Packing Pieces can be stacked to form a suitable Clear Area opening
within the overall depth available and/or
k. where the product’s cover-to-frame seating positions are located well-away
from the frame Clear Area opening and sit over the intended chamber wall, slab
or proprietary Packing arrangement.
2. Where available, ensure an area 50mm (min) greater than the frame size around
the chamber top opening is clean, dry and clear of any loose debris, but not
smooth, if this area is not already of sufficient surface texture to mechanically
‘key’ with the foundation mortar; abrade the surface locally, to achieve this aim.

3. install any necessary proprietary Packing Pieces to fill the majority of the
underlying frame void, interleaving each Packing Piece with bedding mortar to
ensure a robust, void-less construction.
4. During frame placement, ensure that the frame Clear Area is centralized over
the chamber opening.
5. Tamp the frame into the underlying mortar to align the top edge of the frame
level (within +5/-5mm) with the expected finished F.F.L., wearing course or
pavement surface.
6. Add additional bedding mortar on top of the frame flange in order to completely
envelope it to a minimum depth of 15mm, ensuring that this layer of mortar
completely merges with the mortar extruded around and through the frame
flange and any apertures.
7. This additional layer of bedding mortar should not be troweled smooth so that it
will mechanically key to subsequent road-fill materials.
8. Before the remaining road-fill materials are applied, heavily-coat the outside
exposed vertical face of the frame with a proprietary Cold Joint Sealer
9. Install the remaining road-fill and wearing course/pavement materials around
the frame taking care not to disturb the frame, particularly where mechanical
equipment is employed.
10. Apply a joint sealer to the joint between the frame and surrounding wearing
course/pavement, taking care not to contaminate the cover or its frame
seating’s.
11. Ensure that trafficking of the finished installation does not occur before the
bedding mortar and surrounding surfacing materials have fully cured
DRAINAGE CHAMBERS STEPS
A. Steps shall be cast into the walls of base, risers and conical top sections, and
shall be aligned vertically and spaced so as to be on equal centers in the
assembled manhole at a maximum distance apart of 12 inches (305 mm). Steps
shall be located a minimum of 6 inches (152 mm) from the ends of base, riser,
and top sections, and shall be securely embedded in manhole sections by
mortar or cast in place polypropylene inserts.
BACKFILLING
A. Excavations shall be backfilled with an approved or specified soil material free

from large stones, rocks, pavement, and other items that could damage the
installed manhole structure. Expansive soil material shall not be used as backfill
around the structure.
B. If required by site specifications, when drainage structure is placed in an

unpaved area, slope the area around the entrance frame and cover to provide
drainage away from the entrance cover. Slope the final grading upward to
within 1 inch (25 mm) of the top surface of the frame and cover.
C. Backfill Procedure, Backfilling shall be achieved by using lifts (layers) and
compactive effort or flooding (jetting) the excavation to meet the required soil

density requirements. Backfill shall be placed around all sides of the installed
section in lifts that shall provide adequate densification and not induce a lateral
load shifting the drainage structure sections. If required by project specification,
backfill lifts shall be placed uniformly around all sides of the installed section in
lift thickness and with compaction to densities specified, generally Filling
material to excavations shall be deposited in layers not exceeding 250 mm
unconsolidated thicknesses and compacted to 95% modified proctor.
D. The contractor is to provide special care and placement of bedding and backfill
material under and surrounding pipe connections to drainage structure to
provide firm, uniform support of the pipe at these junctions. This compactive
effort is to reduce the potential of pipe shear at the manhole interface due to
differential settlement of the surrounding soil.
E. Restoration of the area where the circular manhole structure was installed shall
meet the requirements of the project requirements or the engineer.
F. Follow-up inspections for settlement are required. Should settlement occur, the
contractor shall be responsible for the necessary repair to restore the area to its
original condition in accordance with the terms of the project requirements. If
settlement is observed at the surface level, pipe connections should be
inspected to ensure soundness.
ACCEPTANCE FOR DRAINAGE STRUCTURES
A. Visual Inspection
1. All work constructed will be subject to visual inspection for faults, defects, or
deviations from the Plans and any such deviation or omission will be corrected
at once. All tests will be made by the Contractor who will provide necessary
equipment for testing and lamping the manhole or structure in the presence of
and under the supervision and instructions of the Engineer. Lamp tests will be
observed first hand by the Engineer. All defects found will be corrected before
conducting leakage tests. Repair methods must be approved by the Engineer.
B. Leakage Testing
1. Temporary Plugs: Temporary plugs for testing shall consist of a watertight plug
and timber bulkhead or may be a steel plug at the contractor option.
Temporary plugs shall be removable without damage to pipe stub outs and shall
be capable of withstanding all internal pressures, external loads and external
pressures without leakage.
2. All drainage structure shall be visually inspected for leakage during hydrostatic
tests and before the backfilling of the chamber is complete. Any leakage of
water through the drainage structure walls or joints shall be caused for the
chamber to be rejected and replaced or repaired to the Engineer’s satisfaction.
3. To test the drainage structure hydrostatically the Contractor shall fill the
chamber with water after plugging, to the bottom of the frame.
4. After 6 hours the water shall be again brought to the bottom of the frame. The
quantity of refilled water shall be measured and considered to be the leakage.

5. The permissible leakage rate shall not exceed 1 liter/per hour/meter of chamber
depth.
C. Vacuum Testing:
1. All drainage structure shall be subjected to a vacuum test. The Contractor will
furnish all necessary equipment and labor needed for conducting the tests.
2. The Contractor shall have the option to test drainage structure prior to
backfilling. Preparation and testing of manholes shall be as follows:
a. All mortar joints shall be adequately cured;

b. Pipes entering and leaving the drainage structure shall be plugged;
c. Draw a vacuum of 10 inches of HG (Mercury).
d. The test shall pass if the vacuum drops to no less than 9 inches HG in 1 minute.
1. If the manhole fails the test, the Contractor shall locate the leak(s), make proper
repairs, and then re-test until a successful test is obtained.


ISSUED FOR
PURCHASE
CONSTRUCTION

NO. BY BY BY
0 March 2022 M.S. 6 ISSUED FOR TENDER
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP S.A. OVERHEAD TRAVELING CRANE SYSTEM
CAIRO - EGYPT 412215.10 - 2874 0

CONTENTS
SECTION 412215.10
OVERHEAD TRAVELING CRANE SYSTEM
Page
PART 1 GENERAL 2
1.2 Summary 2
1.4 Submittals 2
1.6 Coordination 3
1.7 Warranty 3
PART 2 PRODUCTS 3
2.1 General 3
2.2 Constituents Of The Overhead Crane 4
2.3 Materials 5
2.4 Technical Specification 5
PART 3 EXECUTION 5
3.1 Installation 5
3.3 Unauthorized Use By Contractor 6
Overhead Traveling Crane System Section 412215.10

SECTION 412215.10 - OVERHEAD TRAVELING CRANE SYSTEM
PART 1 GENERAL
A Drawings and general provisions of the contract, including General Conditions,

Conditions of Particular Application and Division1 Specification Sections, apply to
1.2 SUMMARY
A This section covers the specifications for Overhead Traveling Crane’s.
A Reference Standards: All materials used in the work shall be performed in strict
accordance with specifications, drawings and the general equipment stipulations of
the international standards as noted herein below:
Crane Manufacturer's Association of America

CMAA No.
70 Specification of Electric Overhead Traveling Cranes

ANSI
ANSI MH27.1 Specifications of Underhung Cranes and Monorail System
ANSI B30 American National Standards Institute
Hoist Manufacturer Institute HMI No.
100 Specifications of Electric Wire Rope Hoists
NFPA
National Fire Protection Association Standards NFPA 70
1.4 SUBMITTALS
A Product Data: Submit product data for the crane unit, sizes, performances,
operations, safety features, controls, finishes and similar information according to
indicated capacity. Indicate any variations from specified requirements.
B Shop Drawings: Submit shop drawings including dimensioned drawings for the
cranes, showing plans, elevations, sections and large-scale details indicating
fabricated steel girders coordination with building structure and relationship with
other constructions, activities, indicate any variations from specified requirements

plus maximum dynamic and static loads imposed on structure at points of support.
Indicate access for hoistways.
C Maintenance Manuals: Provide manual with operating and maintenance

instructions, spare parts listing, with sources indicated, recommended parts
inventory listing, emergency instructions and similar information.
A Provide certification that manufacturer and installer are regularly engaged in the
production and erection of components and equipment of this type and whose
equipment have been satisfactorily used in similar service for not less than 5 years.
1.6 COORDINATION
A Contractor shall furnish inserts and anchorages which must be built into other work
for installation of Overhead Traveling Crane’s and related work; coordinate delivery
with other work to avoid delay.
B All equipment and accessories furnished and installed under this section shall be
fabricated, assembled, erected and placed in proper operating condition in full
conformity with drawings, specifications, instructions and recommendations of the
equipment manufacturer.
1.7 WARRANTY
A Provide project warranty, agreeing to replace, repair or restore defective materials

and workmanship of monorail crane work during warranty period.
PART 2 PRODUCTS
2.1 GENERAL
A Provide motorized operated hoist and trolley and carriage for provided cranes.
B Ball or roller bearings shall be employed, and the load hook shall revolve on a ball
swivel. A load chain collection box shall be incorporated on the crane.
C A reliable breaking and locking arrangement shall be incorporated.
D The hoisting gear shall be such that one man is capable of easily raising the
maximum load. There shall be included for each item of lifting equipment:
1. 1 No. Double leg chain sling

2. 1 No. Double ended rope sling

E In addition to any special spacer that may be required to lift any of the equipment in
each location.
F Complete operating and installation include hoist and trolley, carriage fasteners,
inserts, ropes, end stop, cable and track.
2.2 CONSTITUENTS OF THE OVERHEAD CRANE
A The cranes shall consist but not limited to the following:
B Bridge Crane: double beam bridge crane assembly including bridge girder beams,
track and trolley for hoist support.
1. The bridge shall be double I-beam section or flat flanged type rigidly fixed.
The bridge shall be constructed to accommodate a top running or underhung
hoist and trolley.
C Track: Includes but not limited to rails, inserts, end stops fastenings, etc., required
for construction of the track.
1. Steel design and fabrication shall comply with applicable portions of the
specifications of the American Institute of Steel Construction. Loadings,
impact allowances, and allowable stresses shall be in accordance with the
governing standards. Deflection of the main girder shall not exceed 1/800 of
the span with the maximum load at any point.
D Wheels: Trolley wheels for I-beam section shall be made of rolled, forged, or cast
steel. Trolley side plates shall be cut from hot rolled steel plate and extend past the
wheels to provide bumper protection on all four wheels trolley. Axles shall be
heated treated alloy steel rigidly supported in the trolley side plates. Wheel bearings
shall be permanently shielded, lifetime-lubricated ball or tapered roller type,
antifriction type, adequate for radial and end thrust landing.
E The load chain anchorage associated fittings and framework at the slack end shall be
at least equal in strength to 2.5 times the maximum tension in the load chain when
the working load limit is being lifted. Any links used for connecting the load chain to
a terminal fitting shall be of the material specified for the chain and heat treated to
provide mechanical properties and strength equivalent to those of the load chain.
The hook shall be made from high grade forged steel and provided with a safety
latch. The safe working load shall be marked on the hook in kilograms.
F Longitudinal motions shall be provided on the crane and shall be such that operation
is speedy without impairing safety in working. They shall be operated by means of
hand chains which shall extend to within 600 mm of the operating floor. The
hoisting and lowering chains shall be of the same length. The hook and load chain
shall be such that the hook shall reach to the lowest floor or duct level.
G An extending, portable aluminum ladder shall be provided for access to the crane for
maintenance, etc..

H The crane shall bear a permanent inscription readily legible from floor level stating
the safe working load expressed in kilograms. The crane shall also bear the
manufacturer’s name, serial number and year of manufacture.
I Bumpers and Stops: Bumpers and stops for the trolley shall meet the requirements
of the governing standards.
2.3 MATERIALS
A Trolley Materials:
1. Frame Steel; rigid construction.

2. Wheels Rolled, forged, or cast steel with hardened treads.
3. Wheel Axles High carbon steel or heated treated alloy steel; fixed type.
4. Bearings Permanently shielded, lifetime lubricated ball, antifriction
5. Trolley Drive Sealed worm of spur gear unit; permanently lubricated with an
oil bath.
6. Gear Machined from machine steel or drop forging, and full depth gear teeth.
7. Drum Steel, machined groover to 50% of the rope diameter.
8. Brakes Dual braking system: disc motor brake and a mechanical load brake.
B Hoist Material: Hoist materials shall be as follows:
1. Bearings Antifriction type; oil lubrication or lifetime grease packing.

2. Gearing Spur or helical type; fully enclosed in oil tight housing.
3. Wire Rope As recommended by rope manufacturer for specified drum.
4. Lower Block Safety type fully enclosed with guarded sheaves.
5. Lifting Hook Forged steel, slow opening, fracturing, with safety latch
2.4 TECHNICAL SPECIFICATION
A Overhead Bridges Crane:
1. Hoist capacity (kg), span, hook lifting range as per indicated in drawings.
PART 3 EXECUTION
3.1 INSTALLATION
A Equipment and accessories installed under this section shall be assembled, erected,
and placed in proper operating condition in full conformity with drawings,
specifications, engineering data, instructions, and recommendations of the
equipment manufacturer unless exceptions are noted by the Engineer.
B Beam Hoist: The beam and trolley and hoist shall be erected by workmen regularly
engaged in crane erecting and acceptable to the crane manufacturer. The
orientation of installation of the hoist and trolley on the beam shall be as directed by
the Engineer.

C Bumpers and Stops: Bumpers and stops shall be installed on the bridge, trolley, and
located so that no part of the bridge or trolley approaches on clearances specified or
indicated on the shop drawings.
A Installation Check: Overhead Travelling Crane, installation shall be inspected and

checked by an experienced and competent technical representative of the
equipment manufacturer.
B The Contractor shall make all adjustments to the equipment as directed by the
technical representative.
C Operational Tests: After installation the Contractor shall conduct operational tests as
required to demonstrate that the crane shall operate in accordance with the
requirements of these specifications.
D Prior to acceptance of the crane, the Contractor shall clean and lubricate the
equipment and make all final adjustments necessary to ensure operation
satisfactory.
3.3 UNAUTHORIZED USE BY CONTRACTOR
A Contractor shall not use the Crane provided to install other equipment in the
performance of his work under this contract.
END OF SECTION 412215.10


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TECHNICAL SPECIFICATION COVER SHEET REVISED SHEETS

THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS BUT

ECG Form No. E409 Rev. 5/03 Sheet 0 of 5

METHOD OF MEASUREMENT, BILL OF QUANTITIES & LIST OF MANUFACTURERS

000010 Table of Contents

DIVISION 1: GENERAL REQUIREMENTS

012700 Method of Measurement

TECHNICAL SPECIFICATIONS – PART A

033000 Cast In Place Concrete

042000 Unit Masonry

051200 Structural Steel

Divisions 06 Wood, Plastics, and Composites

064200 Wood Paneling

Table of Contents Section 000010

071113 Bituminous Damp-Proofing

081113 Hollow Metal Doors and Frames

092400 Cement Plaster

Table of Contents Section 000010

111500 Parking Control Equipments

Division 13 Special Construction

131200 Fabric Shades

Division 14 Conveying Equipment

142100 Electric Traction Elevators

TECHNICAL SPECIFICATIONS – PART B

Division 21 Fire Suppression

220513 Common Motor Requirements for Plumbing Equipment

Division 23 Heating Ventilating and Air Conditioning

230500 Common Work Results for Hvac

Table of Contents Section 000010

Division 25 Building Management System

250000 Integrated Automation Systems

TECHNICAL SPECIFICATIONS – PART C

260500 Conmen Work Result For Electrical Work

Table of Contents Section 000010

271000 Structured Cabling System

Division 28 Electronic Safety and Security

281300 Access Control System

312000 Earth Moving

Division 32 Exterior Improvements

321123 Aggregate Base Courses

331000 Water Supply And Firefighting Networks

Division 41 Material Processing And Handling Equipment

412215.10 Overhead Electrical Cranes

Table of Contents Section 000010

THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS BUT

REV. DATE PREPARED REVIEWED APPROVED PAGES REMARKS

0 March 2022 M.M. 17 ISSUED FOR TENDER

ECG Form No. E409 Rev. 5/03 Sheet 0 of 17

CONMEN WORK RESULT FOR ELECTRICAL WORK

Conmen Work Result For Electrical Work Section 260500

1.1 RELATED DOCUMENTS

A Drawings and General Provisions of the Contract including General Conditions,

B The scope of work includes, but is not limited to the following:

1. Switchboard and Panelboards

Conmen Work Result For Electrical Work Section 260500

1. Electrical utility and authority’s up-to-date requirements, recommendations

G Training of Technical Personnel: A rate shall be included in the Schedule of Prices to

H Alternatives: Redesign of section or part of electrical or mechanical work, which is

K Although substitution in general is forbidden, proposed alternatives may be