Vol. III (B)

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

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

NO. BY BY BY
A Oct. 2021 M.M. C.AMAM C.MYSM 3 ISSUED FOR DETAILED DSIGN
0 Jan. 2022 M.M. C.AMAM C.MYSM 3 ISSUED FOR TENDER
1 Feb. 2022 M.M. C.AMAM C.MYSM 3 ISSUED FOR CONSTRUCTION
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP TABLE OF CONTENTS
KSA 000010 - 2970 1
ECG Form No. E409 Rev. 5/03 Sheet 0 of 3

RIYADH SEDRA 2
CONTENTS
VOLUME I
(Not Included)
VOLUME II
METHOD OF MEASUREMENT, BILL OF QUANTITY,

LIST OF MANUFACTURERS
DIVISION 0: INFORMATION
000010 Table of Contents
DIVISION 1: GENERAL REQUIREMENTS
012700 Method of Measurement

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

035440 Cement-Based Screeds
Divisions 04 Masonry
042000 Unit Masonry
Divisions 05 Metals
051200 Structural Steel

055000 Metal Fabrications
055213 Pipe And Tube Railings
Division 07 Thermal and Moisture Protection
071340 Polyethylene Sheet

071416 Cold Fluid-Applied Waterproofing
071613 Polymer Modified Cement Waterproofing
071616 Crystalline Waterproofing
075213 Atactic-Polypropylene (APP) Modified Bituminous Membrane Roofing
075216 Styrene-Butadiene-Styrene (SBS) Modified Bituminous Membrane
078413 Penetration Firestopping
079200 Joint Sealants
Table of Contents Section 000010

Riyadh Sedra 2 (Prj. 2970) Page 1 of 3
Divisions 08 Openings
081113 Hollow Metal Doors and Frames

081416 Flush Wood Doors
083323 Overhead Coiling Doors
085113 Aluminum Windows
087100 Door Hardware
088300 Mirrored Glass
089000 Louvers and Vents
Divisions 09 Finishes
092400 Cement Plaster

093000 Tiling
096600 Precast Terrazzo
096723 Resinous Flooring
099100 Painting
Division 10 Specialties
102800 Toilet and Bath Accessories

104416 Fire Extinguishers
Division 13 Special Construction
131500 Reinforced Concrete Water Structures
Division 21 Fire Suppression
212200 Clean-Agent Fire Extinguishing Systems
Division 22 Plumbing
220523 General-Duty Valves for Plumbing Piping

221116 Domestic Water Piping
221123.13 Domestic-Water Packaged Booster Pumps
221319 Sanitary Waste Piping Specialties
221429 Sump Pumps
Division 23 Heating Ventilating and Air Conditioning
230500 Common Work Results for Hvac

230513 Common Motor Requirements for Hvac Equipment
230700 Hvac Insulation
232300 Refrigerant Piping
233113 Metal Ducts
233300 Air Duct Accessories
233423 HVAC Power Ventilators
233713 Diffusers, Registers, and Grilles
237413 Packaged, Outdoor, Roof Top Units
238126 Split-System Air-Conditioners

VOLUME III
TECHNICAL SPECIFICATIONS – PART B
Division 26 Electrical
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
261201 Medium-Voltage Oil Transformers
261301 Ring Main Unit
262413 Switchboards
262416 Panelboards
262419 Motor Control Centers
262726 Wiring Devices
263213 Engine Generators
263533 Power Factor Correction Equipment
263600 Transfer Switches
265100 Interior Lighting
265600 Exterior Lighting
Division 28 Electronic Safety and Security
283100 Fire-Alarm System
Division 31 Earthwork
312000 Earth Moving
Division 33 Utilities
331000 Water Supply And Firefighting Networks

333000 Sewage Collection Networks
334100 Storm Water Collection Networks
Division 41 Material Processing And Handling Equipment
412215.10 Overhead Electrical Cranes

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
PURCHASE
CONSTRUCTION X

NO. BY BY BY
0 Jan. 2022 M.M. C.MMAL C.EBEE 16 ISSUED FOR TENDER
1 Feb. 2022 M.M. C.MMAL C.EBEE 16 ISSUED FOR CONSTRUCTION
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP MEDIUM VOLTAGE CABLES
KSA 260513 - 2970 1

CONTENTS
SECTION 260513
MEDIUM VOLTAGE CABLES
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 3
1.5 Design Criteria 4
1.6 Shipment 5
1.7 Delivery, Storage And Handling 5
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 Construction Of Cables 6
2.3 Identification Of The Cable Phases And Marking 7
2.4 Multiple-Conductor Unarmoured Cables 8
2.5 Cable Supports And Fittings 8
2.6 Splice Kits 8
2.7 Solid Terminations 8
2.8 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

Riyadh Sedra 2 (Prj. 2970) Sheet 1 of 16
SECTION 260513 –MEDIUM VOLTAGE CABLE
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 medium voltage cables, including armored and
unarmored multiple conductor power cables.
B The Contractor manufactures 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
sheets should then be filled and stamped, as mentioned, for the same item.
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 Cu/XLPE/PVC
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
1.4 QUALITY ASSURANCE
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.
b. Saudi Arabian Standard
c. SASO Saudi Arabian Standard Organization
d. SEC Saudi Electric Company standards
e. MOMRA Ministry of municipalities and rural affairs
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
c. Cable sheath

d. IEC 60230 Impulse on cables and their accessories
e. IEC 60270 Partial discharge measurement
f. IEC 60502-2 Extruded solid dielectric insulated power cables for
Rated voltages from 6 kV up to 30 KV (Vmax = 36kV)
g. IEC 60811 Test methods for insulations and sheaths of electric
Cables
h. 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 Contractor manufacturers get approval from Authority Having Jurisdictions (SEC)
so as to finalize the respective 8.7/15 KV XLPE-Insulated medium voltage Cable
System.
B In designing the cable system for the specified cable route the following factors shall
be taken into account:
1. Current carrying capacity

2. Mutual heating between adjacent circuits when more than one circuit is
installed along a common route and simultaneously loaded
3. Earthing requirement
C The cables shall be designed for the following environmental conditions:
1. Ambient temperature: 50°C

2. Relative humidity: 100%
3. Dusty environment.
4. Daily average temperature 45 C°
5. Salty and corrosive environment.

D 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.
1.7 DELIVERY, STORAGE AND HANDLING
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
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 CONSTRUCTION OF CABLES
D. Medium voltage Cable 8.7/15 Cable (17.5 kV maximum between phases), XLPE -
insulated, for use on 13.8 KV system
A Stranded compacted circular plain copper 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 circular compacted
copper conductor Class 2, of concentric strand wires. The conductor shall be of
compacted circular shape.
C Multiple-conductor, cross-linked polyethylene-insulated, jacket/outer sheath to be

PVC outer sheath.
D Conductor Screening: The conductor screen shall consist of an extruded semi-

conducting compound. Each conductor shall be covered with an extruded semi-
conductive material layer. The screen shall fill the interstices between the outer
individual strand wires forming the conductor and provide a smooth, regular
interface to the insulation 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.
E Insulation: Each conductor shall have ozone-resistant layer or cross-linked

polyethylene (XLPE) extruded on the conductor screen.
F Insulation Screening: Non-Metallic, semi-conductive compound 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.
E. Insulation Metallic Screen:
1. The metallic screen shall consist of a layer of copper tape and/or layer of
annealed bare copper wires. Metallic screen shall be applied on 3 individual
screens, one on each core.
2. The screen size shall be as given below excluding copper tape.
A. 16 MM2 FOR UP TO AND INCLUDING 70 MM² CORE.
b. 35 mm2 for sizes in excess of 70 mm2 core.
3. Effective cross-sectional area of three individual metallic screens shall be such that
these (metallic screens) shall be suitable for withstanding the earth fault current
for 1 second duration unless otherwise agreed with the Engineer based on the
short circuit calculations.
G Copper Screen: on each core insulation screening, flat copper tapes shall be applied
helically and overlapped. The number of copper tapes and their percentage overlap,
for each core, shall be selected in such a way to obtain the effective cross-sectional
area of copper screen per phase

H The Contractor manufacturer shall prove by calculation that the interstitial copper
conductors together with the insulation metallic screens are adequate to meet the
specified short-circuit current. The calculation results shall be supported by actual
executed Short-Circuit test results and provided to the Engineer.
I Conductor of medium voltage cables shall withstand short circuit of 21 kA for cables
grade 8.7/15(17.5) kV unless otherwise indicating in the drawings.
J 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.
K The inner covering wrapping the three cores together shall be of extruded corrosion
resistant material.
L 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.
M The material and dimensions of the steel tapes shall be in accordance with IEC 60502
standard.
N 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.
O Current Carrying Capacity: The maximum continuous current carrying capacity and
maximum permissible conductor temperature shall be stated by the supplier. The
maximum continuous current carrying capacity shall be calculated in accordance
with the methods recommended in IEC publications no. 60287.
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 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.
2.6 SPLICE KITS
A Approved connectors shall be provided for splices and terminal connections of all
copper 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.
2.7 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.
2.8 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. copper or copper 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 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 millimeters.
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 millimeters 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 the 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. 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.
2. The dimension of the armour shall not fall below the specified nominal value
by more than 10%.
3. 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.
4. 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) Copper sheath
22) Finished cable
23) Length of cable per drum
24) Diameter of drum
25) Width of drum
26) 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, 60 Hz: ohm/km
16. Impedance per km of Cable at 90°C and 60 Hz: ohm/km
17. Maximum Continuous Current Rating:
a. In Air, 50°C: Amps

b. In Ground, 35°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 11/20 KV XLPE 3*300 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.
END OF SECTION 260513


ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
A Oct. 2021 M.M. C.MMAL C.EBEE 13 ISSUED FOR DETAILED DESIGN
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP LOW-VOLTAGE ELECTRICAL POWER
KSA CONDUCTORS AND CABLES 260519 – 2970 1

CONTENTS
SECTION 260519
LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 References 2
1.4 Submittals 3
1.6 Delivery, Storage, And Handling 4
1.7 Coordination 5
PART 2 PRODUCTS 6
2.1 Generally 6
2.2 System Characteristics 6
2.3 Lv Wires And Cables 450/750 V Grade 6
2.4 Lv Cables 600/1000 (1200) V Grade. 7
2.5 Performance And Design Requirements 7
2.6 Connectors (LV Power) 10
PART 3 EXECUTION 10
3.1 Inspection 10
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.
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.
B. Extent of electrical wire and cable work is indicated by Drawings and schedules.
C. Types of electrical wire, cable, and connectors specified in this section include the
following:
1. Single core copper conductor/cables

2. Multi-core copper conductor/cables
3. Control and signal cables.
1.3 REFERENCES
A. Governing Standards: Except as modified or supplemented herein, all equipment and

materials required in this section including their installation shall conform to the ap-
plicable requirements of the following standards. Standards current at the time of
tender shall be used.
Bare copper cables for earthing (grounding) IEC 60228 Class 2

PVC insulated or PVC Sheathed cables, 0.6/1 kV IEC 60502 or NEMA WC 7
XLPE insulated or PVC Sheathed cables, (90C) 0.6/1 IEC 60502 or NEMA WC 7
kV
XLPE/SWA/PVC Direct Buried Armored Cable IEC 60502 or NEMA WC 7
Cable glands for single and multi-core PVC and/or BS 6121, BS 5467 or BS
XLPE cables 2874
Surge arrestors for cables IEC 60099 Part 1
Cable conductor identification by color or numerals IEC 60446
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
B. British Standards (BS)
C. International Building Code IBC 2018
D. Saudi Building Code 2018
1.4 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 at-
tached to a section) and stamp it by the proposed supplier and by the pro-
posed electrical sub-contractor (or himself if no sub-contractor). If the Con-
tractor 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.
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, identifica-
tion 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.
4. Manufacturing Data and Test Reports: Showing dimensioned sketches, thick-
ness of insulation and sheath, factory tests, drum data and shipping details.
5. 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 ac-
cordance with final conduit routing.
f. Cable sizing calculations.
g. Cable schedule.
h. Cable termination schedule.

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.
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.
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver wires and cables properly packaged in factory packed or fabricated contain-
ers, wound on factory reels.
B. Store wires and cables in dry areas, and protect from weather, fumes, water, debris,
etc.
C. 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.
D. 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.
E. 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.
F. 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.
G. No space shall exist between the adjacent layers of the cable and between the drum
flange and the cable.
H. Cable shall be wrapped with black polyethylene sheet inside the wood covering of
the drum.
I. 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 un-
rolling.
J. 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.
K. Immediately after the Works tests, both ends of every length of metal sheathed cable
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.
L. 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.
M. The cable end which is left projecting from the drum shall be adequately protected
against damage.
N. 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.
O. 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.
P. Wooden drums shall be suitably constructed to avoid problems due to shrinkage, rot
and attack by insects.
Q. 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.
1.7 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 GENERALLY
A. Conductors: Unless otherwise specified, cables and other feeders are to have copper
conductors. Cable conductors are to be stranded for sections 4 mm2 and above,
based on IEC 60228 Class 2. Signal and control cables are to have solid conductors
unless otherwise specified. Flexible cords are to have finely stranded conductors.
Conductors of single-core cables 25-mm2 and above are to be compacted.
B. Conductor sizes are to be metric. Conductors with cross-sectional area smaller than
specified will not be accepted.
C. Building wiring insulation is to be color coded or otherwise identified as required by

the Saudi Regulations.
D. Buried Cables: Cables buried directly in the ground are to be armored type, unless
otherwise indicated in particular Sections of the Specification.
E. Buried cables in high water content soil are to be watertight type, provided with wa-
ter blocking swell able tape above insulation as longitudinal water barrier, PE lami-
nated aluminum foil longitudinally applied with suitable overlap as radial water bar-
rier and an external outer sheath made of extruded black polyethylene compound.
F. Outdoor cables exposed to sunlight are to be provided with ultraviolet resistant PVC
sheath having 2.5% black carbon content.
2.2 SYSTEM CHARACTERISTICS
A. Nominal voltage: 400/230 volt
B. Maximum voltage: 0.6/1 KV
C. Frequency: 60 H
2.3 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, 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 with Flexible Copper Conductors 450/750 V grade:
Soft annealed Copper fine wires, bunched together in subunits or stranded bunched
groups into a main units, twisted and Sheathed which forms the flexible conduc-
tor. 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.
2.4 LV CABLES 600/1000 (1200) V GRADE.
A Cables are produced Multi-Core PVC Insulated Cables (0.6/1 kV): soft annealed,
copper conductors, 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.
B Single Core XLPE Insulated Feeder Cables (0.6/1 kV): Single-core circular stranded,
annealed copper conductors, compacted, insulated with flame retardant, moisture
and heat resistant cross-linked polyethylene (XLPE) , according to IEC 60502 or BS
7889 suitable for wet locations and conductor temperatures of 90 deg. C. and PVC
over-sheath. Armored cables are to have taped bedding, single wire aluminum armor
and PVC over-sheath.
C Multi-Core XLPE Insulated Feeder Cables (0.6/1 kV): Single core annealed copper
conductors, 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.
Armored cables are to have single layer of galvanized 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.
D Armored cables are to have single layer of galvanized steel wire or steel tape
armored (as shown on the drawings) with PVC over-sheath. Cables are to comply
with IEC 60502 or BS 6346. Armored cables shall be used where mechanical damages
are expected.
2.5 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 Conductors above 3 mm2 shall be stranded copper.
D 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 / 700 V
4. Irrigation cables shall be moisture and heat resistant sheathed.
5. Steel wire armoring shall be galvanized type.

E The armour of single-core cables for use on A.C. Systems shall consist of non-
magnetic material, unless a special construction is chosen.
F Cable Sizing and Selection: The applicable IEC or local regulations for Electrical
Installations shall be used as the basis for sizing cables and conductors.
G 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.
H Voltage drop on main distribution cables shall not exceed four percent from the
source to the farthest end of any sub-circuit.
I No cable shall be loaded to more than 80 percent of its current carrying capacity
after application of all the appropriate derating factors.
J The spacing of cables shall be as determined in the calculation of the derating factors
for the current carrying capacity of cables.
K 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.
L 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 the
drawings and single line diagram, indicating the nominal cross section area of PVC
type cables.
M 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
N Cables for motors above 2 kW, shall be sized to conform to the Governing Standards,
so that the current ratings is not less than 125 percent of the full load current of the
motor and that the cable is not smaller than
1. PVC Cables 4.0 mm²

2. Remote control circuits 2.5 mm²
O 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.
P 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.
Q All cables shall be color coded in accordance with the relevant IEC and local
Standards.
R 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.
S 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.
T 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.
U 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.
V 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.
W Flexible Cables: The use and type of flexible cables or cords shall suit the applications.
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.
2.6 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 al-
loy 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.
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 con-
duit 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. 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.
E. The cross-section of cables must be selected according To the expected load, voltage
drop, ambient temperature and installation conditions including appropriate group-
ing factors. The maximum Voltage drop from the Connection Point to the remote end
of any Final Circuit must not exceed 4%, except in special Cases where equipment has
been designed to operate under a greater voltage drop (such cases must be clearly
stated in the Electrical Installation design and approved by the Distribution Compa-
ny).
F. 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.
G. The minimum bending radius shall be not less than that recommended but the cable
manufacturer and contra twisting shall be avoided.
H. Spacing between cables shall be suitable for the derating factors applied to the cable
installation design.
I. Cables shall be installed using the loop-in principle, unless otherwise specified no
straight through or tee joints will be permitted.
J. 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.
K. 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.
L. 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.
M. Where cables pass through holes in panels or other metalwork, they shall be protect-
ed by rubber grommets, compression glands or their equivalent.
N. 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.
O. Single-core conductors or cables in metal conduits shall not be used.
P. 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.
Q. 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.
R. Both high, medium, low voltage and intrinsically safe cables shall be on separate ca-
ble runs.
S. All cable runs shall have minimum 30% spare space after all cables is installed.
T. Cable runs, supports and all its splices shall be conductive and be well earthed.
U. 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.
V. 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.
W. 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.
X. Where steel wire 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. 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.
E. Cables shall be installed parallel to the building lines and shall not be run diagonally
in floor or ceiling finishes.
F. 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.
G. 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.
H. Prohibited terminal blocks and taped connections
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.


BUT THESE REMARKS ARE NOT A PART OF THE SPECIFICATION. THE ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP GROUNDING AND BONDING FOR
KSA ELECTRICAL SYSTEMS 260526- 2970 1

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 11
3.1 Applications 11
3.2 Equipment Grounding 12
3.3 Installation 12
3.4 Connections 14
3.5 Field Quality Control 14
Grounding and Bonding For Electrical Systems Section 260526

SECTION 260526 - GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
tary Conditions and Division 01 Specification Sections, apply to this Section.
B. The following Sections include requirements which relate to this section:
1. Division 26 Section "Panelboards ".

2. Division 26 Section “Low Voltage Electrical Power Conductors and Cables".
3. Division 26 Section “Generators".
4. Division 26 Section “Cable tray".
5. Division 26 Section “Raceways and Boxes for Electrical Systems”
6. Division 26 Section “Interior Lighting”
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. LV Panelboards
2. Main earthing terminals or bars in electrical, etc.
3. Exposed conductive parts of electrical equipment (light fittings, switches and
socket outlets, etc.).
4. Extraneous conductive parts (generators, Panelboards, etc.).
5. Building main ring system of electrodes and conductors.
B. Earthing requirements specified in this Section may be supplemented by special re-

quirements of systems described in other Sections.
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
installation 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. radiators, 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. Saudi building Codes.
6. SASO standard.
PART 2 - PRODUCTS
2.1 CONDUCTORS
A. Insulated Conductors: Copper wire or cable PVC insulated in green and/or green-
yellow color for 400 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 70 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

copper 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 phosphor bronze or copper silicon alloys. Bolted connections are
not permitted in run of the earthing conductors unless approved by the Engi-
neer.
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. 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'.
D. 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.
E. 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.
F. 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.
G. 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 to be
used in the design of the earthing system.
B. The value of resistivity 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.
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 calculated
in accordance with the standards given in IEEE 80 and BS 7430 for
the proposed surface layer. The formula for allowable body current
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, interconnect-

ed 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 earth-
ing conductors to this ring. Additional earth rods connecting with the
earth ring are to be provided, as necessary, to bring down earth elec-
trode resistance to the specified value.
c. Functional earth electrode is to be provided separately from, but in-
terconnected 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 Specifica-
tion and recommendation of the manufacturer.
4. Connect all earthing conductors, protective conductors and bonding conduc-

tors 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 tempera-
ture not exceeding 160 deg. C at 1 second for medium voltage systems and 0.4
seconds for low voltage systems. Main earthing conductors’ sizes are to be
minimum 70 mm2 unless otherwise indicated in the drawongs.
5. 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.
6. 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).
7. 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.
8. 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.
9. Ensure by calculation that Earth Fault Loop Impedance values for final circuits

are to satisfy the requirements of BS 7671 regulations.
10. 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.
11. 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 conduc-
tor or both sides of the joint shall be separately bonded to earth un-
less the joint is intended to be an insulated joint for cathodic protec-
tion or other purposes.
12. 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.
13. 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.
14. 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.
15. Exposed external earth / grounding conductor connection joints are to be pro-
tected from corrosion with grease caps or bituminous tape or approved equal.
16. In general earthing conductor connections to structures, conductors, are to be
exothermic copper-weld type unless stated otherwise.
17. 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.
18. Grounding and bonding fasteners and connectors must conform to the re-
quirements of UL 467, and Section 26 27 26 “WIRING DEVICES”.

19. Grounding and bonding fasteners must be copper/bronze.
20. 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.
PART 3 - EXECUTION
3.1 APPLICATIONS
A. Conductors: Install solid conductor for 10 mm2 and smaller, and stranded conduc-
tors for 16 mm2 and larger, unless otherwise indicated on the drawings.
B. Underground Grounding Conductors: Install bare copper conductor, 70mm2 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 3 meters
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 2 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 or as
indicated on the drawing and calculation.
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 70 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. Earthing Of 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.
B. 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.
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. 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.
E. 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.
F. 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.
G. 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.
H. Conduits stubbed-up below a switchboard shall be fitted with insulated grounding

bushings and connected with the equipment ground bus.
I. 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.
J. 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.
K. 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.

L. 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.
3.5 FIELD QUALITY CONTROL
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 oth-
er than natural drainage or seepage and without chemical 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.

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

ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP RACEWAY AND BOXES FOR ELECTRICAL
KSA SYSTEMS 260533 - 2970 1
ECG Form No. E409 Rev. 5/0 Sheet of 14

CONTENTS
SECTION 260533
RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 References 2
1.4 Submittals 3
1.6 Coordination 3
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 General 4
2.3 Application Considerations 4
2.4 Intermediate Metal Conduit 5
2.5 Electrical Metallic Tubing (Emt) 5
2.6 Flexible Metal Conduit 5
2.7 Rigid Heavy Gauge Upvc Conduit 6
2.8 Under Groung Upvc Conduits 6
2.9 Flexible Pvc Conduit 6
2.10 Steel Conduit Accessories 7
2.11 Wiring And Cable Trunking 7
2.12 Weatherproof Wiring And Cable Trunking 8
2.13 Outlet Boxes, General 8
2.14 Metallic Outlet Boxes 8
2.15 Moulded Plastic Outlet Boxes 9
2.16 Underfloor Trunking 9
PART 3 EXECUTION 10
3.1 Examination 10
3.2 Equipment Installation Requirements 10
3.3 Installation And Wiring 10
3.4 Outlet Boxes 12
3.5 Junction, Pull 13
3.6 Grounding And Bonding 13
3.7 Connections 14
3.8 Empty Conduits 14
3.9 Protection 14
3.10 Cleaning 14
Raceway And Boxes For Electrical Systems Section 260533

SECTION 260533 - RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS
PART 1 GENERAL
A Drawings and general provisions of the Contract, including General and Supplemen-
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, Rigid PVC Conduit, Electrical Metallic tubing (EMC), Intermediate metal
conduit (IMC), Flexible Conduit, wire ways, Surface Raceways, galvanized
trunking, rigid PVC trunking, etc.
2. Boxes, enclosures, and cabinets include the following devices: floor boxes, pull-
ing 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 “Cable Trays for Electrical Systems”.
4. Division 26 Section “Wiring Devices”.
1.3 REFERENCES
A. Saudi building Codes (SBC)
1. All requirement and Standards Referenced in the latest version of SBC code
shall be part of the requirements for this Project. Where differences occur be-
tween the provision of SBC Code and Referenced Standards, the provisions of
SBC Code shall apply. Where related SASO Standards exist, they shall apply and
have precedence.
B. ANSI/NFPA 70 - National Electrical Code.
C. ASTM A 123 - Specification for Zinc (Hot-Galvanized) Coatings on Products Fabricated

from Rolled, Pressed, and Forged Steel Shapes, Plates, Bars and Strip.
D. ASTM A 525- General Requirements for Steel Sheet, Zinc-Coated Galvanized by the
Hot-Dip Process.

1.4 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 regulations for com-
ponents 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.
D Material shall comply with the latest edition of the following standard:
1. ANSI C80.1: Rigid Steel Conduit (RSC)

2. ANSI C80.3: Electrical Metallic Tubing (EMT)
3. UL 1: Flexible Metal Conduit
4. UL 6: Rigid Steel Conduit (RSC)
5. UL 360: Liquid-Tight Flexible Metal Conduit
6. UL 514: Fittings for Metal Conduit
7. UL 651: Nonmetallic Conduit (PVC)
8. UL 797: Electrical Metallic Tubing (EMT)
9. UL 886: Fittings for Hazardous Locations
10. UL 1242: Intermediate Metal Conduit (IMC)
11. NEMA RN1: Plastic Coated Metal Conduit
12. ASTM-F-512: Utility duct type EB-35
1.6 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: Subject to compliance with require-

ments, provide products by one of the following or approved equal:
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 EMT, FMC, LFMC, NEMA 1 (IP20)

false ceiling not used as return UPVC
plenum)
2. Concealed (above false ceiling EMT, FMC, NEMA 1 (IP20)
used as return plenum).
3. Dry locations, exposed, subject to IMC NEMA 4, 4X (IP 56)
damage.
4. Dry locations, exposed, not sub- IMC, FMC, NEMA 4, 4X (IP 56)
ject to damage. LFMC, UPVC
5. Outdoor locations, embedded in PVC --
concrete, under concrete slab
6. Underground, direct burial UPVC --
7. Industrial location, general EMT, FMC, LFMC NEMA 12, 12K (IP 52)
8. Industrial location, subject to cor- IMC, LFMC NEMA 4X, 11 (IP56)

rosion

B Legend:
1. EMT Electrical metal tubing.

2. FMC Flexible metal conduit.
4. LFMC Liquid tight flexible metal conduit.
13. PVC Polyvinyl chloride (flame retardant).
C Notes
1. PVC conduits are permitted for installation above false ceiling, only if the area
above false ceiling is not used as return plenum. Metal conduits shall be used
instead if the area above false ceiling is used as return plenum.
2. Corrosion protection required for all metal conduits.
3. Fittings for purpose required for all conduits.
4. Aluminum materials not permitted.
2.4 INTERMEDIATE METAL CONDUIT
A. Intermediate Metal Conduit (IMC): Rigid high grade mild strip welded steel, hot dip
galvanized over the entire length including factory made treads after cutting with or-
ganic corrosion resistant polymer inside coating and to US Federal Specification, UL
1242 and ANSI C80.6.
B. IMC Fittings: Generally Threaded fittings and connectors and terminations with rigid
coupling, concrete tight where required, and with red lead coated threads where site
cut. Factory made bands are to be provided where site bending is not possible.
2.5 ELECTRICAL METALLIC TUBING (EMT)
A Welded steel, non-threaded type, galvanized externally and protected internally with
corrosion resistant enamel, and to U.S. Federal Specifications, UL 797 and ANSI
C80.3.
B EMT Fittings Generally: Thread less pressure type, galvanized or cadmium plated mal-
leable cast iron. Fittings used in corrosive atmospheres are to be specially treated.
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.
2.6 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 mal-
leable cast iron. Fittings used in corrosive atmospheres are to be specially treated.
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.
2.7 RIGID HEAVY GAUGE UPVC CONDUIT
A Material: Rigid unplasticized 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.
2.8 UNDER GROUNG UPVC CONDUITS
A UPVC conduits 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 utility grade PVC type EP-
35.
C For Direct Buried conduit to be Rigid Non-metallic conduit (RNC) NEMA TC 2,

Type EPC-40-PVC or Type EPC-80-PVC according to the application and engineer ap-
proval, UL 651, with matching fittings by same manufacturer as the conduit, comply-
ing with NEMA TC 3 and UL 514B.
2.9 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.

2.10 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.
2.11 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.

2.12 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.
2.13 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.
D Device and junction boxes shall be deep type.
2.14 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 Device and junction boxes shall be deep type.

2.15 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 pro-
vide additional support for pendants or for heat conduction. Neoprene gaskets are to
be provided for weatherproof installations.
C Device and junction boxes shall be deep type.
2.16 UNDERFLOOR TRUNKING
A Type: For installation in floor screed, laid on unfinished concrete floor, secured and
grouted flush with screed.
B Material: 3.3 m lengths of 2 mm thick (14 gauge) galvanized sheet steel, protected by
corrosion resistant coating on inside and outside surfaces. Single, double or triple
systems, as required. Dimensions are to be as required. Covers to be minimum 3 mm
thick. Galvanizing to be at least 270 gms/m2.
C Openings: Ducts are to have 32 mm openings spaced at 600 mm with screw plugs for
receiving initial or future installation of outlet boxes. Screw plugs are to be replaced
by brass ferrules, inserted and securely fastened by crimping tool, for installation of
pedestal type outlet boxes.
D Fittings: Ducts are to be supplied with approved standard manufacturer's fittings,

couplings, adjustable duct supports, duct to conduit adapters, horizontal 45 and 90
degree bends, vertical 90 degree bends, terminal bushings to cabinets, cross under,
offsets, plugs, ferrules and complete set of tools for installation and maintenance
after installation.
E Junction Boxes: Flush, cast iron, or galvanized sheet steel or die-cast metal protected
by corrosion resistant coating and suitable for double or triple duct systems, as
required. Openings are to be provided for ducts and conduits. Interior of boxes is to
be partitioned for two or three services; completely isolating each duct system and
providing straight cross-junctions. Leveling and anchoring of boxes is to be by adjust-
ing screws at four corners. Flush cover plates are to form smooth surface with floor-
ing.
F Flush Outlet Boxes: Factory designed, with accessories necessary to accommodate

specific outlets or cable outlets as required for signal or control services, with cord-
grip nipples.
G Supports are to be capable of adjustment for height and arranged for maintenance of
alignment and spacing of raceways during concreting.
H Recessed Service Fittings: Modular fittings that match with preset inserts and include

covers/ receptacles, outlets and associated device plates to provide service indicated
at each location. Covers are to be flush with floor and have a recess to match floor
finish and level with the area. Boxes' covers are to be firmly held in place and non-
rocking. Coordinate with architectural designs and materials approved for finishes
and for electrical devices. Internally mounted receptacle / outlets are to be as re-
quired.
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 con-
nections as indicated, specified and required. Assure proper fits for all equipment
and materials in the space as shown on the Drawings. Conduits installed under-
ground shall be provided with preformed long radius PVC elbows encased in
concrete. Liquid-tight lengths of flexible conduit shall be used for connections to all
motors 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. Exposed interior conduits shall
have supports spaced 1.00 m, 1.5 m, 2.00 m apart for conduits 20 mm, 25 mm, 32
mm, respectively, with at least one support between couplings and be installed paral-
lel or perpendicular to walls, structural members or intersections of vertical planes
and ceilings with right-angle turns to be made with symmetrical bends. Conduit shall
be supported on approved types of galvanized strap hangers, pipe straps or be se-
cured by means of expansion bolts on concrete, wood screws on wood or machine
screws on metal surfaces. Conduit supports shall be provided on each side of conduit
bends or elbows and not more than 0.5 m on each side of each outlet. Field- formed
bends and offsets shall be avoided where possible, but where necessary shall be
made with an approved conduit-bending means. In case, the conduits to be in-
stalled are galvanized steel, the junction and pull (draw) boxes shall be galvanized
with galvanized locknuts and bushings and full number of threads projecting through
to permit the bushing to be drawn tight against the box to ensure good electrical
contact.
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.
D Open conduit ends shall be carefully closed during construction to prevent foreign
materials from entering the conduit. Conduits, which have been crushed or de-
formed in any way, shall not be installed; or if so deformed after installation, shall be
replaced. Where conduits cross building joints, furnish and install, expansion fittings
for contraction, expansion and settlement 300 mm long, on both sides. Heavy gauge
rigid PVC conduits running in the concrete slab shall be interconnected with flexible
PVC conduits through the expansion joints.
E Conduit buried in concrete shall have 35 mm depth of cover over its entire length.
F Conduit shall not be installed in plastering layers.
G A draw in (Pull) box shall be provided in all conduit runs exceeding 30 m or

containing more than two right angled bends. Any unused opening shall be plugged.
H 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.
I 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.
J The ends of conduits shall be cut straight and the length of screw thread (for the
galvanized 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.
K The ends of galvanized conduits shall be carefully reamered 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
immediately prior to erection.
L 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.
M Where space permits their use, plain bends are preferred than elbows. Maximum
number of bends is 3 as total.
N Draw-in boxes with wide flanged robust covers shall be used.
O 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.
P 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.
Q 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.
R 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.
S 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.
T Nails shall not be used for fastening the boxes installed in concrete slabs.
U The box shall be so constructed as to prevent contact between the conductors in the
box and the supporting screws.
V 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 relocated as
directed by the Engineer.
W All circuit wires shall be tagged to indicate clearly the circuit number and panel
designation at each pull box or access point. Circuit wires in excess of 600 V shall
have voltage identification.
X 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
schedules, scale drawings, large scale and full size details of finished rooms, approved
shop drawings of other trades or from the Engineer. Equipment outlet boxes and the
required termination shall be obtained from the equipment suppliers with all the
necessary dimensions. Contractor shall provide accordingly detailed shop drawings of
suitable scale for approval prior to installation. It shall be understood that any outlet
may be relocated a distance from the location shown on Drawings, if so directed by
the Engineer. Contractor shall make any necessary adjustment of his work to fit
conditions for recessed fixtures and for outlets occurring in glazed tile, block, terra
cotta, marble, wood paneling or other special finish material, in order that all boxes
may register flush with finish and shall be centered properly. In centering outlets,
due allowance shall be made for overhead piping, ducts, window and door trim, vari-
ations in thicknesses of furring, plastering, etc., as erected, regardless of conditions
which may be otherwise shown on small scale Drawings. Outlets incorrectly located
shall be properly relocated at Contractor's expense.
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
manufactured 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 30 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

distribution 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
supplementary 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 EMPTY CONDUITS
A All empty conduits shall be provided with suitable nylon rope or other approved. Not
less than 250 mm of slack shall be left at each end of the conduit run. Empty
conduits shall be tagged at each accessible end with a plastic tag identifying the pur-
pose of the conduit and the location of the other end.
3.9 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
accumulations or shall be replaced. Open conduit ends shall be carefully closed dur-
ing construction 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

Manufacturer.
2. Repair damage PVC or paint finishes layer with matching touchup coating
recommended by the Manufacturer.
3.10 CLEANING
A Upon completion of installation of system including outlet fittings and devices,

inspect 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 X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP
CABLE TRAYS FOR ELECTRICAL SYSTEMS
KSA 260536 - 2970 1

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 4
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
2.10 Cable Trunking 5
3.1 General 6
3.2 Installation 6
3.3 Grounding 7
3.4 Warning Signs 7
3.6 Cleaning 8
3.7 Protection 8
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.

2. Division 26 Section “Low Voltage Electrical Power Conductor and Cables”.
3. Division 26 Section “Medium Voltage 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 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. Cable trays shall be epoxy coated externally and internally for corrosion pro-
tection.
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: 100 mm
2. 150 mm
3. 200 mm
4. 300 mm
5. 400 mm
6. 600 mm
7. 800 mm
8. Inside Depth: 100 mm
9. Cross-Rung Spacing: 300 mm
C. Perforated-Type Trays.
1. Width: 100 mm
2. 150 mm
3. 200 mm
4. 300 mm
5. 400 mm
6. 600 mm
7. 800 mm
8. 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.
2.10 CABLE TRUNKING
A. Installation: Secure trunking of all sizes at intervals not exceeding 1200 mm. Joints
are not to overhang a fixing by more than 500 mm.
B. Trunking passing through walls and ceilings is to have the cover fixed solidly for 25
mm either side of walls and for 150 mm either side of floors and ceilings.
C. Vertical sections of trunking over 900 mm long are to have staggered insulated tie-off
studs to support weight of cables.
D. Cabling Provisions: Separation of power, low current and control circuits is to be by

two channel trunking or by barriers inserted in trunking before installation of cables.
Cable retaining straps are to be provided at no more than 600 mm centers. Openings

in front of trunking are to facilitate drawing-in cables.
E. Coupling: Trunking parts are to be mechanically and electrically coupled without

causing abrasion to wiring.
F. Earthing: Do not use metal trunking as earth continuity conductor. Provide protective
conductor in accordance
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 sherardized steel rawl bolts.
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 13.8 or 18kV) 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.

ECHNICAL SPECIFICATION COVER SHEET REVISED SHEETS

ISSUED FOR
PURCHASE X
CONSTRUCTION X
REV. PREPARED REVIEWED APPROVED

DATE PAGES REMARKS
NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP MEDIUM-VOLTAGE OIL
KSA TRANSFORMERS 261201 - 2970 1

CONTENT
SECTION 261201
MEDIUM-VOLTAGE OIL TRANSFORMERS
Page
PART 1 - GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.4 Warranty 3
1.7 Project Conditions 4
1.8 Coordination 4
PART 2 - PRODUCTS 4
2.1 Identification Devices 8
3.1 Examination 9
3.2 Installation 9
3.3 Identification 9
3.4 Connections 9
3.6 System Validation 10
Medium-Voltage Oil Transformers Section 261201

SECTION 261201 - MEDIUM-VOLTAGE OIL TRANSFORMERS
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. This Section includes the oil type with medium-voltage primary 13.8 KV and low-
voltage secondary 400/230 V, 60 Hz.
B. The Contractor is responsible to supply and install the transformer (s) according to
the latest requirements of Saudi Electricity Company (SEC). This shall require from
the contractor’s manufacturer to obtain the approval (before delivering) for the type,
voltage, losses, etc. from SEC. Any additional requirements shall be considered
without any extra cost to the Contract.
1.3 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 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, cable routing and method of ventilation.

2. Dimensioned concrete base, outline of transformer, and required clearances.
3. Ground rod and grounding cable locations.
4. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity
and locate and describe mounting and anchorage provisions.
5. Detailed description of equipment anchorage devices.
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 and /or BS

1.4 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 and commissioning.
A. Comply with IEC, IEEE (latest editions at time of tendering).
B. Comply with SEC DISTRIBUTION MATERIALS SPECIFICATION:
1. 51-SDMS-01 (Distribution transformers up to 36 KV)
C. Comply with the reference Standards of Saudi Arabian Standards Organization

(SASO):
1. SSA 422: Power Transformer (SASO – Saudi Arabian Standards Organization)

2. SSA 421: Testing Methods for power transformer
D. Except as modified herein, the equipment shall be designed, manufactured and

tested in accordance with IEC Standard publication no.
1. IEC 60076-1: Part one - General

2. IEC 60076-2: Part two – Temperature Rise.
3. IEC 60076-3: Part three – Insulation levels and dielectric tests.
4. IEC 60076-4: Part four – Guide to the lightning impulse and switching impulse
testing - Power transformers and reactors
5. IEC 60076-5: Part five – Ability to withstand short circuit.
6. IEC 60076-7: Part seven – Loading guide for oil immersed power transformer
7. IEC 60076-10: Part ten – Determination of sound levels
8. IEC 60137: Insulated bushings for alternating voltages above 1000 V
9. IEC 60296: Fluids for electro-technical applications - Unused mineral insulating
oils for transformers and switchgear
10. IEC 62631-3-4: Dielectric and resistive properties of solid insulating materials -
Part 3-4: Determination of resistive properties (DC methods) - Volume
resistance and volume resistivity at elevated temperatures
E. Product Options: Drawings indicate size, profiles, and dimensional requirements of

transformers and are based on the specific system indicated. Refer to Division 01
Section "Product Requirements."
F. Electrical Components, Devices, and Accessories: Listed and labeled as defined in IEC
and/or BS, by a testing agency acceptable to authorities having jurisdiction, and
marked for intended use.

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 (with bushings installed) shall be crated, as required. All pipe

connections shall be provided with sealing devices and valves. 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.
1.7 PROJECT CONDITIONS
A. The transformer should be manufactured for Saudi service conditions as:
1. Altitude: More than 1000 m (Dearing Shall Apply)

2. Max. Ambient temperature: +45° C.
3. Min. Ambient temperature: -5° C
4. Relative Humidity: 10-100%
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, spill retention areas, and sumps.

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.
C. Coordinate installation a sump pit of sufficient size retains the liquid capacity of
transformer according to the mechanical drawings. The transformer room floor shall
be sloped to drain any transformer seepage to the sump pit.
PART 2 - PRODUCTS
A. Description: Liquid-filled, 2-winding transformers.
B. Insulating Liquid: High quality mineral oil class 1, complying with IEC 60296.The
insulating oil shall contain an inhibitor to extend its oxidation life. Rating and
stipulated capacity shall be continuous Site-rated capacity under all encountered
environmental and climatic conditions. The oil shall be best quality mineral oil of high
breakdown strength, low viscosity, high resistance to oxidation and shall not
deteriorate under all loading condition.
C. Top Oil Temperature Rise: 45 deg C above the ambient temperature.

D. Average Winding Temperature Rise: 50 deg C above the ambient temperature.
E. Maximum winding Hot Spot temperature: 98 deg C
F. Average Temperature due to Short circuit: 250 deg C
G. Insulation class: F (105 deg C maximum rise above 40 deg C)
H. Basic Impulse Level: 95kV for 13.8 kV transformer nominal voltage.
I. Impedance voltage (Z%): 5% up to 1500 KVA.
J. Full-Capacity Voltage Taps (13.8 kV): Total fife taps, four nominal 2.5 percent taps, 2
above and 2 below rated primary voltage; with externally operable tap changer for
de-energized use and with position indicator and padlock hasp. The tape changer
shall be gang-operated and be capable of withstanding full transformer short circuit
current without damage. Tap changer shall have at any tap position indicator visible
from base level.
K. Maximum Losses: The indicated table below are the maximum acceptable values.
And according to SEC Requirements:
Transformer Rating No-Load Losses (Watts) Load Losses (Watts)
500 KVA 750 4700
1000 KVA 1100 9000
L. Permissible Overload: after thermal equilibrium has been rated at 75% of rated load,
the transformer shall be capable of sustaining the overload conditions listed in the
following table without the transformer winding hot spot temperature exceeding 140
deg C.
Minimum Duration in Minutes at Ambient

Load Percent of rating (%) Temperature of
30 deg C 40 deg C
133 240 155
150 98 65
M. Cooling System: Class OA, self-cooled (ONAN) (for oil immersed transformers the
identification is expressed by a four letter code as following.
1. O (internal cooling medium): Mineral oil or synthetic insulating liquid with fire
pointless than or equal 300 deg. C.
2. N(Circulation mechanism): natural flow through cooling equipment and in
windings,
3. A(External cooling medium): Air
4. N (circulation mechanism for external cooling medium): Natural convection

N. The distribution transformer shall provide for future extension to a minimum of 25%
above the total connected load
O. Vector Group: Dyn11 unless otherwise indicated on the drawings.
P. Core: The cores of the transformer are made of grain-oriented magnetic, high
permeability cold-rolled silicon steel laminations with low losses. The lamination
should be insulated with suitable varnish or paint; solid insulation is not acceptable.
Design of the core shall be made to reduce the vibration and minimize noise level.
Q. Windings: Windings shall be of high grade electrolytic copper conductors with low loss
as per SEC and IEC requirements. the winding shall be clamped effectively so that
they withstand shocks and vibrations during transport and forces produced by the
most sever short circuit current. The winding shall be uniformly insulated using high
dielectric strength tapes having very good temperature stability and be firmly braced.
R. Noise Level: the noise level emitted by a transformer at full load shall not exceed 48
dB at measured distance of one meter. And measurement shall be accordance to IEC
60076-10
S. 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 where the short circuit level current that the
transformer should withstand for two seconds is
1. 25 times full load current for ratings of 50, 100, 200 and 300 kVA.
2. 20 times full load current for rating of 500 kVA.
3. 17 times full load current for ratings of 1000 and 1500 kVA.
T. Terminations: High voltage terminations shall be complete with cable glands as

necessary. Low voltage termination shall be suitable for feeder bus-way or cables as
shown on the drawings.
U. Bushing: High and low voltage bushings shall be of highest quality glazed porcelain.
Suitable for rated voltage and current, indoor and outdoor installations. Bushings
shall generally comply with the requirements of IEC Standard 60137. The minimum
creepage distance shall not be less than 2 cm/KV for indoor and 4 cm/KV for outdoor
or according to SEC requirements. The MV bushings shall be labeled U, V, W by using
indelible black color paint. Phase identification by adhesive stickers is not acceptable.
V. Tank and Base: Transformer tank shall incorporate cooling fins. Final finish shall take
the form of sand blasting to bare metal, followed by at least two coats of suitable
primer and two final coats, medium grey color or any other color recommended by
the supplier. Transformer tank shall be welded steel construction, suitable for
vacuum filling (300 mm vacuum) oil and able to withstand all stresses during
transport and operation including full short circuit. The tank base shall be fitted with
oil drain and sampling valve. Gasketed joints for tank and cover, bushings and other
bolted attachments shall be so designed that gaskets shall not deteriorate due to
weathering.
Transformer base shall be designed to permit skidding in directions parallel to either
centerline.

W. Oil Expansion Conservator: Expansion conservator shall be made of sheet steel with
appropriate size and is connected to the tank. The conservator is provided with oil
level indicator, oil filling plug and a connection pipe for connecting the oil to the
transformer.
X. Cable End Boxes
1. MV Cable End Box: The transformer shall be fitted with suitable end
termination box with cable entry coming vertically from bottom/top according
to the approved workshop drawings. The box shall include cable clamps,
grounding connectors, and its size shall be adequate for terminating MV cables
with size as shown on the drawings. The box shall be single gasketed
removable bolted cover. The box shall be fitted with cables entries steel
knockouts suitable for cables. Loose rubber bushings shall be provided inside
of this box for these knockouts.
2. LV Cable End Box: The transformer shall be fitted with suitable LV cable end
box having non-magnetic material gland plate with appropriate size single
compression brass gland according to the cable size shown on the drawings
Y. Accessories: Grounding pads, lifting lugs, and provisions for jacking under base.
Transformers shall have a steel base and frame allowing use of pipe rollers in any
direction, and an insulated, low-voltage, neutral bushing with removable ground
strap. Include the following additional accessories:
1. Magnetic oil level indicator.

2. Dial-type thermometer with maximum indicating points and alarm contacts
(2 NO, 2 NC).
3. Combination drain and lower filter valve and oil sampling valve.
4. Facilities for lifting core and coil assembly from tank without draining oil from
transformer.
5. Lifting lugs for complete transformer.
6. Skid base with jacking and pulling provisions.
7. Two grounding pads on diagonally opposed sides for the tank base with bolt
type cable clamp adjustable for copper ground cables ranging from 95 mm2 to
240 mm2 for tank grounding. One of the pads shall be located at the side
where the secondary neutral bushing is mounted.
8. Fill hole fitted with plug.
9. 4 Bi-directional rollers DIN42561.
10. Diagrammatic weather-proof engraved or etched nameplate. The nameplate
shall show full rating of transformer, voltage and tap ratios, impedance,
weight, gallon of oil, operational pressure, withstand pressure, vector diagram,
etc. and shall bear a connection diagram showing studs, tap changers and
other parts. Nameplate shall be in English.
11. Explosion diaphragms, to relieve sudden pressure from severe internal fault
and sudden pressure protective relay (DGPT2) or equivalent.
12. In addition to items listed hereinbefore, provide relaying and protection as
manufacturer's standard practice.
13. Buchholz relay and Silica Gel.

2.1 IDENTIFICATION DEVICES
A. Nameplates: Engraved, laminated-plastic or metal nameplate for each transformer,

mounted with corrosion-resistant screws. Nameplates and label products are
specified in Division 26 Section "Identification for Electrical Systems."
A. Reference Standards:
1. Except as modified herein, the equipment shall be designed, manufactured

and tested in accordance with IEC 60076, Parts 1 to 10 inclusive, latest
editions.
2. The oil shall conform to the relevant IEC 60296 and Amendment 1.
3. The loading of the oil transformer shall conform to the relevant IEC 60076-7.
4. The transformer bushings shall conform to the relevant IEC 60137.
B. Factory Tests: Perform the following factory-certified tests on each transformer

according to the IEC and/or BS in the presence of the owner or his representative:
1. Measurement of voltage ratio and checking of voltage vector relationship.

2. Insulation tests between windings and between windings and earth.
3. Power frequency withstand test.
4. Induced over voltage withstand test.
5. Measurement of no load losses at rated voltage and rated frequency.
6. Measurement of no load current.
7. Measurement of load losses.
8. Measurement of winding resistance.
9. Measurement of short circuit impedance.
10. Oil leak test.
C. The owner and/or his representative to be notified by the date of tests at least 14
days before date of the tests and indicate the tests approximate duration.
D. Certifications: A certificate for the following type tests shall be submitted
1. Impulse voltage test.

2. Measurement of maximum temperature rise of oil and windings.
3. Audible sound level measurement.
E. Prior to shipment the assembled transformer shall be liquid-filled and pressure

tested for at least 8 hours at the maximum operating pressure for detecting the
presence of leaks.

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.
F. 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 X
X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP RING MAIN UNIT
KSA 261301 - 2970 1

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 Requirements 5
2.3 Components 5
2.4 Accessories 9
2.5 Voltage Presence Indicators (Vpi) 9
2.6 Fault Passage Indicator 9
2.7 Fabrication 10
PART 3 EXECUTION 10
3.1 Installation 10
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.
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 All equipment and material shall be designed manufactured and tested in

accordance with the latest applicable IEC standard.
D During tendering, the Contractor shall select one of the manufacturers whose is
capable of delivering Ring Main Unit which fulfill the requirement of Saudi Electric
company (SEC) 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.
E Before delivery, the Contractor is responsible to obtain the approval for the
manufacturer, type, voltage, protection devices, meters, etc. from the Saudi
Electrical Company (SEC) 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 AC metal- Enclosed switchgear and controlgear for rated voltages

Above 1 KV and up to and including 52 kV
2. 627271-1 Part 1 -Common specifications for alternating current switchgear
And Controlgear
3. 62271-102 Part 102- High-voltage alternating current disconnectors and
Earthing switches
4. 62271-103 Part 103- Switches for rated voltages above 1 kV up to and
Including 52 kV
5. I62271-105 Alternating current switch-fuse combination).
6. 61869 Instrument Transformers
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 in KSA or Gulf Area.
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 26, 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 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.
Spare parts list for normal operation and maintenance for 3 years recommended by
manufacture.
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
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
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
Conditions of Contract.
PART 2 PRODUCTS
2.1 MANUFACTURERS

be incorporated into the Work.
2.2 PERFORMANCE AND DESIGN REQUIREMENTS
A System Characteristics: The system will be rated at 13.8 KV, 3-Phase, 60 Hz. The
approximate fault current shall be 500 MVA unless otherwise as shown on the
drawing.
B Station Criteria: Ring Main Unit as indicated in the drawings
1. Two SF6 Load break switches with earthing switch mechanically interlocked.
2. One SF6 Load break switch with ampere rating as indicated in the drawings for
feeding power transformer
3. Earth leakage indicator with Ferranti C.T.
4. Complete with bus bars and supporting insulators
5. Complete with copper earthing bar and there shall be a 25 mm2 earthing
copper braid install from each earthing switch to earthing bar
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 (IP 3X).
D All bus bars shall be electrical copper of section not less than 400 mm2, mounted on
support insulators enough to withstand mechanical forces which may happen due to
short circuit 21 kA r.m.s. at 13.8 kV for 1 sec.
E Busbars: high conductivity copper, modular, designed to withstand worst short-

circuit conditions without allowing permissible temperature rise at ambient
conditions, in accordance with the Standards.
F Each switch compartment shall be equipped with suitable clamp or any other mean
for supporting and fixing the cable or end box.
G All wiring shall be in PVC conduits.
H Each switch board shall be supplied with a delachable insulated operating handle ≥
650 mm.
I Switchboard design according to IEC 62271-200 standards.
J Detailed drawings and technical specifications shall be attached with the offer.
K Load break Switches:
1. Load break switch and its mechanically interlocked earthing switch shall be
SF6 insulation.
L Voltage and Current Ratings according to IEC 62271-1
1. Rated Voltage Un 13.8 kV

2. Basic Impulse Level U1 (1.2/50 µs) 95 kV
3. Rated Power Frequency Withstand Voltage 1 min KVRMS 38 kV
4. Rated Current for Cable L.B.S. 400 A
5. Rated current for Transformer L.B.S 200A
6. Rated Short-time Withstand Current 1 sec 21 kA
7. Rated Making Withstand Current peak 52.5 kA
M Specifications and tests shall comply with IEC 62271-103 for load break switch
(L.B.S.).
N There shall be an earthing switch with each cable L.B.S.
O The earthing switch shall be manual operated with mechanical lock which prevents
its switching while the main switch is on.
P 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.
Q The rated short-time withstand current of the earthing switch shall be at least equal
to that assigned to the disconnector (L.B.S.)

R The peak withstand current of the earthing switch shall be at least equal to that
assigned to the disconnector (L.B.S.)
S Cable L.B.S. shall also fulfill the conditions for isolating distance acc. To IEC 62271-
102 prescribed for isolators.
T 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.
U Contractor shall submit type tests certificates for the offered equipments according
to IEC.
V Routine tests shall be in accordance with IEC and shall be attended by Employer’s
representative(s).
W Earth Fault Indicators: 220 V, 60Hz, 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.
X Current Limiting Fuses: 13.8 KV H.R.C. FUSES (if required)
1. Conditions in Normal Services

2. Maximum ambient air temperature 50°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%
Y To withstand effect of humidity and occasional condensation outdoor fuses shall be

used indoor.
Z 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.
AA 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.
BB Strikers shall comply with the requirements specified in Sub-clause 18.3 of IEC
60282-1.
CC 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.
DD After operation, the fuse shall be capable of withstanding the power frequency
recovery voltage across its terminals.
EE Fuse Ratings:
1. Rated Voltage 13.8 kV

2. Rated Frequency 60 Hz
3. Rated Current As shown on drawings
4. Rated Breaking Capacity ≥ 50 kA
FF 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 60282-1.
GG Time-current characteristics shall be in compliance with IEC 60282-1 and shall be

offered with tender.
HH 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 5P10 for protection
n10.
2. Potential Transformers (PT's): Class 0.5 for the first core (metering) and class
3P for the second core (protection).
II All potential transformers shall be provided with current limiting fuses. Voltage
rating for the secondary winding shall be of ratios:
13800 / 110 / 110

3 3 3
For metering and protection. the open delta winding shall be loaded by a resistor to
avoid Ferro resonance; the resistor is to be selected by the switchgear manufacturer.
JJ 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.
KK CT's shall have mechanical and thermal rating equal to the rating of the circuit
breaker and 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.
LL 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.
2.5 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.
2.6 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.
2.7 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.
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
according to same above IEC publications.


ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP LOW VOLTAGE SWITCHBOARDS
KSA 262413- 2970 1

CONTENTS
SECTION 262413
LOW VOLTAGE SWITCHBOARDS
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.6 Warranty And Product Quality 4
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 General 5
2.3 Switchgear 7
2.4 Incoming Supply And Outgoing Circuits 10
2.5 Circuit Breakers 11
2.6 Power Air Circuit Breakers (Pacbs) 12
2.7 Distribution Board For Outdoor Lighting 15
2.8 Instrumentation And Controls 15
2.9 Mcc Special Requirements 16
2.10 Surge Protection Device (Spd) 16
2.11 Factory Testing 16
2.12 Painting And Anticorrosion 17
PART 3 EXECUTION 17
3.1 Inspection 17
3.2 Preparation 17
3.3 Electrical Work 17
3.4 Mounting 18
3.5 Installation Supervision 18
3.6 Field Testing 18
3.7 System Validation 19
Low Voltage Switchboards

Riyadh Sedra 2 (Prj. 2970) Section 262413
Page 1 of 19
SECTION 262413 - LOW VOLTAGE SWITCHBOARDS
PART 1 GENERAL
A. Drawings and General Provisions of the Contract, including General Conditions,

work of this Section.
B. The Contractor is responsible to supply and install the low voltage switchgear accord-
ing to the latest requirements of the Saudi Electricity Authority (SEC). This shall re-
quire from the contractor’s manufacturer to obtain the approval (before delivering)
for the type, voltage, form, etc. from Authority have jurisdiction.
1.2 SUMMARY
A. This section covers low voltage metal enclosed switchgear as indicated on the
Drawings and required by the Contract and shall include the following items:
1. Switchboard
2. Distribution Boards
B. Related Sections
1. The following sections of work contain requirements that relate to this

Section:
a. Division 26 Section “conmen work result for electrical work “

b. Division 26 Section “Package Engine Generator “
c. Division 26 Section “Power Factor Correction Equipment “
d. Division 26 Section “Automatic Transfer Switches “
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

Page 2 of 19
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 requirements shown on the single
line diagrams
Test Programs:
8. Standard and optional factory tests program

9. Post-installation test procedure
10. Final test reports procedure
C. Calculations and charts proving that discrimination in the breaker characteristics is

achieved. Detailed short circuit level calculation to select the short circuit rating of
the various switchboards. Bus bar sizing calculation for each switchboard. Calculation
for Temperature rise inside switchboards
D. Equipment Data: The equipment data to be provided by the Contractor prior to

ordering 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, provision for expansion
including 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.
E. 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).

Page 3 of 19
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.
3. Electrical Regulations/Code Compliance: comply with applicable local
regulations/code requirements (SASO). This will have precedence over other
codes/standards nominated for the project, unless otherwise approved in
writing. Switchboard to be approved by SEC and manufacturer to be listed in
SEC vender list.
A. Shipments shall be securely packed for delivery and transit, protected against
excessive 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.
1.6 WARRANTY AND PRODUCT QUALITY
A. one year warranty after the date of Substantial Completion, for the low voltage
switchgear 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.

Page 4 of 19
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 type
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
factory.
B. All Switchboards shall be Type tested (Design Verified Assemblies) against short
circuit as a minimum as per the latest IEC 61439 and manufactured only by
manufacturer having ISO 9001 Certificates. The Manufacturer shall also submit test
certificates such as KEMA, ASTA or as issued by any other accredited testing
authority confirming the declared short circuit ratings of Switchboards and circuit
breakers
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 400/230

volt, 3-phase, 5 wires, 60 Hz, solidly grounded neutral power supply. Ambient
conditions shall be as specified by Section 260500.
E. Index of protection for all distribution boards & panel boards shall be as follow:
1. IP43 for surface mounted indoor installations.

2. IP55 for outdoor & wet areas unless otherwise indicated on the drawings and
schedules.
F. Switchgear shall be metal enclosed, form (2b) 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
accordance with the requirements for the installation and operation and
maintenance of the equipment as specified and supplied by the Manufacturer, and
as per IEC 61364, 61439. Any inaccuracy in the building shall be corrected as
required and directed by the Engineer, and at no extra charge to the Employer.

Page 5 of 19
I. Ratings are shown on the one-line diagrams and the panel details and should be
checked based on the actual loads.
J. The switchgear shall contain equipment with ratings as indicated on the one-line
diagram, panel details, and in this Specification.
K. All equipment designated as "spare" shall be fully equipped with all of the necessary
items required to make the equipment operable by connecting to the outgoing
power and control leads.
L. Switchgear shall have additional "space" for at least 20% of its outgoings for future
extension. Equipment shall have a blank front cover and shall be equipped with
horizontal and/or vertical bussing complete with the necessary screens required and
circuit breaker cassette for the future addition of a circuit breaker suitable or a
combination of breakers within the space factor limits.
M. Approved barriers between adjacent sections of switchboard shall be provided.
N. Switchgear shall be suitable for future extension on both ends. Unequipped space
units will be furnished only as required to balance the switchgear assembly.
O. All ratings shown on the one line diagrams are the required operational equipment
ratings at the ambient temperature.
P. The Contractor shall assume all responsibility for mechanical and electrical
coordination of equipment and devices required by the Drawings and Specifications.
Q. Interrupting capacities and short circuit ratings shown on the Drawings are for
guidance only; Contractor shall submit calculation for actual levels to the Engineer
for approval.
R. 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 (e.g. bus, bars, bolts, circuit breakers, etc. shall
withstand.
S. Buses shall be 99.8% electrolytic copper of sufficient size to limit temperature rise to
45C or an additional derating would be necessary.
T. Crowded bus-bar arrangement to fit maximum possible number of branch circuit

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

Manufacturer design tables in accordance with temperature rise type tests.
V. Any switchboard column housing a number of circuit breakers summing more than
3000 Amp of name-plate ratings should be fitted with a top heat extraction fan and a
bottom ventilating louver fitted with a front filter to maintain the switchboard
protection degree.
W. 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.
Page 6 of 19
X. 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
coordinated. All design must be in accordance to temperature-rise type test.
Y. All switchboard doors shall have a key lock and indicating lamp for ON/OFF-READY, in
addition to the necessary equipment for security identification.
Z. All indicating lamps used in the switchboards should be semi-conductor LED diodes.
Use of neon or incandescent indicating lamps is not acceptable.
AA. All indicating lamps and pushbuttons should be chromatid metallic base and body.
BB. All panel access doors shall be provided with a master key for maintenance and
operation.
CC. The panel shall be designed to permit continuous operation of all components
mounted therein with panel ambient temperatures of up to 45C for indoor
installation and 50C for outdoor (with shade) installation.
DD. Main circuit breakers of the MDB shall be provided with smart interface module SIM
for ACB and MCCB circuit breakers as indicated on the drawings.
EE. Digital Power Meters with Modbus communication protocol for Main switch boards
shall be provided as required in single line diagram and according to the following:
1. Accuracy class 0.5, dual source, digital energy meters with provision for Time
of Day (TOD) tariff and Real Time Clock (RTC)
2. The meter shall be suitable for satisfactory continuous operation under the
following condition:
a. Max. Ambient air temperature: +50°C.

b. Min. Ambient air temperature: -5°C.
c. Average Relative Humidity: 95%.
3. The meter shall be protected against malfunction due to the ingress of vermin.
4. All meters and equipment’s shall be complying with IEC and ISO standards:
a. IEC 61557-12 Part 12: Power metering and monitoring devices

b. IEC62052-11 Electricity metering equipment (AC) – General
Requirements,– Part 11: Metering equipment
c. IEC 62052-21 Part 21: Tariff and load control equipment
2.3 SWITCHGEAR
A. The switchgear shell is composed of a rigid frame, the frame structure is assembled
with a C-shaped skeleton not less than 2 mm thick shaped in one time by a flexible
processing line, the inner part of the partition plate is also made of aluminum zinc
coated plate. All the metal structural parts of the cabinet are treated with anti-
corrosion.

Page 7 of 19
B. The enclosure body has sufficient mechanical and electrical strength to withstand the
influence of external force in transportation, installation and electrodynamic force in
case of an accidental short circuit without damage, lifting rings are set on the cabinet
body. The top of the shell should be covered with a cover plate to prevent foreign
objects and water dripping from causing bus bar short circuit. The bottom plate of
the enclosure shall be made of steel plate with knockout holes for cables to enter
and exit the cabinet.
C. Each low-voltage cabinet has a nameplate. The equipment nameplate shall be made
of stainless steel plate. All rating values shall be indicated on the nameplate at least
as specified in the standard. Each drawer unit is equipped with a circuit label marked
with circuit name, which shall be in Chinese and English.
D. The switchgear should have good ventilation and heat dissipation conditions and
sufficient temperature rise margin, such as the ventilation is equipped with louvers
or other vents, measures shall be taken to prevent water leakage and small animals
from entering, and relevant standards shall be complied with SEC Requirements.
E. Cabinet materials and cabinet structure should be able to prevent the generation of
fault arc. Once the fault arc occurs, it can be extinguished in a short time. The
structure of the switchgear compartment should be able to withstand the arc
generated by the three-phase short circuit or the pressure generated by the free gas
without causing damage, and should provide appropriate measures to eliminate the
gas.
F. The drawer type cabinet should be separated into three small rooms, i.e. main bus
bar room, electrical room and cable room. The compartment can meet the following
requirements:
1. The separation between functional units and compartments is clear and relia-
ble, so that the work of other units will not be affected by the failure of a unit
and the failure will be limited to a minimum range.
2. The openings between the compartments ensure that the gas generated by
the circuit breaker during short-circuit breaking does not affect the normal op-
eration of the functional units of the adjacent compartment.
G. Apparatus: All auxiliary equipment, transition sections, bus duct, and other necessary
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.
H. 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.
I. 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.
J. Fuses (if applicable) shall be of the same manufacturer, dual elements current
limiting type.

Page 8 of 19
K. Overload relays shall be of the anti single phasing type.
L. Bolted covers on compartments incorporating live connections shall bear a suitable

warning label.
M. 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.
N. Fuses or miniature circuit breakers shall be provided so that relays, controls and
instruments may be isolated whilst other essential circuits are kept energized.
Accordingly, the control circuit should be divided into two separate circuits
(indicators circuit) and (circuit breakers control circuit).
O. 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.
P. 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
maximum setting of the protective device on the incoming side whichever is greater.
Q. Copper bus bars require tinning or silver plating at the lap joint. All copper rows are
tinned and bolted securely and tightly so that the bus bar temperature remains
essentially constant at the initial contact pressure around the bolt hole from the
standard rated ambient temperature to the rated full load temperature. The contact
surface temperature of the connector section is less than 70°C at full load under the
operating ambient temperature.
The bus-bars shall be insulated with a 1000 V electrostatic epoxy insulating paint to
limit the possibilities of internal short circuit. The bus-bar dropper shall be rated at
125 % of the current carried by the bus-bar
R. The creepage distance and electrical clearance between the live parts of the bus bar
and main circuit connections and their grounded metal components shall be not less
than 15 mm.
S. All bus-bars shall be fully rated and extend with the same size along the entire length
of the switchgear assembly.
T. All horizontal bussing shall have provisions for future extension on either end.
U. All main bus connections shall be tight and tin plated, corrosion-free and with
sufficient bolts to withstand the symmetrical fault currents indicated on the
Drawings.
V. 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
materials should be of a non-magnetic material.

Page 9 of 19
W. All bus-bars and tap connections shall be connected in such a manner that initial
contact pressure remains substantially undiminished at bus temperatures ranging
from indicated rated ambient to rated full load temperatures, to maintain minimum
contact resistance for the full service life of the equipment.
X. 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
section shall have full height and depth, fire stop barriers of approved fire resistant
material.
Y. Vertical bus compartment shall be completely enclosed and isolated from other
components.
Z. All vertical bus connections shall be tight, corrosion free and be able to withstand the
symmetrical fault currents indicated.
AA. Neutral Bus: Neutral buses shall be sized for the same capacity of the main bus and
shall be of copper.
BB. 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.
CC. All neutral bus connections shall be tight and corrosion free.
DD. 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.
2.4 INCOMING SUPPLY AND OUTGOING CIRCUITS
A. Source: Incoming supply shall be 400 volts, 3-phase, 5 wires, 60 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
considered a minimum and the Contractor shall adjust to conform to the IEC 60364
Regulations after final equipment selection, same gland plates mentioned above will
be applicable.

Page 10 of 19
2.5 CIRCUIT BREAKERS
A. Main incoming, bus tie circuit breakers shall be four-pole, single-throw, molded case
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 or as indicated in the drawings
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
allow 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
application in accordance with the drawings, allocated spaces and the "Regulations"
as applicable 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
mechanism 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
protection 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.

Page 11 of 19
M. The service short-circuit 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.
Switchboard 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

unless 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. Frame sizes (or continuous current ratings) indicated shall be the minimum accepted
ratings based on a fully-rated interrupting duty (non-current-limiting) as shown on
the drawings. The trip current rating (amps) indicates the nominal rating at which the
thermal overload element operates.
Q. When tripped by either the thermal or magnetic elements, the handle shall
automatically assume a position midway between ON and OFF positions which
clearly indicates a "TRIPPED" position.
R. All poles shall be constructed so as to open, close or trip simultaneously.
S. Non-interchangeable trip breakers shall have their covers sealed and breakers with
interchangeable trips shall have the trip unit sealed to prevent tampering.
T. All incoming and outgoing circuit breakers in the same switchboard shall be totally
selective at the prospected short circuit level.
U. Molded case circuit breakers shall have trip units that achieve full selective system
for overload, short circuit and instantaneous protection.
V. Circuit breakers of rating 250 Ampere and above shall have electronic trip unit.
W. Thermal overcurrent trips shall be ambient-temperature compensated to allow for

an ambient temperature at the breaker higher than at the protected circuit or
device.
X. 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.
Y. All circuit breakers shall be derated according to climatic conditions and operating
temperature as per manufacturer standards.
Z. All main circuit breakers to be provided with necessary accessories connection with
BMS system as required and specified in BMS schedules.
2.6 POWER AIR CIRCUIT BREAKERS (PACBs)
A. Type: Encased in high strength, high temperature resistant, molded plastic insulating

Page 12 of 19
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 120V ac 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, 2 - 9 times current setting, 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 interrupting capacity of Circuit Breaker.

Page 13 of 19
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. Trip unit shall have inputs from conventional potential transformers for every phase.
Current sensors transformers for every phase. Current sensors shall be encased in
epoxy filled plastic housing to protect against damage and moisture and shall be in-
tegrally mounted in breakers.
J. 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.
K. Circuit breaker accessories are to include the following:
1. Padlocking or key-locking provisions for all positions (disconnected, test, con-

nected, 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.
L. 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.
M. 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.

Page 14 of 19
2.7 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
2. 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
3. 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.
4. Selection switch and push buttons.
2.8 INSTRUMENTATION AND CONTROLS
A. All instruments, relays and components as contained in the one-line diagrams

specified herein or required by manufacturers standard practices, shall be provided.
B. Control switches, if any, shall be the rotary enclosed rear-mounting type with
positive 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
voltage 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 and SEC requirements.

Page 15 of 19
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.
2.9 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
system 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
Breakers 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
together with instrument cables.
E. Motor with frequency converters in EEX-zone need thermistor in motor windings.
2.10 SURGE PROTECTION DEVICE (SPD)
A. Transient voltage suppressor – shall be provided at the incoming supply side of main
low voltage panel, as shown on the drawings. These should be as manufactured by
FURSE (UK), ESP or approved equivalent. The Contractor should select the proper
type recommended by the supplier and submit to the Engineer for approval
supported by calculations.
2.11 FACTORY TESTING
A. The switchgear shall be factory assembled and tested before shipping. Test reports
shall be furnished by the Contractor.

Page 16 of 19
B. All components shall be thoroughly inspected and tested to ensure alignment and
adequacy of all functions.
2.12 PAINTING AND ANTICORROSION
A. The Bidder shall make treatment and painting on the equipment surface according to
different operation conditions of the equipment, and illustrate the equipment sur-
face treatment method, painting scheme and construction technologies. Before
painting construction, the Bidder shall report to the Tenderer for approval, and be
responsible for clarifying the opinions of the Tenderer until they are passed; during
this process, the commercial price changes due to scheme change cannot be pro-
posed to the Tenderer. The submitted anticorrosion scheme shall contain equipment
name, surface treatment method, roughness after surface treatment of base materi-
al, selected supporting paint (including specific paint model, dry film thickness of
each paint layer and gross dry film thickness of paint), finish coat color (marked with
RAL color number), instruction to construction technology, etc.
B. Corrosion environment in the project according to the latest edition of (ISO 12944)
PART 3 EXECUTION
3.1 INSPECTION
A. Inspect each switchgear assembly and related accessories for damage, defects,
completeness 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
completed 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.

Page 17 of 19
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.
Directories shall be typewritten in English and Arabic to indicate load served by each
circuit, and shall be mounted in a holder behind protective coating. Contractor shall
follow manufacturer's installation instructions.
B. 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
installation.
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
accordance with the Specifications herein, until the installation and operation are
acceptable. 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

corresponding IEC) for the type of equipment.
C. The tests shall be both electrical and mechanical to demonstrate satisfactory

operation. Where protection relays or adjustable overcurrent trips are incorporated,
primary/secondary injection tests shall be carried out to demonstrate the correct
setting 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
Manufacturer's works. Witnessed tests shall comprise Routine Tests in accordance
with BS EN 61439 and/or IEC 61439 include but not limited to 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
protection 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
simulation of operation of remote control circuits and all protection devices.
Page 18 of 19
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
manufacturer'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
intended functions as specified and detailed in the approved Post-Installation Test
Procedures. 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
certifying completion of validation of each system.

Page 19 of 19

ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
SPECIFICATION REV.
PANELBOARDS
KSA 262416 - 2970 1

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) 6
2.6 Miniature Circuit Breakers (Mcbs) 8
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 Lighting Control Panel 12
PART 3 EXECUTION 12
3.1 Installation 12
3.3 Connections 13
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.
B. The Contractor shall execute the required work as per requirements of latest revision
of Saudi Building Codes.
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 “Low Voltage Switchboards”.

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 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 61439-0, 1, 2 “Low Voltage Switchgear and Control Gear Assemblies”.

2. IEC 60947-1 “Circuit breaker”.
3. Other components where not specified are to comply with the relevant IEC
standards.
4. NFPA 70
5. 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. Panel boards are to be totally enclosed, dead front type, protection code IP 31 for
indoor installations and IP 55 for outdoor & Wet Area installations, in accordance
with IEC 60529, and are to be factory designed and assembled.
C. Earthing bar is to be sized as half size of phase bus bars.
D. Neutral bar is to be sized as the phase bus bars.
E. Protection is to be fully rated throughout the systems.
F. Selectivity coordinated protection (integrated equipment short-circuit ratings) will

only be acceptable within final branch circuit panel boards, between branch circuit
breakers and the main incoming circuit breaker, in accordance with an integrated
series combination chart prepared by the manufacturer, tested and certified in the
country of origin by an internationally authorized organization, where short-circuit
ratings are beyond available fully rated types specified, and with the approval of
Engineer.

G. 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.
H. 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.
I. 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 Electro-galvanized sheet
steel of gauges not less than specified and 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 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 55), without knockouts, but with removable
sealed/gasketed bottom gland plates and gasketed 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. Padlocking devices are to be provided.
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 IEC 60947-2.
B. Minimum short-circuit breaking capacities to IEC 60947-2 are to be as follows:
1. 6 - 125A MCB :
2. 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 45 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 45deg.c, available as 1, 2, 3 and 4-pole circuit breakers. De-
rating above 45 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 and bus bars
ranging from 630 A to 1250 A, 3-phase, 4-wire (or 3-wire where specifically
indicated), suitably and orderly arranged for any selected combination of branch
MCCBs ranging from 150/160 A to 1250 A frame size and short-circuit interrupting
ratings. Circuit breakers smaller than 250 A frame size, where indicated, may be
grouped on an integral sub-assembly mounted to main chassis.
B. DP Type 2: Form 1 to IEC 61439-1, and have a minimum rated insulation voltage of
690V. Panel board is to be recessed or surface mounted type complete with trim and
door, adjustable trim fixation for flush panels, and with ratings of main circuit
breaker and bus bars up to 400 A, 3-phase, 4-wire, with 2 or 3-pole branch circuit
breakers, 100 A or 150/160 A or 250 A frame size.
C. CIRCUIT BREAKERS for DP’s shall be fitted with a plug-in base type of modular
construction complete with its accessories; non draw-out type.
D. 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.
E. Interior of panel board is to be pan assembly consisting of galvanized sheet steel

chassis minimum 2 mm thick, folded, flanged and reinforced, with bus bars vertically
arranged and mounted on molded insulators.

F. Molded insulators are to have minimum temperature rating of 130 deg C and
insulation grade of 3.5 kV for one minute.
G. 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 61439-3.
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 LIGHTING CONTROL PANEL
A. Enclosure: Comply with IEC 60529.
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 X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP MOTOR CONTROL CENTERS
KSA 262419 – 2970 1

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 11
2.7 Circuit Protectors And Switches 11
2.8 Motor Control Center 12
2.9 Control Switches 14
PART 3 - EXECUTIONS 15
3.1 Applications 15
3.2 Installation 15
3.4 Control Wiring Installation 16
3.5 Earthing 17
3.6 Connections 17
3.8 Cleaning 18
3.9 Demonstration 18
Motor Control Centers Section 262419

SECTION 262419 - MOTOR CONTROL CENTERS
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 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.
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
1.8 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.
A. one-year warranty after the date of Substantial Completion, for the low voltage
switchgear shall be provided, for the materials and manufacturing quality control.
the requirements or fails in work
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 kM 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: 400V, three-phase ±10 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: 50 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, IEC 61439-2.

b) Protection Class: IP 55 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) Flying start: The drive shall have a built-in Flying Start feature. This
feature will allow a motor unit which is still rotating, to be restarted
without first stopping it. The VSD shall restart the motor from the
rotating speed and then reaccelerate to the speed indicated by the
speed reference signal. The Flying Start feature shall be available in both
directions, to be able to start the drive in the required direction
regardless of the rotation direction of the motor.
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) Harmonic Distortion: The VSD shall have built-in ac or dc chokes to

minimize the total harmonic distortion (THD). The THD of the unit for
current has to be less than 50 percent in a supply network with a short
circuit ratio (Rsc) of 300 (i.e. the ratio of the supply network's short
circuit current to the unit's nominal current). If the supply voltage is 440
V or higher, the THD value has to be less than 55 percent. However, the
VSD manufacturer shall submit to the Contractor the VSD harmonic
spectrum for the Project specific supply network. The spectrum shall be
used in the design of appropriate harmonic filters. The single harmonics
shall be presented up to 25th harmonic and the THD has to be
calculated taking into consideration harmonics up to 40th harmonic.
b) 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.
c) 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.
d) 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.
e) Efficiency: The full load efficiency of the VSD shall be at least 95 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 IEC 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. All ammeters shall be available with “dead rider” Max. Demand indicators of the re-
settable type.
S. 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 disconnector 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 Disconnector 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 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, 1000V 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
and anti-corrosion lock.
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 .
2.8 MOTOR CONTROL CENTER
A. Type: Totally enclosed, IP 42 for free standing-indoor installation, and IP 55 for

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

braced for maximum rigidity, sand blasted, rust inhibited after fabrication and
sprayed with 1 coat primer and 2 coats enamel internally and externally.
C. 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 multifunctional display unit, with software
connection to BMS/Fire Alarm Control Panel FACP for low voltage MCC.
2. Main incomer of MCC shall have KWH and power quality meter connected to
the BMS/FACP.
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, tinned copper, rated at full capacity of main bus bar and
distributed throughout whole motor control center.
6. Earth bus bars, tinned 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. One voltmeter 144mm X 144mm size, moving iron type, with commutator,
range 0-415 V. Voltmeter shall carry CE marking and shall have certified
compliance to BS EN 60051.Voltmeter burden shall not be more than 4.5 VA
and enclosure shall be suitable for a RH of 95 % non-condensing. The
Voltmeter enclosure shall comply to IEC 60529.
9. 3 Ammeters 144mm X 144mm size with expanded scale in the operating
region and with MDI indicators on all feeders with necessary current
transformers. Ammeter shall carry CE marking and shall have certified
compliance to BS EN 60051. Ammeter shall be of 600V insulation class and
shall have overload scales for motor start duty. Ammeter burden shall not be
more than 0.5 VA and enclosure shall be suitable for a RH of 95 % non-
condensing. The ammeter enclosure shall comply to IEC 60052.
10. 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.
11. 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.
12. 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.
13. Each MCC section shall be equipped with anti-condensation heater with
related accessories.
14. 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.
D. All internal painting shall be RAL 7035.
E. Door interlock shall be defeat able by means of a tool.
F. Wiring: Motor control center wiring to be coordination type 2 to IEC standard.
G. 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.
H. Compartment doors to be interlocked so that isolators or breakers must be in OFF

position before door can be opened.
I. Spare Positions: Fully equipped cells, ready for connection to motors, are to be
provided in adequate number.
J. Space Positions: if required to be fully equipped cells ready to receive control unit are
to be provided in adequate number.
K. 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.
L. Incoming line connections to be made with solder less terminal 4 bolt type clamps.
M. 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.
N. Control wiring and BMS wiring shall not be routed through power areas within the
BMS.
O. 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.

P. All internal wiring and cabling shall be terminated with tinned copper lugs.
Q. Current transformers provided in the MCC shall conform to IEC 61869-2, class H
insulation, accuracy class 1 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.
R. Certified and stamped Schematic and wiring diagrams to be firmly fixed within motor
control center, showing each component and cross- referenced with component
labels.
S. 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.
2.9 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.
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 and VSDs 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
X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP WIRING DEVICES AND
KSA DISCONNECTORS 262726 - 2970 1

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 Touch-Up Paint 6
2.4 Floor Outlet Boxes 6
PART 3 EXECUTION 8
3.1 Installation 8
3.2 Grounding 9
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.
B. The Contractor shall execute the required work as per requirements of latest revision of
Saudi Building Codes.
1.2 SUMMARY
A. This Section shall cover various types of receptacles, receptacles with Ground Fault Circuit
Interrupter (GFCI), 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.
PART 2 PRODUCTS
2.1 MANUFACTURERS

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 13/16 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-fiber
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. GFCI RECEPTACLES: Shall be used in the wet areas with voltage and current ration as
indicated in the drawings
1. Straight blade, non-feed through type.

2. Comply with NEMA WD 1, NEMA WD 6 Configuration 5-20R, UL 498, and UL
943, Class A.
3. Include trip/reset buttons.
4. Include correct wiring/trip indicator LED light.

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 230 V
and continuously rated at 10/16 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-fiber 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 3x(1x2.5) mm2
20 A 3x(1 x 4) mm2
25 A 3x(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: Load break switches or disconnector shall be
provided and installed as shown on Drawings and on wiring schedules.
1. 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.
2. The LBS shall be a non-fusible for three phases, or fusible for single phase,
single-throw, as indicated on Drawing, provided with arc quenching devices on
each pole, making it capable of interrupting at least six times the normal
switching current.
3. Switches shall effectively interrupt the power supply for all line conductors
where it exists, and simultaneously disconnect the supply for control circuits.
4. The operating mechanism shall be quick-make, quick-break with the external
operating handle mechanically interlocked with the enclosure cover.
5. 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.
6. 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.
7. Indication to the position of the switch shall be positive and clearly indicated
on the cover.
8. Enclosure shall be polycarbonate or GRP for wall mounting in areas not subject
to mechanical damage and Steel for free-standing type IP20 for general
purpose application, and IP54 for weatherproof installations unless otherwise
required.
9. Enclosure shall have provisions for locking the operating handle in the "OPEN"
and "CLOSED" positions.
2.3 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.
2.4 FLOOR OUTLET BOXES
A. Provide corrosion resistant, hot-dip galvanized, zinc coated sheet steel floor outlet boxes
of the types, shapes, sizes and depths to suit each respective location and installation. The
floor outlet boxes shall be suitable for raised floor trunking or under floor ducting system
as required.
B. Depths of floor outlet boxes shall be sufficient to accommodate conduit entries from
sides and all kinds of wiring devices with plugs from the top.
C. Cover of floor outlet boxes shall be capable of closing completely after installation of
plugs and connecting devices inside the box. The cover shall be suitable for flush floor

Installation with provision of fixing carpet, vinyl sheet, etc. above the cover to match with
the finish of the floor.
D. Floor outlet boxes shall be waterproof when fully closed. Appropriate rubber grommet
for cable protection shall be available for cable outlets from the floor base. The
grommets shall have an automatic lock function that prevents the cables from
getting cut should traffic pass over the box. The trap shall be fully reversible to allow
for change of direction of cable exit without the need to remove the trap frame.
E. The floor outlet boxes shall have a fully flexible plate configuration within them to ensure
that difficult configurations are achieved with ease.
F. Service outlet boxes for raised floor trunking system shall comprise an electro-
galvanized steel base frame to be installed in the raised floor tile. A die cast zinc alloy
service outlet frame and trap shall be mounted in the base frame. The base unit,
service outlet frame and traps shall have an oven baked epoxy powder paint finish
for protection against rust and corrosion. Provide flexible conduit of minimum 3
meter length to connect the service outlet box to the raised floor trunking.
G. Provide service outlet boxes and junction boxes for under floor ducting system,
constructed from high pressure zinc alloy die casting base frame and fixed to heavy
gauge hot-dip galvanized steel base plate adequate in strength and performance.
These boxes shall comply with the following requirements:
1. The design of the base frame shall cast the whole unit in one piece without
any joints/fabrication to prevent corrosion and concrete slippage into the box
during casting of concrete or screeding. The boxes shall be constructed with
provisions for ducting or conduit access on all four sides. Unwanted entries
shall be blanked off with detachable side blanks. All exposed portion of the
boxes shall be epoxy coated.
2. Cover for service outlet boxes shall be made of high pressure zinc alloy die
casting provided with suitable hinges designed to enable the trap cover to
open through 180 degrees and giving access at all times to the power, data,
telephone and other outlets.
3. Covers for service and junction boxes shall be made of high pressure zinc alloy
die casting secured by counter sunk screws. The covers shall be provided with
recess to accept the same floor finish.
4. All boxes shall be adjustable in height, independent of the ducting system to
take account of difference in floor / screed thickness.
5. Adequate segregation shall be provided between service runs within junction
boxes by using cross-over bridges and rigid compartments.
6. Cables emerging from service outlet boxes shall be protected against damage
by means of nylon cable-exit grommets or equivalent and approved material
and shall be reversible to close position when not in use. The lifting handle and
cable grommets shall be provided in opposite sides of the trap cover to allow
easy access to lifting handle and to avoid damage of the cable insulation.
H. All floor outlet boxes shall be complete with waterproof gasket and circuit protective
conductors between the covers and the boxes.

I. Provide combination of slab boxes under raised floor and PVC grommets flushed
with raised floor tile when required and shown on the drawings for raised floor
trunking system. The slab box shall be constructed from hot-dip galvanized sheet
steel suitably sized to accommodate all power, data, telephone and other outlets
fixed on top cover plate or on the sides as required and approved by the Engineer.
The grommets with lid shall be suitable for the raised floor tile and have opening
sufficient to allow passage of all the cables and plugs through it.
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.
M. FLOOR OUTLET BOXES INSTALLATION
1. Mark the locations of all service outlet boxes and junction boxes on the floor
slab as preapproved shop drawings, and review all practical aspects before
start of installation.
2. Cover junction boxes and service outlet boxes in under floor ducting system
with the disposable screeding lids, approximately levelled and tapped to
ensure no cement/mortar gets into the boxes during screeding.
3. Adjust floor outlet boxes so that closure plates are flush with the surface of
the floor tile, or the floor if carpeting is specified. Provide under floor duct
fittings and outlets or single flush outlets with waterproof covers, as indicated
on the drawings.
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 X

NO. BY BY BY
B Oct. 2021 M.M. C.MMAL C.EBEE 16 ISSUED FOR DETAILED DESIGN
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP ENGINE GENERATORS
KSA 263213 - 2970 1

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 10
2.4 Control And Monitoring 10
2.5 Generator Overcurrent And Fault Protection 11
2.6 Generator, Exciter, And Voltage Regulator 12
2.7 Vibration Isolation Devices 12
PART 3 EXECUTION 13
3.1 Examination 13
3.2 Installation 13
3.4 Grounding 14
3.5 Connections 14
3.7 Demonstration 15
3.8 Equipment Schedule 15
Engine Generator Section 263213

SECTION 263213 - ENGINE GENERATORS
PART 1 GENERAL
B. The Contractor shall execute the required work as per requirements of latest revision
of Saudi Building Codes and SASO Standards
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. Division 26 transfer switches for transfer switches including sensors and relays
to initiate automatic starting and stopping signals for engine generators sets.
2. Division 26 “grounding and bonding”
3. Division 26 “Low voltage conductors and cable”
4. Division 26 “Cable tray”
5. Division 26 “Raceway and boxes”
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 tested 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.
A. References Standards.
Governing 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
1. Institute of Electrical and Electronics Engineers Inc. (IEEE) No. 115

2. Test Procedures for Synchronous Machines.
American National Standards Institute. (ANSI No. B16.5)
3. Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24-157
4. National Electrical Manufacturers Association. NEMA MG 1& NEMA 250
5. MG1 Motors and Generators.
6. National Fire Protection Association. NFPA No. 70.72 & 110.
7. Occupational Safety and Health Act (OSHA).
8. BS 5514 reciprocating internal combustion engines performances.
9. International Commission (IEC) Standard – IEC 60034.1
10. British Standards (BS 4999/5000 & BS 5514).
11. ISO Standard (8528, 3046-1, 3744).
12. SASO Standards.
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
400Y/230 Volts AC, 60 Hz, three-phase, 5-wire or as may be required by manufactur-
er’s 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
operation and maintenance of the equipment specified under this section. Training
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 50 deg. C.

2. Relative Humidity: 0 to 50 percent.
3. Altitude: Not exceed 1000 meter.(if exceeded Derating Shall Apply)
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, indoor 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: Light Fuel Diesel oil, Grade DF-2.
B. Rated Engine Speed: 1800 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: Mechanical or Adjustable isochronous, with speed sensing for sensi-

tive 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 db.
K. Air-Intake Filter: Heavy-duty, engine-mounted air cleaner with replaceable dry-

filter element and "blocked filter" indicator.
L. 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 110 for Lev-
el 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.
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: Class H for stator, rotor and temperature rise.
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.
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.
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.
3.8 EQUIPMENT SCHEDULE
Diesel Engine Generators Schedule

Duty Cycle Stand by
Output Electrical Power 800 KVA
Frequency 60 HZ
Volt 400 V
Speed 1800 R.P.M
Performance G2 according to ISO 8528
(20% voltage drop / free drop at 100%
loading)
Emergency Power Supply System Comply with NFPA 110, Type 1
Start Time Comply with NFPA 110, Type 10
Engine Type Compression-ignition type, with direct
solid-injection, turbo-charged after
cooled, water cooled, with air-cooled
radiator inline or V-type cylinder ar-

rangement suitable for direct coupling
to driven machine.
Engine Cycle 4 Stroke cycle
Fuel Light Fuel Diesel oil, Grade DF-2.
Noise Rating 85 dBA at 1 m outside the room in any
direction
Governor Electronic Type conform with ISO
3046-4
provide isochronous governing
Battery Lead-acid, sealed-in-plastic type, com-
plete with battery rack and inter-cell
connectors. Battery shall have suffi-
cient capacity to provide minimum four
cranking periods.
Generator, Exciter and Voltage regulation Comply With NEMA MG-1
Generator Type Synchronous, low reactance, high effi-
ciency, revolving field type, with brush-
less exciter and flexible coupling, sized
to pick up effective load without ex-
ceeding transient and steady-state
voltage deviation limits specified up to
its full nominal rating.
Insulation Class H for stator and class H for rotor
& exciter and Class H for Temperature
Rise


ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP LOW VOLTAGE POWER FACTOR
KSA CORRECTION EQUIPMENT 263533- 2970 1

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
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 General Description 4
2.3 System Configuration 4
2.4 Identifications 6
2.5 Fault Current Considerations 6
2.6 Performance Requirements 6
2.7 Withstanding Transients 6
2.8 Bms Signal 7
PART 3 EXECUTION 7
3.1 Inspection 7
3.2 Installation 7
3.4 Maintenance 8
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.
B. The Contractor is responsible to supply and install the Power Factor Corrections
according to the latest requirements of the Saudi Electricity Company (SEC). This
shall require from the contractor’s manufacturer to obtain the approval (before
delivering) for the type, voltage, form, etc. from Authority have jurisdiction.
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. Standards Compliance: Comply with requirements of applicable local codes

and D1N/VDE, 1EC, BS, EN, NEC, UL, AND IEEE Standards pertaining to
centralized automatic power factor capacitor assemblies. Provide centralized
automatic power factor capacitor assemblies and components conforming to
one or more of the foregoing codes and standards. Power factor correction
unit to be approved by SEC and manufacturer to be listed in SEC vender list
2. Electrical Regulations/Code Compliance: comply with applicable local
regulations/code requirements (SEC). This will have precedence over other
codes/standards nominated for the project, unless otherwise approved in
writing.
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 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.
A. one (1) year warranty after the date of Substantial Completion, for the power factor
correction equipment shall be provided, for the materials and manufacturing quality
control.

PART 2 PRODUCTS
2.1 MANUFACTURERS

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. Capacitor Banks and associated components shall be suitably designed and selected
to ensure reliable and continuous operation at a maximum system Voltage of 440V
and at a maximum ambient temperature of 50°C.
B. 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 (480V. rated) shall be self-healing utilizing dry

polypropylene films as a dielectric with vacuum deposited conductors
on the polypropylene as electrode.
b. Capacitor units shall be temperature class D according to IEC 60831
c. 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.
d. Dielectric material shall be low loss, less than 0.5 Watts per KVAR.
e. Dry cells encapsulation medium shall be a thermoplastic material which
allows out gassing to engage the pressure interrupter.
f. Terminal bushings shall withstand 10 KVAC to ground and be rated
30 kV or greater.
g. Nominal design life of individual capacitor cells shall be 10 years.
h. Individual capacitor cells shall be covered by a five (5) year warranty.
i. All capacitor cells shall have threaded terminals for wire connection.
j. To reduce line transients on system no stage shall switch more than 120
KVAR and no capacitor cell shall exceed 50 KVAR.
k. Multiple fused capacitor banks dry metallized dielectric, self-healing
type.
l. 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.
m. 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.
n. 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.
o. Potential transformer needed for the under-voltage relay.
p. Under-voltage relay that interrupts capacitor switching for power supply
interruption longer than 15 ms.
q. “Advance” and “Retard” pushbuttons on the control panel shall permit
manual sequencing of capacitor switching.
r. On-off switch.
s. 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.
t. 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.
u. 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.
v. Indicating lights LEDs to designate energized capacitor banks.
w. Power factor meter.
x. Blown fuse indicators, three (3) “push-to-test” blown fuse piolet lights,
one per phase, door mounted to indicate a blown fuse condition.
y. Circuit breakers magnetic characteristics shall be Curve “D” and as per
IEC recommendations for switching and protecting capacitors by circuit
breakers.
z. 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.
aa. 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.
bb. Fuses shall be designed for capacitor applications and shall be rated not
less than 200% capacitor current rating.
cc. Alarms for:
Low power factor

Over load
Over current
Under voltage
Over voltage
Over/temperature
2.4 IDENTIFICATIONS
A. Each capacitor shall be provided with a permanent nameplate, which includes the
following:
1. Name of the manufacturer

2. Serial number
3. year of manufacture
4. Rated reactive power
5. Rated Voltage (RMS)
6. Number of phases
7. Rated frequency
8. Statement of discharge device
9. Short-circuit current
2.5 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.
2.6 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.
2.7 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.
2.8 BMS SIGNAL
A. Provide status signal to the Building Management – or Monitoring – System (BMS)

showing all details every 10 seconds.
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’s 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 X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP AUTOMATIC TRANSFER SWITCHES
KSA 263600 - 2970 1

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 Automatic Transfer Switch (Ats) 4
2.3 Enclosure 6
2.4 Testing 7
PART 3 EXECUTION 8
3.1 Installation 8
3.2 Operational Testing 8
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.
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 ATS 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 ATS 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.
B. Certificates: Test certificates shall be executed and submitted prior to final inspection and
acceptance in accordance with the requirements of NEMA/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
National Electrical Manufacturers Association (NEMA)
ICS 1 Industrial Controls and Systems

ICS 2 Industrial Control Devices, Controllers and Assemblies
ICS 4 Terminal Blocks for Industrial Use
ICS 6 Enclosures for Industrial Control and Systems
National Fire Protection Association (NFPA)
70 National Electrical Code

99 Standards for Health Care Facilities
110 Emergency and Standby Power Systems
Underwriters Laboratories, Inc. (UL)
1008 Automatic Transfer Switches
B. 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 installations 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.
C. 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
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
A. Subject to compliance with requirements, manufacturers offering products that may be

incorporated into the Work.
2.2 AUTOMATIC TRANSFER SWITCH (ATS)
A. ATS shall be double throw, electrically operated, mechanically held, fully protected,
complete with voltage sensing relay. ATS is mechanically held and electrically operated
by a single solenoid mechanism energized from the source to which the load is to be
transferred. ATS shall be suitable for use in emergency or standby systems described in

NFPA 70. ATS shall be UL listed, and test reports are approved as being equivalent of test
results and certified test reports as those determined and reported by UL. ATS withstand
symmetrical short circuit RMS except that the ATS shall not be equipped with either
overload or fault current protective devices and shall be designed and manufactured to
prevent stops in an intermediate or neutral position during transfer by the use of
electrical actuators and stored-energy mechanisms.
B. Automatic Transfer Switch (ATS) 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, 400 Volts, 4P, 60 Hz and according to final short
circuits calculations approved by the Engineer.
C. No Circuit Breaks System shall be allowed.
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 ATS shall also be furnished with the following:
1. ATS Shall have a withstand and closing rating (WCR) according to OEM tables and the
manufacturer shall provide a suitable WCR values to the Engineer for review and
approval taking into consideration the delay setting of the upstream breaker due to
the selectivity study.

2. Engine start contact
3. Pilot lights to indicate switch positions
4. Alternate source monitor
5. Test switch
6. Close differential protection
7. Three-position selector switch “STOP”, “TEST”, “Automatic”
J. Motor Starter Control: Under-voltage and timing relays, including any auxiliary relays
required, shall be installed in the ATS enclosure to provide an adequate number and type
of properly rated contacts to control the operation of remote motor controllers or
starters shown. Devices and wiring in an external to the ATS shall cause motors to be de-
energized for an adjustable period of time before the operation of the ATS in either
direction and, subsequently, to cause motors connected to the ATS load bus to be
energized immediately after transfer at time intervals shown. The time range shall be
approximately from 1 to 15 seconds and factory set at 3 or 5 seconds.
K. Operator: A manual operator, conforming to the applicable provisions of UL 1008, shall

be provided to permit manual operation of the ATS without opening the ATS enclosure,
and incorporate features to prevent operation by other than authorized and qualified
personnel. The ATS shall be designed for use of the manual operator under no load
conditions in the usual instances, but with the capability of operation under load
conditions when necessary.
L. 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.
M. Green Indicating Lights: A green indicating light shall supervise the normal power source
and shall have a nameplate engraved NORMAL.
N. Red Indicating Lights: A red indicating light shall supervise the emergency power source
and shall have a nameplate engraved EMERGENCY.
2.3 ENCLOSURE
A. ATS and accessories shall be in a wall mounted, free-standing or floor-mounted IP 43,

Type 1, smooth sheet metal enclosure constructed in accordance with UL 1008. Intake
vent shall be screened and filtered. Exhaust vents shall be screened. Gauge of the metal
shall be not less than 2 mm. Doors shall have suitable hinges, locking handle latch, and
gasketed jambs. Enclosure shall be equipped with at least two approved size and type of
grounding lugs or bar for the purpose of grounding the enclosure using at least 25 mm2
copper conductors to the Facility Ground System. A thermostatically controlled heater
shall also be provided within the enclosure to prevent condensation over the
temperature range stipulated in paragraph SERVICE CONDITIONS. Factory wiring within
the enclosure and the Contractor's field wiring terminating within the enclosure shall
comply with NFPA 70. If wiring is not color coded, wires shall be permanently tagged
near the terminal at each end with the wire number shown on approved detail drawings.
Terminal blocks shall conform to NEMA ICS 4. Terminal facilities shall be suitably arranged
for entrance of external conductors from the top or bottom of the enclosure or from the

top and bottom, as shown. Main switch terminals, including the neutral terminal, shall be
of the pressure type and suitable for the termination of the external copper conductors
shown. Extension of bars can be connected to the terminal to accept the conductors.
B. 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 ATS shall be constructed to protect personnel from energized
components.
C. 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 ATS to be supplied under these
specifications, or shall have been completed on a previous, randomly selected standard
production ATS unit having the same model number and capacity as the ATS specified.
Endurance and temperature tests shall be conducted in that sequence and within the
shortest practicable period of time on the same ATS without de-energization of that ATS
under test. The test sequence for the ATS listed below shall be followed. No deviation
will be granted that is less stringent. Approval will not be granted to deviate from the
endurance and temperature test sequence.
1. General
2. Normal Operation
3. Over voltage
4. Under voltage
5. Endurance
6. Temperature rise
7. Dielectric Voltage - Withstand
8. Contact Opening
9. Dielectric Voltage - Withstand (Repeated)
10. Withstand
11. Instrumentation and Calibration of High Capacity Circuits
12. Closings
13. Dielectric Voltage - Withstand (Repeated)
14. Strength of Insulating Base and Support
B. Factory Testing: In addition to other factory tests, each completely assembled ATS unit
shall be subjected to dielectric and operational tests, and withstand tests.
C. Withstand Test in Excess of UL 1008 Requirements: The ATS shall be tested and rated to
withstand an available fault or short-circuit current of 30 kA symmetrical minimum
interrupting capacity, or as shown on the drawings.
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 ATS 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 ATS 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 ATS, 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 ATS
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.


ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
SPECIFICATION REV.
LIGHTING
KSA 265100 - 2970 1

CONTENTS
SECTION 265100
LIGHTING
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Submittals 2
1.6 Warranty 4
PART 2 PRODUCTS 5
2.1 Manufacturers 5
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 10
2.9 Lamps 10
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.
1.6 WARRANTY
A. Contractor shall agree to repair or replace the materials that does not comply
with the requirements or fails in work.
1. Warranty period: One year after the date of Substantial Completion.

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 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, illuminance 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 Fluorescent 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, 230 V, 60 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 45 °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 Ingress protection for outdoor luminaires shall be as indicated on the drawings.
F 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.
G 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.
H LED fixtures shall be modular and allow for separate replacement of LED lamps and
drivers. User serviceable LED lamps and drivers shall be replaceable from the room
side.
I 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.
J 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.
K 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.
L 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.
M 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 of 3500 degrees K, 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 Class 2 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 UL 8750 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 ≥90.
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 comply with the requirements of IEC 61000-4-5 for surge immunity, 6 kv
for outdoor lighting.
N Individually fused drivers shall have their fuses accessible from outside of the fixture
chassis.
O 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 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.
C Sizes of lettering shall comply with IEC or DIN/VDE Standards.
D Self-energized signs (in respect of luminosity) shall comply with IEC or DIN/VDE
standards.
E Shall be equipped with a battery kit with 3 hours.
F Emergency Lighting System: Exit signs shall be manufactured to meet the

appropriate requirements of IEC or DIN/VDE standards.
G Each sign shall be internally illuminated by two separate systems of lighting.
H 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.
I Description: Internally Lighted Signs:
1. Lamps for AC Operation: LEDs, 70,000 hours minimum rated lamp life.
2. 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 shall be furnished and installed in all lighting fixtures supplied.
C LED Lamps: shall be designed for more than 50,000- operation hour at 50°C ambient.
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 50,000 hrs. shall be reviewed and declared consistent with their data
by the LED chip manufacturer and provided to the Engineer for approval.
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
leangth 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 X

NO. BY BY BY
SPECIFICATION REV.
EXTERIOR LIGHTING
KSA 265600 - 2970 1

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 4
PART 2 - PRODUCTS 5
2.1 Manufacturers 5
2.2 General 5
2.3 Street Lighting Luminaire 6
2.4 Optional Photoelectric Relay 7
2.5 Required Data In Catalog 7
2.6 Luminaire Support Components 8
2.7 Lighting Poles 8
2.8 Decorative Poles 9
3.1 General 9
3.2 Inspection 9
3.3 Pole Installation 9
3.4 Grounding 10
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.
B. Related Sections include the following:
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 luminarie 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. Comply with IEEE C2, "National Electrical Safety Code."
D. Comply with 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

be incorporated into the Work include, but are not limited to, the ones mentioned on
the attached list of manufacturers Section 01295.
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 50°C, 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 hand-hole
(with hinged door) in pole wall as per drawings. Fiberglass may be an acceptable
alternative to steel, but shall be embedded type with underground cable entry (and
access hand-hole) or as per manufacturer’s standard.
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 augured 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 augured 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
PURCHASE
CONSTRUCTION X

NO. BY BY BY
A Oct. 2021 R.M. C.AMAM C.MYSM 21 ISSUED FOR DETAILED DESIGN
0 Jan. 2022 R.M. C.AMAM C.MYSM 21 ISSUED FOR TENDER
1 Feb. 2022 R.M. C.AMAM C.MYSM 21 ISSUED FOR CONSTRUCTION
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP FIRE-ALARM SYSTEM
KSA 283100 – 2970 1

CONTENTS
SECTION 283100
FIRE-ALARM SYSTEM
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Definitions 2
1.4 System Integration 2
1.5 Performance Requirements 3
1.6 Submittals 3
1.8 Reference Codes And Standards 5
1.10 Software Service Agreement 6
1.11 Extra Materials 7
1.12 Coordination 7
1.13 Warranty 7
PART 2 PRODCUTS 8
2.1 Systems Operational Description 8
2.2 Interface Between The Bms And The Fire Alarm System 9
2.3 Fire-Alarm Control Unit (Main Fire Alarm Control Panel) 10
2.4 Sub-Fa Control Panels (S-Facp) 12
2.5 Repeater Panel 12
2.6 Manual Fire-Alarm Stations 13
2.7 System Detectors 13
2.8 Notification Appliances 14
2.9 Magnetic Door Holders 15
2.10 Addressable Interface Device 15
2.11 Fault Isolation Module 15
2.12 Automatic Telephone Dialer 16
2.13 System Printer 16
2.14 Device Guards 16
2.15 Wiring 16
PART 3 EXECUTION 17
3.1 Equipment Installation 17
3.2 Connections 18
3.4 Grounding 19
3.6 Training 21
Fire Alarm System Section 283100

SECTION 283100 - FIRE-ALARM SYSTEM
PART 1 GENERAL
1.2 SUMMARY
A. Section Includes:
1. Fire-alarm control unit.

2. Manual fire-alarm boxes.
3. Multi Detectors
4. Heat detectors.
5. Notification appliances.
6. Magnetic door holders.
7. Remote annunciator.
8. Addressable interface device.
9. Digital alarm communicator transmitter.
10. System printer.
1.3 DEFINITIONS
A. LED: Light-Emitting Diode.
B. NICET: National Institute for Certification in Engineering Technologies.
C. NFPA: National Fire Protection Association
D. UL: Underwriters Laboratories
E. LPCB: Loss Prevention Certification Board
F. VDS: Verand der Schadversicherer
G. FACP: Fire Alarm Control Panel
1.4 SYSTEM INTEGRATION
A. System installer shall coordinate with Main Contractor to perform all system inte-
gration requirements.
B. Project Main Contractor should perform all required interfaces between all ELV/ICT
and related life safety and security systems in terms of software and hardware.

C. The Main Contractor should approve all systems contractors technical material
submittals prior to submitting to the engineer for system approval
D. The Engineer has the right to approve and reject the documents after assessing the
integration procedures followed in addition to the system compliance with this
specification.
E. The Main Contractor is responsible for achieving all integration requirements men-
tioned throughout the documents (specs and drawings) for the project
F. Based on certain alarm or rule violation a POP UP screen should be shown immedi-
ately with the camera view responsible for the area of concern.
1.5 PERFORMANCE REQUIREMENTS
A. Seismic Performance: Fire-alarm control unit and raceways shall withstand the ef-
fects of earthquake motions determined according to [SEI/ASCE 7].
1. The term "withstand" means "the unit will remain in place without separation
of any parts from the device when subjected to the seismic forces specified
and the unit will be fully operational after the seismic event.
B. All the equipment shall operate reliably under the following environment condi-
tions:
1. Ambient Temperature 4 to 500 C.

2. Relative Humidity Max. 95%.
1.6 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data, including:
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 de-
viations, also indicate any extra features / specifications. .
2. Pin to pin riser diagram showing all system components and interconnection
between the system and all other related systems.
3. Provide calculations to support the size of stand-by batteries for the emer-
gency power supply. The batteries sizing shall allow for system operation
under quiescent load for a minimum of 24 hours and then shall be capable of
operating the system during fire or other emergency condition for a period of
30 minutes at a maximum connected load. Batteries system must provide an
alarms indicating the need to replace or recharge batteries
4. Provide calculation of the DC lines to indicate the no. of audible alarms and
visual strobe lights per each circuit.
5. Complete sequence of operations and functions of the system.
6. A list of every system address provided for purposes of alarm initiation, status
monitoring, supervised signaling and auxiliary controls (Cause and Effect Ma-
trix). Contractor is fully responsible to submit the detailed cause and effect
matrix based on the guidelines indicated in this design package. Detailed

cause and effect matrix prepared by the contractor must be submitted and
must include all labeling for all items defined according to the area of respon-
sibility based on the architectural package.
B. Shop Drawings: Provide shop drawings showing equipment, device locations and
connecting wiring of the systems, including riser diagrams. Shop drawings shall in-
clude, but not be limited to the following:
1. Complete pin to pin one-line riser diagram(s) showing all approved equip-
ment, size, type and number of all conductors, interconnection between the
system and all other related systems.
2. Installation details for detectors, manual stations raceways and all the other
components of the system. Installation details drawings shall show all acces-
sories used in installation such as back boxes, glands, washers, etc.
3. Exact location of every single component of the system in coordination with
all other adjacent works (Electromechanical, Arch., and Civil).
4. Signature of all involved engineers representing different disciplines (Electro-
mechanical, etc) to confirm their approval of such locations, installations and
coordination.
5. Voltage drop calculations for notification appliance circuits & DC lines.
6. Signal control module calculations.
7. Battery-size calculations.
8. Complete sequence of operations and functions of the system.
C. Qualification Data: For qualified Installer.
D. Maintenance Data: Submit maintenance data and spare parts list for each type of
Fire Alarm equipment installed, including furnished specialties and accessories. In-
clude this data, product data, and shop drawings in the maintenance manual in ac-
cordance with other relevant documentation.
E. Composite Coordinated drawings illustrating all MEP devices equipment that are
monitored and controlled by the fire alarm system.
F. Finalized Reflected ceiling drawings illustrating all works in the ceilings after finaliz-
ing the coordination process.
A. Installer prequalification shall include official documents issued by the manufacture

indicating that the installer is the authorized representative in this country.
B. Installer Qualifications: Personnel shall be trained and certified by manufacturer for

installation of units required for this Project. The Installer must have at least 5 years
of experience in installation of similar projects. Contractor shall submit in coopera-
tion with the installer the official documents issued by the manufacture to prove the
pre experience and training of the installer.
C. Installer Qualifications: Installer shall have at least 5 years of successful installation

experience in projects with Fire Alarm Systems similar to those required for this pro-

ject.
D. Source Limitations for Fire-Alarm System and Components: Obtain fire-alarm sys-
tem from single source from single manufacturer. Components shall be compatible
with, and operate as, an extension of the existing system.
E. Electrical Components, Devices, and Accessories: Listed and labeled as defined in

NFPA 70, by a qualified testing agency, and marked for intended location and appli-
cation.
F. Addressable system, with automatic sensitivity control of certain Multi detectors

and multiplexed signal transmission, dedicated to fire-alarm service only.
1.8 REFERENCE CODES AND STANDARDS
A. All works shall be performed in strict accordance with the drawings, specifications
and stipulations of the Local Building and safety Codes, the National Fire Protection
Association (NFPA), International Electrical Commission (IEC) and other related in-
ternational standards:
1. Relevant Local and State Building Codes.
B. For National Fire Protection Association Standards; the following standards to be

considered:
1. NFPA 72 National Fire Alarm Code

2. NFPA 101 Life Safety Code
C. The Cables used for Fire Alarm System shall meet the following standards:
BS Standards
1. BS6387: Specification for performance requirements

for the required cables to Maintain Circuit In-
tegrity under Fire Conditions.
2. BS EN 50267-2-3:1999: Common test methods for cables under fire

conditions. Tests on gases evolved during
combustion of the cables’ materials. Proce-
dures. Determination of degree of acidity of
gases for cables by determination of the
weighted average of pH and conductivity. BS
5839-8,-6, -9, -1+A2: Fire detection and fire
alarm systems for buildings. Code of practice
for the design, installation, commissioning
and maintenance of voice alarm systems.
3. BS EN 60332-3-10:2009: Tests on electric and optical fiber cables un-
der fire conditions.

IEC standards:
1. IEC 60331-1 edition 1.0 (2002): Tests for Electric Cables under Fire Condi-
tions – Circuit Integrity
2. IEC 60754-1 edition 2.0 (1994): Tests on Gases Evolved during Combustion
of Material from Cables.
3. IEC 61034-1 edition 3.0 (2005-04): Measurement of Smoke Density of Cables
Burring under Defined Conditions.
4. IEC 60228 edition 3.0 (2004-11): Conductors of Insolated Cables.
5. IEC 60332 edition 3.0 (1993): Tests on Electric Cables under Fire Condi-
tions.
6. All fire alarm cables sizes shall meet the manufacturer requirements justified
by calculations and official documents.
7. All fire alarm cables must be fire resistant (105 C ° three hours) produce no
hazardous toxic gases at least 2.5 mm.
D. Equipment and installations shall comply with the latest revision of the current pro-
visions of the following codes and standards:
1. Local Electrical Standard

2. Local safety Standard
3. Standards of local authorities having jurisdiction
4. Electrical Component Standard: Provide work complying with applicable re-
quirements of NFPA 70 "National Electrical Code"
5. Approved from one or more of the nationally recognized agencies such as UL
– LPCB – VDS.
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. Inspection shall be performed in two stages, first time upon receiving the equip-
ment, devices and cables on site before storing and second time after installation
according to installation phases.
1.10 SOFTWARE SERVICE AGREEMENT
A. Technical Support: Beginning with Substantial Completion, provide software sup-

port for two years.
B. Upgrade Service: Update software to the latest version available at the Project
completion. Install and program software upgrades that become available within
two years from date of Substantial Completion. Upgrading software shall include
operating system. Upgrade shall include new or revised licenses for using of soft-
ware.

1.11 EXTRA MATERIALS
A. Furnish extra materials that match products installed and that are packaged with
protective covering for storage and identified with labels describing contents.
B. The Contractor shall provide the suggested spare parts for 5 years for approval.
Spare parts lists shall be submitted within the technical submittal, at the shop draw-
ings stage and close out documents.
1. Lamps for Strobe Units: Quantity equal to 3 percent of amount installed, but
not less than 1 unit.
2. Multi Detectors, Fire Detectors and Flame Detectors: Quantity equal to 5 per-
cent of amount of each type installed, but not less than 1 unit of each type.
3. Detector Bases: Quantity equal to 5 percent of amount of each type installed,
but not less than 1 unit of each type.
4. Keys and Tools: One extra set for access to lock and tamper proofed compo-
nents.
5. Audible and Visual Notification Appliances, Monitor modules, Controls and
Signal Control Modules: 3 percent of amount installed, but not less than 1
unit.
6. Manual Stations: Quantity equal to 5 percent of amount of each type in-
stalled, but not less than 1 unit.
7. FACP Power Supply: Quantity equal to one.
8. FACP Communication Card: Quantity equal to one.
9. FACP Loop Card Quantity equal to one unit.
10. FACP Power Card /Module Quantity equal to one unit.
1.12 COORDINATION
A. The Fire Alarm System supplier shall be responsible to coordinate and exchange in-
formation with the Suppliers of other systems and equipment which shall communi-
cate with, in order to achieve the required specified functions and achieve the civil
defense requirements. 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.
B. A detailed integration document must be submitted illustrating all integration issues

and how they are addressed in the submittal to achieve all interfacing requirements.
1.13 WARRANTY
A. Contractor shall provide the Warranty certificates on which manufacturer and In-
staller confirm that they shall provide required maintenance / repair for the system
and all of its components including required spare parts and any other work re-
quired to keep the system working with the required performance within the speci-
fied warranty period (two years) without any extra cost.

PART 2 PRODCUTS
2.1 SYSTEMS OPERATIONAL DESCRIPTION
A. Fire-alarm signal initiation shall be by one or more of the following devices:
1. Manual stations.
2. Heat detectors.
3. Multi Detetors
4. Verified automatic alarm operation of Multi detectors.
5. Automatic Sprinkler System Water Flow/Foam Flow.
6. Multi detectors in elevator shaft and pit.
7. Fire-extinguishing system operation.
8. Fire standpipe system.
B. Fire-alarm signal shall initiate the following actions:
1. Continuously operate alarm notification appliances.

2. Identify alarm at fire-alarm control unit and remote annunciators.
3. Transmit an alarm signal to the remote alarm receiving station.
4. Unlock electric door locks in designated egress paths if there is any
5. Release fire and smoke doors held open by magnetic door holders.
6. Activate voice/alarm communication system.
7. Switch heating, ventilating, and air-conditioning equipment controls to fire-
alarm mode.
8. Activate smoke-control system (smoke management) at firefighter smoke-
control system panel If any.
9. Allow for manual override for smoke control system via HVAC dedicated
smoke control panel If any.
10. Close Steel shutters, the steel shutters should have manual override function
11. Activate stairwell and elevator-shaft pressurization systems.
12. Close smoke dampers in air ducts of designated air-conditioning duct systems.
13. Recall elevators to primary or alternate recall floors.
14. Activate emergency lighting control.
15. Activate emergency shutoffs for gas and fuel supplies.
16. Record events in the system memory.
17. Record events by the system printer.
18. Sending Alarm Messages to the Fire Brigade Unit using the Auto Dialer.
C. Supervisory signal initiation shall be by one or more of the following devices and ac-
tions:
1. Valve supervisory switch.

2. Low-air-pressure switch of a dry-pipe sprinkler system.
3. Elevator shunt-trip supervision.
4. Flow supervisory switch.
5. Sprinkler system Tamper switch
6. Fire fighting panels auxiliary contacts
7. Auxiliary contact indicating cylinders weight
8. Water Level switches

D. System trouble signal initiation shall be by one or more of the following devices and
actions:
1. Open circuits, shorts, and grounds in designated circuits.

2. Opening, tampering with, or removing alarm-initiating and supervisory signal-
initiating devices.
3. Loss of primary power at fire-alarm control unit.
4. Ground or a single break in fire-alarm control unit internal circuits.
5. Abnormal ac voltage at fire-alarm control unit.
6. Break in standby battery circuitry.
7. Failure of battery charging.
8. Abnormal position of any switch at fire-alarm control unit or annunciator.
9. Fire-pump power failure, including a dead-phase or phase-reversal condition.
E. System Trouble and Supervisory Signal Actions: Initiate notification appliance and
annunciate at fire-alarm control unit and remote annunciators. Record the event on
system printer.
2.2 INTERFACE BETWEEN THE BMS AND THE FIRE ALARM SYSTEM
A. The Main Fire Alarm Panel shall have a data port to enable the transfer of infor-
mation 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 sys-
tem shall communicate a list of all equipment shut down and start by fire alarm sys-
tem.
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 fire fighting panels, MCC panels, elevator panels…etc. All other sub-
systems 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 Sys-
tem (BMS) by means of software in addition to dry contacts to monitor various
points in the system. The BMS shall receive all events, actions and reports from the
FACP through the appropriate protocol. The protocol converter and software shall
be included with FACP, so as to be fully compatible with the BMS. All addressing in-
formation 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.
2.3 FIRE-ALARM CONTROL UNIT (Main Fire Alarm Control panel)
A. General Requirements for Fire-Alarm Control Unit:
1. Field-programmable, microprocessor-based, modular, power-limited design

with electronic modules, complying with related fire codes.
a. System software and programs shall be held in flash electrically erasa-

ble programmable read-only memory (EEPROM), retaining the infor-
mation through failure of primary and secondary power supplies.
b. Include a real-time clock for time annotation of events on the event re-
corder and printer.
2. Addressable initiation devices that communicate device identity and status.
a. Multi sensors shall additionally communicate sensitivity setting and al-

low for adjustment of sensitivity at fire-alarm control unit.
b. Temperature sensors shall additionally test for and communicate the
sensitivity range of the device.
3. Addressable control circuits for operation of mechanical equipment.
B. Alphanumeric Display and System Controls: Arranged for the interface between
human operator at fire-alarm control unit and addressable system components in-
cluding annunciation and supervision. Display alarm, supervisory and component
status messages, with the programming and control menu.
1. Annunciator and Display: Liquid-crystal type, 3 line(s) of 40 characters, mini-

mum.
2. Keypad: Arranged to permit entry and execution of programming, display,
and control commands and to indicate control commands to be entered into
the system for control of smoke-detector sensitivity and other parameters.
C. Circuits:
1. Initiating Device, Notification Appliance, and Signaling Line Circuits: NFPA 72,
Class A.
a. Install no more than 80 percent addressable devices on each signaling

line circuit.
2. Serial Interfaces: Two RS-232 ports for printers.
D. Stairwell Pressurization: Provide an output signal using an addressable relay to start

the stairwell pressurization system. Signal shall remain on until alarm conditions are
cleared and fire-alarm system is reset. Signal shall not stop in response to alarm
acknowledge or signal silence commands.

1. Pressurization starts when any alarm is received at fire-alarm control unit.
2. Alarm signals from Multi detectors at pressurization air supplies have a higher
priority than other alarm signals that start the system.
E. Smoke-Alarm Verification:
1. Initiate audible and visible indication of an "alarm-verification" signal at fire-

alarm control unit.
2. Activate alarm-verification sequence at fire-alarm control unit and detector as
per related fire codes.
a. Activation of all actions required in case of fire shall be delayed for thir-
ty (30 seconds), which is software adjustable, for receiving the first sig-
nal from an alarm-initiating detector.
b. If an alarm signal from a second detector in same zone area or a second
alarm signal from the same detector is received within 30 seconds, a
confirmation is assured and the programmed actions shall take place.
c. If no second alarm signal is received or a sustained detection condition
exists within the first thirty (30) seconds, the system shall reset to nor-
mal.
3. Record events by the system printer.

4. Sound general alarm if the alarm is verified.
5. Cancel fire-alarm control unit indication and system reset if the alarm is not
verified.
F. Elevator Recall:
1. Multi detectors at the following locations shall initiate automatic elevator re-
call. Alarm-initiating devices, except those listed, shall not start elevator re-
call.
a. Elevator lobby detectors except the lobby detector on the designated

floor.
b. Multi detector in elevator machine room.
c. Multi detectors in elevator hoist way.
2. Elevator lobby detectors located on the designated recall floors shall be pro-
grammed to be transferred to the alternate recall floor.
3. Water-flow alarm connected to sprinkler in an elevator shaft and elevator
machine room shall shut down elevators associated with the location without
time delay.
a. Water-flow switch associated with the sprinkler in the elevator pit may
have a delay to allow elevators to move to the designated floor.
G. Remote Smoke-Detector Sensitivity Adjustment: Controls shall select specific ad-

dressable Multi detectors for adjustment, display their current status and sensitivity
settings, and change those settings. Allow controls to be used to program repeti-
tive, time-scheduled, and automated changes in sensitivity of specific detector
groups. Record sensitivity adjustments and sensitivity-adjustment schedule changes

in system memory, and print out the final adjusted values on system printer.
H. Transmission to Remote Alarm Receiving Station: Automatically transmit alarm, su-

pervisory, and trouble signals to a remote alarm station.
I. Printout of Events: On receipt of signal, print alarm, supervisory, and trouble

events. Identify zone, device, and function. Include type of signal (alarm, superviso-
ry, or trouble) and date and time of occurrence. Differentiate alarm signals from all
other printed indications. Also print system reset event, including same information
for device, location, date, and time. Commands initiate the printing of a list of exist-
ing alarm, supervisory, and trouble conditions in the system and a historical log of
events.
J. Primary Power: 24-V dc obtained from 230 Vac service and a power-supply module.
Initiating devices, notification appliances, signaling lines, trouble signals, supervisory
and digital alarm communicator transmitters shall be powered by 24-V dc source.
1. Alarm current draw of entire fire-alarm system shall not exceed 80 percent
(80%) of the power-supply module rating.
K. Secondary Power: 24-V dc supply system with batteries, automatic battery charger,
and automatic transfer switch.
1. Batteries: Sealed without any gases leakages.
L. Instructions: Computer printout or (a written type ) type written instruction card

mounted behind a plastic or glass cover in a stainless-steel or aluminum frame. In-
clude interpretation and describe appropriate response for displays and signals.
Briefly describe the functional operation of the system under normal, alarm, and
trouble conditions.
2.4 SUB-FA CONTROL PANELs (S-FACP)
A. Sub- panel operate in a network configuration with the M-FACP and can operate in-
dependently if communication seizes between them. S-FACP exchange data and
commands with the M-FACP and the other S-FACP panels of the system by means of
communication link connecting the M-FACP and the S-FACP.
B. The S-FACP panel shall include the necessary hardware and software required to
function as specified and according to the code requirements
2.5 REPEATER PANEL
A. A repeater panels shall be connected to the FACP and installed as indicated on

drawings. The repeater panels shall display all the states indicated on the FACP.
Repeater panels shall include LEDs, LCD and any other required indicating facility
and buttons.

2.6 MANUAL FIRE-ALARM STATIONS
A. General Requirements for Manual Fire-Alarm stations: Comply with related fire
codes. Boxes shall be finished in red with molded, raised-letter operating instruc-
tions in contrasting color; shall show visible indication of operation; and shall be
mounted on recessed outlet box. If indicated as surface mounted, provide manufac-
turer's surface back box. The word Fire shall appear on the front of the station.
1. Double-action mechanism requiring two actions to initiate an alarm, first lift

the upper door, then pull the alarm handle; with integral addressable module
arranged to communicate manual-station status (normal, alarm, or trouble) to
fire-alarm control unit (Other double action mechanisms also accepted).
2. Station Reset: Key- or wrench-operated switch.
3. Indoor Protective Shield: Factory-fabricated clear plastic enclosure hinged at
the top to permit lifting for access to initiate an alarm. Lifting the cover actu-
ates an integral battery-powered audible horn intended to discourage false-
alarm operation.
4. Weatherproof Protective Shield: Factory-fabricated clear plastic enclosure
hinged at the top to permit lifting for access to initiate an alarm.
2.7 SYSTEM DETECTORS
A. INTELLIGENT MULTI-SENSOR DETECTOR
1. The detector shall process and analyze information from each sensor sepa-
rately.
2. The multi sensor shall combine optical smoke detection, heat detection and
microprocessor control with analogue addressable communications.
3. Integrated Photoelectric Smoke sensor, and 135°F (+57°C) Fixed-Temperature
Heat Sensing Technologies.
4. The detector shall have non-volatile memory which permanently stores serial
number, type of device and automatically shall update the historic infor-
mation including hours of operation, last maintenance date, number of alarms
and troubles, time of last alarm and analog signal patterns for each sensing
element just before last alarm.
5. The detector shall be On-board microprocessor based.
6. Continuous self-diagnosis and storage of environmental and operational data
sensitivity check.
7. Auto-addressing.
8. Automatic device mapping by means each detector shall transmits wiring in-
formation regarding its location with respect to other devices on the circuit.
9. Built in isolator.
10. Special algorithm for optimum combination of optical and thermal character-
istic.
11. Automatic localization of interruptions and short circuits.
12. Thermal only detection mode.
13. Environmental Compensation.
14. Day/Night Sensitivity Adjustment.

B. HEAT DETECTORS
1. General Requirements for Heat Detectors: Comply with related fire codes.
2. Heat Detector, Fixed-Temperature Type: Actuated by temperature that ex-

ceeds a fixed temperature of [57 deg C + 5 deg C].
3. Mounting: Twist-lock base interchangeable with smoke-detector bases.
4. Integral Addressable Module: Arranged to communicate detector status

(normal, alarm, or trouble) to fire-alarm control unit.
C. GAS detectors (Chlorine (Cl2) )
1. Operating voltage 24VDC

2. Gas leak sensor with sensor/transmitter ,on board relays for the following sig-
nals (early warning), (alarm) and trouble. Each relay shall be monitored by fire
alarm monitor module to report its status to the main fire alarm control pan-
el..
3. Gas detectors shall be used to detect CL2 in locations as shown on drawings.
4. Protection grade IP65, resolution ±2% F.S. toxic, Maintenance periods: Annu-
al.
5. The measuring range shall be 0-10 ppm
6. The device shall comply with the relevant CE standards
2.8 NOTIFICATION APPLIANCES
A. General Requirements for Notification Appliances: Connected to notification appli-

ance signal circuits, zoned as indicated, equipped for mounting as indicated and with
screw terminals for system connections.
B. Horns: Electric-vibrating-polarized type, 24-V dc; with provision for housing the op-
erating mechanism behind a grille. Comply with related fire codes. Horns shall pro-
duce a sound-pressure level up to 95 dBA, measured 3 m from the horn as per relat-
ed fire codes.
C. For Outdoor Audible Announcements shall be the same as indoor but with weather
proof housing with minimum IP55.
D. Visible Notification Appliances: Xenon strobe lights comply with related fire codes,
with clear or nominal white polycarbonate lens mounted on an aluminum faceplate.
The word "FIRE" is engraved in minimum (25-mm-) high letters on the lens.
1. Rated Light Output:
a. 15/30/75/110 cd, selectable in the field.
2. Mounting: Wall mounted unless otherwise indicated.

3. For units with guards to prevent physical damage, light output ratings shall be

determined with guards in place.
4. Flashing shall be in a temporal pattern, synchronized with other units.
5. Strobe Leads: Factory connected to screw terminals.
6. Mounting Faceplate: Factory finished [red or white as per Arch. Recommen-
dations].
7. For Outdoor Strobe light shall be the same as indoor but with weather proof
housing with minimum IP 55.
2.9 MAGNETIC DOOR HOLDERS
A. Description: Units are equipped for wall or floor mounting as indicated and are
complete with matching doorplate.
1. Electromagnet: Requires no more than 3 W to develop 111-N holding force.

2. Wall-Mounted Units: Flush mounted unless otherwise indicated.
3. Rating: 24-V ac or dc.
4. Rating: 230 -V ac.
B. Material and Finish: Match door hardware.
2.10 ADDRESSABLE INTERFACE DEVICE
A. Description: Microelectronic monitor module, NRTL listed for use in providing a sys-
tem address for alarm-initiating devices for wired applications with normally open
contacts.
B. Two (2) state alarm or supervisory signals shall be transformed by the MMs to ad-
dressable digital form to be processed by the system.
C. Integral Relay: Capable of providing a direct signal to elevator controller to initiate

elevator recall or to circuit-breaker shunt trip for power shutdown or to fire fighting
panels for activation…etc.
D. Each control module must have at least two independents outputs with two sub ad-
dresses
2.11 FAULT ISOLATION MODULE
A. Description: Addressable fault isolation module shall be used in signal circuits to in-
dicate and isolate wiring faults.
B. Fault isolation modules shall be installed in order to help FACP to allocate break in
communication wiring.
C. Fault isolation shall be provided at riser and loop circuits at locations not exceeding
the maximum number of devices in between according to Manufacture’s require-
ments.
D. The minimum number of isolators allowed is one (1) for every fifteen (15) device in

the loop.
2.12 AUTOMATIC TELEPHONE DIALER
A. The Automatic Telephone Dialer shall provide the system with automatic ability to
dial a remote fire fighting location and deliver pre-recorded emergency message
through a dedicated line, the message length shall be of 50 second at least.
B. Telephone dialer shall provide message test speaker and a message test switch.
C. The dialer shall be provided with battery backup operation and programming facili-
ty.
2.13 SYSTEM PRINTER
A. Printer shall be listed and labeled by an NRTL as an integral part of fire-alarm sys-
tem.
B. All Alarm, trouble, supervisory and command events shall be memorized by the sys-
tem and printed by the event printer (EP). The system shall bear sufficient memory
to store not less than 1000 events and print them on command.
2.14 DEVICE GUARDS
A. Description: Welded wire mesh of size and shape for the manual station, Multi de-
tector, gong, or other device requiring protection.
1. Factory fabricated and furnished by manufacturer of device.

2. Finish: Paint of color to match the protected device.
2.15 WIRING
A. Wire and cable for fire alarm systems shall be UL listed and labeled as complying
with NFPA 70, Article 760 and meet the above general standard requirements.
B. Cable must be separated from any open conductors of power, or Class 1 circuits,
and shall not be placed in any conduit, junction box or raceway containing these
conductors.
C. All wire and cable shall be listed and/or approved by a recognized testing agency for
use with a Protective Signaling System
D. Embedded conduits shall be PVC and all surface conduits shall be EMT
E. The wiring which interconnects all addressable devices (detectors, etc.) with control
equipment shall be fire resistant ( 105 C ° three hours ) produce no hazardous toxic
gases LSZH . The Fire alarm system manufacturer requirements shall be considered ,
1.5 mm2 minimum copper cables constituting supervised Class A circuits of the ap-

propriate style to meet the alarm and trouble requirements in extreme fault con-
dition. The cables must be approved by the fire alarm system supplier in terms of
types and cable cross section which shall be verified by the manufacturer software
and official documents.
F. Fire alarm wiring shall be UL approved, or equivalent, and shall be in full compliance
with the Codes and the requirements of the fire alarm equipment Manufacturer.
G. The wiring of high current devices shall be fire resistant ( 105 C ° three hours ) pro-
duce no hazardous toxic gases and according to the Manufacturer requirements,
the cross section area shall not be less than 2.5 mm2 and shall not cause more than
five percent (5%) voltage drop. DC calculations shall be provided.
H. All wiring shall be color coded and cabled. Junction boxes shall be red colored and
include wiring identification numbering.
I. Wires and cables shall provide sufficient resistance to the spread of fire (according
to NFPA) and generate no hazardous smoke to human life.
J. Wiring System shall include all indoor and outdoor wires and cables necessary for
complete fire alarm system. Including control and supervisory circuits, intercon-
necting with other related systems (HVAC, etc.). Outgoing and returning conduc-
tors.
PART 3 EXECUTION
3.1 EQUIPMENT INSTALLATION
A. Comply with NFPA 72 for installation of fire-alarm equipment.
B. Equipment Mounting: Install fire-alarm control unit on concrete base with tops of
cabinets not more than 1830 mm above the finished floor. Comply with require-
ments for concrete base specified in Division 03 Section.
1. Install seismic bracing. Comply with requirements in Division 26 Section "Vi-

bration and Seismic Controls for Electrical Systems."
2. Install dowel rods to connect concrete base to concrete floor. Unless other-
wise indicated, install dowel rods on 450-mm centers around the full perime-
ter of concrete base.
3. For supported equipment, install epoxy-coated anchor bolts that extend
through concrete base and anchor into structural concrete floor.
4. Place and secure anchorage devices. Use setting drawings, templates, dia-
grams, instructions, and directions furnished with items to be embedded.
5. Install anchor bolts to elevations required for proper attachment to supported
equipment.
C. Equipment Mounting: Install fire-alarm control unit on finished floor with tops of
cabinets not more than 1830 mm above the finished floor.
1. Comply with requirements for seismic-restraint devices specified in Divi-

sion 26 Section "Vibration and Seismic Controls for Electrical Systems."
2. Comply with requirements for seismic-restraint devices specified in Divi-
sion 26 Section "Vibration and Seismic Controls for Electrical Systems."
D. Smoke- or Heat-Detector Spacing:
1. Comply with NFPA 72, "Smoke-Sensing Fire Detectors" Section in the "Initiat-
ing Devices" Chapter, for smoke-detector spacing.
2. Comply with NFPA 72, "Heat-Sensing Fire Detectors" Section in the "Initiating
Devices" Chapter, for heat-detector spacing.
3. Smooth ceiling spacing shall not exceed 9 m.
4. Spacing of detectors for irregular areas, for irregular ceiling construction, and
for high ceiling areas shall be determined according to Appendix A in NFPA 72.
5. HVAC: Locate detectors not closer than 1 m from air-supply diffuser or re-
turn-air opening.
6. Lighting Fixtures: Locate detectors not closer than 300 mm from any part of a
lighting fixture.
E. Heat Detectors in Elevator Shafts: Coordinate temperature rating and location with
sprinkler rating and location.
F. Single-Station Multi Detectors: Where more than one smoke alarm is installed with-
in a dwelling or suite, they shall be connected so that the operation of any smoke
alarm causes the alarm in all smoke alarms to sound.
G. Remote Status and Alarm Indicators: Install near each Multi detector and each
sprinkler water-flow switch and valve-tamper switch that is not readily visible from
normal viewing position.
H. Audible Alarm-Indicating Devices: Install not less than 150 mm below the ceiling.
Install bells and horns on flush-mounted back boxes with the device-operating
mechanism concealed behind a grille.
I. Visible Alarm-Indicating Devices: Install adjacent to each alarm bell or alarm horn
and at least 150 mm below the ceiling.
J. Device Location-Indicating Lights: Locate in public space near the device they moni-
tor.
K. Fire-Alarm Control Unit: Surface mounted, with tops of cabinets not more than
1830 mm above the finished floor.
L. Annunciator: Install with top of panel not more than 1830 mm above the finished
floor.
3.2 CONNECTIONS
A. For fire-protection systems related to doors in fire-rated walls and partitions and to
doors in smoke partitions, comply with requirements in Division 08 Section "Door
Hardware." Connect hardware and devices to fire-alarm system.

1. Verify that hardware and devices are NRTL listed for use with fire-alarm sys-
tem in this Section before making connections.
B. Make addressable connections with a supervised interface device to the following

devices and systems. Install the interface device less than 1 m from the device con-
trolled. Make an addressable confirmation connection when such feedback is avail-
able at the device or system being controlled.
1. Alarm-initiating connection to smoke-control system (smoke management) at

firefighter smoke-control system panel.
2. Alarm-initiating connection to stairwell and elevator-shaft pressurization sys-
tems.
3. Smoke dampers in air ducts of designated air-conditioning duct systems.
4. Alarm-initiating connection to elevator recall system and components.
5. Alarm-initiating connection to activate emergency lighting control.
6. Alarm-initiating connection to activate emergency shutoffs for gas and fuel
supplies.
7. Supervisory connections at valve supervisory switches.
8. Supervisory connections at low-air-pressure switch of each dry-pipe sprinkler
system.
9. Supervisory connections at elevator shunt trip breaker.
10. Supervisory connections at fire-pump power failure including a dead-phase or
phase-reversal condition.
11. Supervisory connections at fire-pump engine control panel.
3.3 IDENTIFICATION
A. Identify system components, wiring, cabling, and terminals. Comply with require-
ments for identification specified in Division 26 Section "Identification for Electrical
Systems."
B. Install framed instructions in a location visible from fire-alarm control unit.
3.4 GROUNDING
A. Ground fire-alarm control unit and associated circuits; comply with IEEE 1100. In-
stall a ground wire from main service ground to fire-alarm control unit.
A. Field tests shall be witnessed by Architect and authorities having jurisdiction.
B. Manufacturer's Field Service: Engage a factory-authorized service representative to

inspect, test, and adjust components, assemblies, and equipment installations, in-
cluding connections.
C. Perform tests and inspections.
1. Manufacturer's Field Service: Engage a factory-authorized service representa-

tive to inspect components, assemblies, and equipment installations, includ-
ing connections, and to assist in testing.
D. Tests and Inspections:
1. Visual Inspection: Conduct visual inspection prior to testing.
a. Inspection shall be based on completed Record Drawings and system

documentation that is required by NFPA 72 in its "Completion Docu-
ments, Preparation" Table in the "Documentation" Section of the "Fun-
damentals of Fire Alarm Systems" Chapter.
b. Comply with "Visual Inspection Frequencies" Table in the "Inspection"
Section of the "Inspection, Testing and Maintenance" Chapter in NFPA
72; retain the "Initial/Reacceptance" column and list only the installed
components.
2. System Testing: Comply with "Test Methods" Table in the "Testing" Section of
the "Inspection, Testing and Maintenance" Chapter in NFPA 72.
3. Test audible appliances for the public operating mode according to manufac-
turer's written instructions. Perform the test using a portable sound-level
meter complying with Type 2 requirements in ANSI S1.4.
4. Test audible appliances for the private operating mode according to manufac-
turer's written instructions.
5. Test visible appliances for the public operating mode according to manufac-
turer's written instructions.
6. Factory-authorized service representative shall prepare the "Fire Alarm Sys-
tem Record of Completion" in the "Documentation" Section of the "Funda-
mentals of Fire Alarm Systems" Chapter in NFPA 72 and the "Inspection and
Testing Form" in the "Records" Section of the "Inspection, Testing and
Maintenance" Chapter in NFPA 72.
E. Reacceptance Testing: Perform reacceptance testing to verify the proper operation

of added or replaced devices and appliances.
F. Fire-alarm system will be considered defective if it does not pass tests and inspec-
tions.
G. Prepare test and inspection reports.
H. Maintenance Test and Inspection: Perform tests and inspections listed for weekly,
monthly, quarterly, and semiannual periods. Use forms developed for initial tests
and inspections.
I. Annual Test and Inspection: One year after date of Substantial Completion, test fire-
alarm system complying with visual and testing inspection requirements in NFPA 72.
Use forms developed for initial tests and inspections.

3.6 TRAINING
A. Equipment’s manufacturer and his authorized, local representative shall provide, in

depth, equipment service and programming on site training to selected Employer’s
personnel for two weeks.


ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
A Oct. 2021 E.M C.AMAM C.MYSM 17 ISSUED FOR DETAILED DSIGN
0 Jan. 2022 E.M C.AMAM C.MYSM 17 ISSUED FOR TENDER
1 Feb. 2022 E.M C.AMAM C.MYSM 17 ISSUED FOR CONSTRUCTION
SPECIFICATION REV.
EARTHWORK
KSA 312000 - 2970 1

CONTENTS
SECTION 312000
EARTHWORK
Page
PART 1 GENERAL 2
1.2 Summary 2
1.3 Reference Standards 2
1.4 Related Sections 3
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 15
3.8 Auxiliary Works 16
3.9 Tolerance Limits 16
3.10 Surface Finish 16
3.11 Disposal 17
Earthwork Section 312000

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
1.4 RELATED SECTIONS
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. the below
table could be followed for soil structural fill gradation:
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) 50-100
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") 80-100
10 mm (3/8") 45-100
4.75 mm (No.4) 25-85
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 - 2.0 m 250 50 10 95
Fill
2.0 - 4.0 m Selected Fill 300 100 15 95
4.0 - 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 - 1.5 m 250 50 10 95
Fill
1.5 - 3.0 m Selected Fill 350 100 15 95
3.0 - 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.
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
ASTM 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
PURCHASE
CONSTRUCTION X

NO. BY BY BY
0 Jan. 2022 H.A. C.AMAM C.MYSM 67 ISSUED FOR TENDER
1 Feb. 2022 H.A. C.AMAM C.MYSM 66 ISSUED FOR CONSTRUCTION
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP WATER UTILITIES
KSA 331000 - 2970 1

CONTENTS
SECTION 331000
WATER UTILITIES
PAGE
PART 1 GENERAL 2
1.2 Description Of Work 2
1.4 Submittals 3
1.5 Quality Control 4
PART 2 PRODUCTS 9
2.1 Warning Tapes 9
2.2 Geo-Textile 10
2.3 Pipes, Fittings And Accessories 10
2.4 Valves 25
2.5 Floating Valve (For Water Tank) 33
2.6 Float Control Modulated Valve (For Water Tanks) 33
2.7 Globe Valves 35
2.8 Ball Valves 35
2.9 Stop Valves (For Water Tanks) 35
2.10 Drain Cocks (For Water Tanks) 35
2.11 Nuts And Bolts With Washers 35
2.12 Flexible - Coupling And Flange Adaptors 35
2.13 Dismantling Joints 36
2.14 Water Meter For House Connections 37
2.15 Valve Chambers 41
2.16 Fire Hydrant 44
PART 3 EXECUTION 45
3.1 General 45
3.2 Pipes, Fittings And Accessories 45
3.3 Valves Installation 53
3.2 Valve Chamber 57
3.3 Valve Chamber Step Irons & Ladders 60
3.4 Valve Chamber Frames And Covers 61
3.5 Tests 61
3.6 Fire Hydrants 61
3.7 Cleaning And Disinfection 62
Water Supply Networks Section 331000

SECTION 331000 – WATER SUPPLY NETWORKS
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 03 Section 032100 "Concrete and Reinforced Concrete”

2. Division 03 Section 033000 "Concrete Cast-in-place"
3. Division 04 Section 042000 “Unit Masonry Assemblies”
4. Division 31 Section 310000 "Earth Work"
5. Division 07 Section 071000 "Corrosion Protection and Odor Control"
1.2 DESCRIPTION OF WORK
A. This section covers water pressure pipes, valves as indicated on the drawings and spec-
ified here in addition to all types of potable water structure such as valve chambers as
required by the Contract. Extent of these structures is indicated on Drawings.
B. The Contractor shall provide equipment, materials, transportation, storing, safety tools
and labor required for proper construction of the water networks.
A. Pipes, fittings and accessories shall be performed in strict accordance with the stipula-
tions of the National Water Company (NWC) Latest Edition, the British Standard Speci-
fications (BS) or the American Standards (ASTM) as noted herein below or other equiv-
alent approved Standards and Sound Practice.
A. GENERAL:
1. BS 8010: Part 1 Pipelines on land. Pipelines on land design,

2. BS 8010: Part 2 Construction and installation.
B. ASTM & AWWA No.
1. AWWA C651 Disinfecting water mains

2. ASTM D2837 Hydrostatic Design Basis
(HDPE) High density Polyethylene pipes pipe and fittings
British Standard Specifications
BS No.
1. BS 6437 Polyethylene pipes (type 50) in metric diameters for general purpose
American Society for Testing and Materials
ASTM & AWWA No.
1. AWWA C901 Polyethylene (PE) pressure Pipe & Tubing, ½

inch through 3 inch for water
2. AWWA C906 Polyethylene (PE) pressure Pipe & Fittings, 4

inch through 63 inch for water
3. ASTM F894 Specification for Polyethylene (PE) Large Diameter Profile Wall
Sewer and Drain Pipe.
4. ASTM D3035 Standard Spec for PE Pipe (DR-PR) Based on Controlled Out-
side Diameter
5. ASTM D3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
6. ASTM D3350 Standard Specification for PE Pipe & Fittings Materials
7. ASTM D1238 Melt Flow Index
In the event of conflict between various codes and standards the most stringent condi-
tions shall apply.
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 mate-
rial.
b. Material Certificates of compliance.
c. Materials Sample.
d. Method statement of pipelines construction.
e. Shop drawings.
f. Record drawings.
g. Maintenance data.
h. Certificates of origin.
2. Valve
a. Materials list, original catalogue, certificate of origin and manufacturer's

data sheet of the valves, valves Accessories, cast iron covers, quick cou-
plers, controllers, drippers, strainers, valve box. etc.
b. Representative samples.
c. Method statement of the construction.
d. Shop drawings of the whole potable water & firefighting system including
control system with cable routing.
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 test-
ing laboratory services in connection with concrete materials and mix de-
signs, the design of asphalt mixtures, gradation tests for embedment, fill,
backfill materials, and all other tests and engineering data required for the
Engineer's review of materials and equipment proposed to be used in the
Work. The Contractor shall obtain the Engineer's acceptance of the test-
ing 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 con-

crete, asphalt mixtures, moisture-density (Proctor) and relative density
tests on embedment, fill, and backfill materials, in-place field density tests
on embedment’s and fills, and other materials and equipment, during and
after their incorporation in the Work. Field sampling and testing will be
performed by the Contractor, in the general manner indicated in the spec-
ifications, with minimum interference with construction operations. The
Engineer shall determine the time and location of field sampling and test-
ing, 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 sam-
pling and field testing activities. The Contractor shall furnish personnel
and facilities to perform the testing activities.
d. If at any time during the construction process the testing services become
unacceptable to the Engineer, the Engineer may request in writing that
such services be terminated. If the Engineer determines that sufficient
cause exists, the Contractor shall terminate the services and engage an ac-
ceptable testing laboratory.

4. Transmittal of Test Reports.
a. Written reports of tests and engineering data furnished by the Contractor

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. Distri-
bution shall be two copies of each test report to the Engineer's Repre-
sentative, one copy to the Contractor within three days after each test is
completed.
A. Codes and Standards: Reference to the standards of any technical society, organiza-
tion, 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.
B. 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, suitability and equivalence of the
substitute codes and standards as well as provide proof of previous successful use.
C. Work specified by reference to the published standard or specification of a govern-

ment agency, technical association, trade association, professional society 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.
D. Where the specific date or issue of the standard is not included with the reference to
the standard, the latest edition, including all amendments published and available on
the first published date of the Invitation to Tender, shall apply.
E. 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.
F. 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 surpass the require-
ments of the specified reference standard.
G. The listing of a trade name in the Contract Documents shall not be construed as war-
ranting that such product conforms to the respective reference standard.
H. Copies of applicable referenced standards have not been bound in this Contract Docu-
ment. 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.
I. Contractors shall clearly identify and submit for approval any requests to use products

conforming to printed standards or publications with a different publication date from
that effective under the Contract. Clearly indicate the changes in product or workman-
ship quality involved in the proposed change, if any, and reasons for the request.
1. Quality of Materials.
a. Unless otherwise specified, all materials and equipment furnished for

permanent installation in the Work shall conform to applicable standard
specifications and shall be new, unused, and free from defects and imper-
fections, when installed or otherwise incorporated in the Work. No such
material or equipment shall be used by the Contractor for any purpose
other than that intended or specified.
b. Where so specified, products or workmanship shall also conform to the
additional prescriptive or performance requirements included within the
Contract Documents to establish a higher or more stringent standard or
quality than that required by the referenced standard.
2. Offsite Inspection
a. When the specifications require inspection of materials or equipment dur-

ing the production, manufacturing, or fabricating process, or before ship-
ment, such services shall be performed by the Contractor, or and inspec-
tion organization acceptable to Engineer.
b. 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 ac-
cess and proper facilities and to cooperate with inspecting personnel in
the performance of their duties.
c. The inspection organization shall submit a written report to the Contractor
who shall provide copies to the Engineer. Reports shall be submitted at
least once each week and at the conclusion of the testing.
A. Pipe Identification and packing
1. The marking information and sequence shall comply with ISO 4427 (clause 8
marking). All pipes and fittings, including test samples shall be clearly and per-
manently marked using indent printing in a color that contrasts with the pipe.
2. All pipes shall be indelibly marked at maximum intervals of 1m The marking shall
indicate at least the following information:
a. The manufacturer's name and/or trademark

b. The dimensions (nominal outside diameter x nominal wall thickness)
c. Material and designation
d. The nominal pressure (PN) in bar
e. The pipe series (S or SDR) (optional)
f. The production period (date or code)
g. The number of this International Standard.
3. The word "water" shall also be included if the pipe is intended for potable water.
4. The maximum quantity of pipe to have the same coil/length number is one silo
(coiled pipe) or one bundle (straight lengths). The maximum combined length of
pipe in the silo or bundle with the same coil/length number shall not exceed the
maximum allowable coil length.
5. When pipe material is boxed, the coil number shall be clearly marked on the out-
side edge of the box or silo. Invoices and packing lists shall include the date of
manufacture and coil/length numbers for all material in the shipment
6. The fittings shall be packaged in bulk or individually protected were necessary in
order to prevent deterioration and contamination. The package shall have at
least one label with manufacturer name, type and dimension of the fittings and
number of units.
7. All compression fittings packed individually by transparent protective bags indi-
cating its type and size.
8. All compression fittings packed in cartoon boxes.
9. If only one type of product packed, all cartoon boxes shall have a label showing
the manufacturer identification, the description of the product, the drawing of
the product, the relevant size and the quantity.
B. Shipping
1. The CONTRACTOR/SUPPLIER shall provide packing and shipping procedures for

approval by the ENGINEER and shall comply with the following requirements.
a. Delivery
Delivery of the plastic pipes and fittings to site shall be no later than six
months after the stamped manufacture date.
b. Weathering
A certificate from the pipe/fitting manufacturers shall be provided, con-

firming that the products may be stored in the open for minimum of 2
years without any adverse effect.
c. Tie-Downs
Tie-downs shall be at least 100 mm wide and be clean and free from sand,
gravel and other such materials. For straight length pipe (up to 12 m), a
minimum of 6 tie-downs are required.
d. Pallets
The pallets shall be suitable for transporting the material from the place of
manufacture to the designated receiving location without causing any
damage to the pipe. The pallets shall not contain any broken planks or ex-
tremities that may damage the coiled pipe or straight lengths. They shall
be durable enough to prevent loose pallet nails from gouging the bottom
coil/straight length.
e. Overhang
The pipes shall be loaded so as not to overhang the vehicle by more than
one meter. The vehicle shall have side supports at centers of no more than
2m and the inner upright surface shall be flat with no sharp edges.
f. Stacking
Different sizes are best stacked separately. If this is not practical, then
stack with the largest pipes at the base. Pipes shall not be nested for long
periods and stacks shall not exceed seven layers or 2m in height.
When socketed pipes are stacked, the bottom layer of sockets shall be
prevented from being in direct contact with the ground, either by excavat-
ing under the socket, or by use of transverse supports.
Alternate layers shall have the sockets protruding from, and opposite to,
the previous layer. In warm climates, stacks shall be limited to 1m in
height and be shaded from direct sunlight.
C. Trucking
1. Loose pipes are hand-loaded and care shall be taken before loading to check the
vehicle's load carrying area for nails and other projections. The pipes must be
evenly supported throughout their length, but where this is not possible, timber
supports of at least 75 mm bearing width shall be placed no more than 2 m
apart. When loading socket and spigot pipes, place the sockets at alternate ends
of each layer, and allow the sockets to protrude so that the pipes are evenly
supported.
2. When a mixed load of pipes (i.e. varying diameters) is to be transported, the
larger, thicker walled and thus heavier pipes shall be placed at the bottom of the
load with the small diameters on top.
3. Fittings shall be supplied in cardboard boxes or plastic bags. The complete load
shall be correctly secured prior to commencement of the journey.
4. When loose pipes have been transported one inside the other, always remove
the inner pipe first.
5. Pipes shall not be dropped or dragged.
D. Banding
1. Pipes and valves shall generally be delivered pre-packed in standard quantities

these pipe bundles shall be held by nylon straps and timber supports and shall
usually be mechanically handled.
2. Pipes and valves shall generally be delivered pre-packed in standard quantities
these bundles shall be held by nylon straps and timber supports and shall usually
be mechanically handled.
E. Vendor Documentation
1. The CONTRACTOR shall furnish following vendor data as a minimum, with the
bid:
a. Catalogues / Brochures.
b. Dimensional details of pipes and fittings.
c. Detailed material specifications.
d. Manufacturer's drawings, showing fittings dimensions.
e. Complete details of testing facilities available at manufacturer's works.
f. Local agent name and address.
2. Bids not accompanied by any of above-mentioned information/data shall be

considered incomplete, and liable to be rejected
PART 2 PRODUCTS
2.1 WARNING TAPES
Service protection tapes shall be installed above all water pipelines and pressure
mains constructed or exposed under this contract excluding individual service connec-
tions.
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.
The tape shall be 150 mm wide and 250 micron thick and produced as a strong com-
posite laminate consisting of: -
 30 Micron polyester film top layer

 12 Micron detectable aluminum foil in between
 208 Micron bottom layer polyethylene
 The thickness of the tape (250 micron / 1000 gauge) shall be measured in accord-
ance with BS 2782: Part 6. Method 630 A.
The following properties shall be demonstrated by appropriate tests:-
 Physical properties :- (Average of 5 tests)

 Tensile strength Longitudinal (MD) : 160 N (Minimum)
 (BS EN ISO 527 – 3 : 1996 Transversal (TD) : 150 N (Minimum)
 Elongation (PE only)
 (BS EN ISO 527 – 3 : 1996 MD : 450%, TD : 550%
 Tear strength MD : 640 gram force
 BS 2782 Part 3, 360A : 1991 TD : 700 gram force Minimum
 Dart Impact
 BS 2782 : P3 : 352F : 1996 1000 grams minimum
Chemical resistance:-
 The tape shall be remaining legible and color fast in all soil conditions at PH 2.5 to
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.
Detect ability after installation and back filling
 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.
Water : Blue
CAUTION : Water Pressure Mains Below
 Municipality logo shall be printed in black between the spaces of repeated mes-
sages.
2.2 GEO-TEXTILE
a. Geo textile for Pipe Bedding (Filter Fabric)
 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.
 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 Engi-
neers 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 permeabil-
ity shall be a minimum of 0.30 cm/sec.
 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.
 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.
 The puncture resistance of the geo textile measured with 8 mm hemispheri-
cal tip in accordance with Method ASTM D3787 shall be a minimum of 43 kg
(95 lbs).
 The material shall be resistant to rot, mildew, aging, rodents, and insects.
The geo-textile shall withstand the abuses of placement by men and equip-
ment without tearing or being punctured.
 Geo textile shall be inert to acids and alkalis within a pH range of 3 to 13.
 The geo textile shall be resistant to ultraviolet light exposure based on testing
in accordance with ASTM D4355.
2.3 PIPES, FITTINGS AND ACCESSORIES
A UPVC pipes and fittings (and preferable for pipes up to 400 mm)
1. General
 The material from which pipe, fitting and accessories is produced shall consist
of substantially unplasticized polyvinyl chloride. Only those additives that are
needed may be used for the manufacture of the polymer, and for its conver-
sion into sound, durable extrusions or molding of good surface finish, me-
chanical strength and opacity.
 UPVC pipes shall not be deteriorated or broken down under the effect of bac-
teria or other micro-organisms.

 Pipes shall be as uniform as commercially practical in color, opacity, density
and other physical properties.
 The pipes, fittings and accessories shall have a registered certification mark
on, or in relation to a product, as an assurance that the goods have been pro-
duced under the scheme of supervision control and testing in accordance
with the certification mark scheme. Fittings and accessories shall comply
with ASTM D 2466.
 Pipes shall be recommended as conduits for the conveyance of potable water
or other liquids as specified.
 Pipes shall have chemical inertness and exceptionally smooth internal surface
preventing the formation of deposits and ensuring better flow rate.
 Pipes shall have long service life, resistance to chemicals and excellent corro-
sion resistance.
 Pipes shall be of great mechanical resistance to external and internal load-
ings.
 Pipes shall have the property of absorption of linear expansion or contraction,
thereby preventing eventual pipe distortions.
 Pipes shall have absolute tightness at the jointing points regardless of wheth-
er there is an over or under-pressure in the network.
 Properties of pipes shall meet the requirements of the physical, chemical and
mechanical characteristics as mentioned hereinafter.
2. Classification of Pipes:
Pipes shall be manufactured in accordance with Table (1) of ES No. 484, Class (5) capa-
ble to withstand a working pressure of 16 kg/cm2.
3. Dimensions:
 Pipe shall conform to the outside diameters, inside diameter and wall thick-
ness specified by the above mentioned standard. Pipes shall be accepted
within the following limits:
 Thickness ± 30 %
 Diameter ± 2.5%
 Length ± 1%
 Weight ± 5%
4. Lengths:
 Pipes shall be supplied in straight lengths, normally of 3 m, 6 m and 9 m or as

denoted in Bill of Quantities and approved by the Engineer.
5. Cutting to Length and Chamfering:
 Pipes shall be of such kind that can be cut to length using fine tooth wood
saw or hacksaw and of an end which can be chamfered with one of the spe-
cial hard tools developed for shaping plastics.
6. Physical and Thermo-technical Characteristics:
a. General Properties:
UPVC pipes shall be manufactured by extrusion and shall have low specific gravity.
b. Appearance:
- The pipes shall be reasonably round, homogeneous throughout, free from

voids, cracks, and other defects that would impair the performance in ser-
vice; and as uniform as commercially practical in color, density, and other
physical properties.
- Pipe surface shall be free nicks, scratches, and other blemishes. The joining
surfaces of pipe shall be free from gouges and other imperfections that
might cause leakage at joints.
- The internal and external surface of the pipe shall be smooth, clean and rea-
sonably free from grooving and other defects. The ends of the pipes and fit-
tings shall be cleanly cut and square with the axis of the component. The
pipe shall be reasonably straight.
c. Specific Gravity:
- Specific gravity of pipes shall not be less than 1380 kg/m3 and not more
than 1425 kg/m3.
d. Heat Reversion:
- When tested in accordance with the manufacturing standards, no point all

around the pipe shall have a length change by more than 5% at 150 ± 2° C.
After testing, the pipe shall show no faults, e.g. cracks, cavities or blisters.
e. Opacity:
- The pipe shall be full opacity and when tested the wall of the pipe shall not
transmit more than 0.2% of the visible light falling on to it.
f. Coefficient of Linear Expansion:
- Expansion shall be 1 mm change in length at 22°C for each 5°C rise or fall in
temperature allowance for every 1 meter length of pipe when operating at
temperature above ambient.
7. Chemical Characteristics:
a. Water Absorption:
- Pipes shall be tested for water absorption, a sample shall be completely im-
mersed in water for 24 hours at 100° C, this test shall meet the requirements
of the Standard Specifications of the country of origin.
b. Resistance to Acetone:
- Pipes shall not delaminate or disintegrate after 2 hours immersion in anhy-

drous acetone at room temperature, examination at 20 minute intervals.
c. Toxic Substances:
- Pipes shall conform with the requirements to toxic substances which shall
ensure that the recommendations of the World Health Organization 1963
concerning toxic contaminants of drinking water are not exceeded.
d. Resistance to Sulphuric Acid:
- According to the manufacturing standards, the mass of the tested specimen

shall neither increase by more than 3.16 g nor decrease by more than 0.13 g.
8. Mechanical Characteristics:
a. Extruded pipes shall have high mechanical characteristics and shall fulfill the fol-
lowing requirements:
b. Tensile strength : 3.5 kgf/mm2, minimum
c. Modulus of elasticity : 197 kgf/mm2, minimum
d. Impact strength : 3.55 kgf/cm at notch, minimum
e. Deflection temperature under load: minimum: 0.1856 kgf/mm2: 55° C mini-
mum.
9. Marking:
a. All pipes shall be indelibly marked at interval of not greater than 3m or as speci-
fied in the origin Standards.
Pipe markings shall include the following marked continuously:
a. Manufacturer’s Name
b. Nominal Size
c. Class Pressure Rating
d. Identification Code
10. Jointing
a. Solvent Cement:
- Solvent cement joints are acceptable only up to size DN 50mm as per the
applicable code of practice for the fittings. The solvent cement shall be of
non-toxic quality suitable for drinking water service. Fittings shall conform to
BS 4346 Part 1/BS EN 1452.
b. Push-on Joints:
- Pipes shall be laid with a gap between the end of the spigot and the base of
the socket. This gap shall not be less than 10 mm or greater than (1/3) one
third of the straight draw of the pipe joint.
c. Rubber Rings:

- Rubber sealing rings supplied with pipes or fittings shall be synthetic rubber
rings, shall comply with the requirements of the Standard Specifications of
ASTM No. F 477 Table No. 1.
- Rings shall be smooth and free from air marks and other blemishes.
- Rings shall be homogenous, free from porosity, grit, blisters and visible sur-
face imperfections. The rubber shall not contain more than one part by
weight of paraffin wax per hundred part of rubber.
- Rubber rings when tested by immersion in water at a temperature of 25 ± 1°
C for 7 days shall not absorb more than 3% by weight of water.
- Rings shall be rapid-installing even in rainy, windy, or hot weathers.
- Only tiny deformation of the material while socketing and forming grooves
may be accepted at the discretion of the Engineer.
11. Lubricant
- Shall be the type recommended by manufacture for use with the employed
pipes and no substitute is allowed.
12. Certification
- The Contractor shall provide the conformance certification of the manufac-

turer, test results or copies of test reports. These reports shall include all
the previously mentioned physical, chemical and mechanical characteristics
concerning the pipes.
B Ductile Iron Pipe And Fittings
1. General:
a. Ductile iron pipe and fittings shall be installed with push-on joints (socket and
spigot) for the buried portion of pipes, and flanged joints inside reinforced con-
crete pipe (sleeve) under the taxiway. Pipes and fittings shall have inside ce-
ment mortar lining and seal coat suitable for installation and service in water
(according to type of service) and a bituminous varnish outside coating. Pipe
shall be centrifugally cast (spun) in metal moulds, fabricated of heavy grade
best quality machine able ductile iron. Castings shall be produced under ade-
quate quality control and shall be sound, true to pattern and showing no im-
perfection, which may affect their use. Fittings and accessories shall be cast in
metal moulds.
b. Each length of pipe and each fitting shall be plainly marked with the manufac-
turer's trade name or initials or registered trademark by which he can readily
be identified and with letters to indicate the classification of pipe. The marking
shall also indicate the nominal diameter of pipe in millimeters. The marking
may be cast, stenciled or otherwise applied on the pipe so as to be clear and
legible at the time of installation. The marking shall be cast on fittings and shall
be located away from spigot and so as not to interfere with proper joining up-
on installation.
c. Where flanged-pipes are used, flanges shall be machined on the back to pro-
vide a flat surface for bolt heads and nuts. After machining, flanges shall be
flat and normal to the bore for the pipe to within 0.125 mm over the flange di-
ameter.
2. Heat treatment:
a. After casting, ductile iron pipe and fittings shall be subject to a suitable heat
treatment to give them the required mechanical characteristics.
3. Wall thickness:
a. Pipes and fittings shall be of wall thickness as specified in ISO 2531, accord-
ing to the following classes:
Type Class
1) Pipes K9
2) All Fittings except Tees K12
3) Tees K14
4. Internal coating:
a. Clean Water
1) All pipes and fittings shall be internally lined with Cement mortar
according to ISO 4179 and BS EN 545. Cement shall be sulphate re-
sistant conforming to ES No. 583 and sand shall be inert, hard,
strong and stable fine aggregate free from opaline, felspar, mica,
fool’s gold, siliceous magnesium, limestone or other deleterious
matters and conforming to ES NO. 1108. Sand shall also be free
from organic impurities and clay-bearing substances. Drinking wa-
ter or water whose composition is acceptable for drinking except for
bacteriological requirements shall be used for mixing.
2) The mortar shall be thoroughly mixed to a consistency, which pro-
duces a dense and homogeneous lining. Prior to applying mortar,
the inner surface shall be checked for the presence of any foreign
bodies, loose scale, or any other material which may be detrimental
to the adherence of lining to the metal. Any metal protrusions shall
be removed. Lining mortar shall be centrifugally cast inside the pipe
so that the inner surface of pipe and fittings, except for joint, shall
be entirely covered with mortar free from visible air bubbles or any
cavities and shall be of uniform maximum density at all points. Cast
lining shall be properly cured. Thickness of lining shall be as de-
fined in Decree 149, 1994, or 6 mm minimum. Hardened lining shall
be of uniformly smooth surface, of no flaky areas, crumbles, waves
or grooves. Single superficial cracks resulting from manufacture of
width up to 0.8 mm shall be acceptable.
3) Thickness of lining shall be tested as per DIN 1164. Each pipe shall
be inspected for the appearance of the surface conditions and fin-
ishing of ends.
b. Dirty water
1) All pipes and fittings shall be internally High alumina cement lined

according to BS EN 598.
2) Pipes to BS EN 598 are required normally to be supplied with a lin-
ing of high alumina cement mortar, with the end surfaces which can
come into contact with the conveyed effluents (socket internal sur-
face and spigot external surface) coated with either an epoxy-based
paint or fusion-bonded epoxy. Lining thicknesses are required to be
in accordance with those shown in Table 10. BS EN 598.
3) Ductile iron fittings and accessories to BS EN 598 are normally re-
quired to be supplied with an internal epoxy coating; this may be ei-
ther epoxy paint, or an epoxy powder all lining materials shall com-
ply with the relevant European standards, BS EN 598.
5. Outside protection:
a. Pipe and fittings shall be externally coated with 2 coats of a hygienically

harmless factory applied bituminous varnish (PF4) 2.5 mm thick over one
coat of zinc-based paint as per ISO 8179 . The applied material shall be a
one-component, filled bituminous solution with a quickly evaporating
phenol-free solvent.
b. All of ductile or pipes shall be wrapped with polyethylene sleeve tubular
film of low density polyethylene slipped over and snugly fitted to a pipe at
the time of laying standard ISO 8180.
6. Allowable tolerances:
a. Straightness: Deviation shall not exceed 1.25 mm per each meter length of
pipe measured from pipe axis.
b. Masses: Tolerance shall not exceed + 5%. Pipe of weights exceeding max-
imum limits mentioned before can be accepted provided conformance
with specifications in all other requirements.
c. Lengths: Tolerance shall not exceed - 50 mm for pipe.
d. Thickness: Tolerance shall not exceed minus 1.3 mm plus 0.001 nominal
diameter of pipe. No limit for plus tolerance.
7. Gaskets:
a. Shall be suitably retained rubber gaskets and lubricant conforming to ISO

4633.
8. Joints:
a. Flexible joints:
1) Flexible joints shall be of spigot and socket "push-on" type suitable

for angular deflection in any direction and capable of axial move-
ment to compensate for thermal expansion or contraction and
ground movement. All flexible joints for D.I. pipes and fittings shall
be designed in compliance with ISO 2531/EN 545. Test certificate to
be provided.
2) Joints may permit angular deflection to accommodate ground
movements and to negotiate large radius bends. All joints shall be
designed to be fully flexible. Consequently, the allowable angular
deflection declared by the manufacturer shall not be less than:
a) 3.50 for DN 40 to DN 300
b) 2.50 for DN 350 to DN 600
c) 1.50 for DN 700 to DN 2000
3) Rubber ring joints shall be of a type that will not deteriorate under
local conditions either during storage or during operation. The rub-
ber gasket shall be of EPDM elastomer or equivalent in accordance
with ISO 4633 suitable for drinking water supply and waste water.
4) Where mechanical type joints are specified, proposed and approved
they shall be supplied complete with approved gaskets, glands, hot
dipped galvanized or cadmium plated bolts, nuts and all other nec-
essary accessories. Where retainer glands are specified they shall be
supplied with bolts and/or other necessary accessories.
b. Flanged joints:
1) Flange ended pipes and fittings shall only be used when connecting
to valves or other special fittings as approved by ENGINEER.
2) The flanges shall be raised faced and integrally cast or welded on.
Screwed on flanges or glued on flanges are not acceptable. Rotata-
ble flanges may be used for pipes and fittings up to DN 600.
3) The dimensions and drilling of the flanges shall be to ISO 7005-2 or
EN 1092-2. However in case connections have to be made to other
systems based on other standards contractor is responsible to veri-
fy. The pressure rating of the flanges shall be as given in the Data
Sheet or Particular Specification. Flanged joints shall be supplied
complete with gaskets, hot dipped galvanized or cadmium plated
nuts, bolts and washers.
4) Rubber gaskets shall be EPDM elastomer or equivalent approved in
accordance with ISO 4633 suitable for drinking water supply. The
gasket shall be minimum 3 mm thick and shall be as per pipe system
requirement. The dimensions of the flange gaskets shall be to ISO
7483.
5) The nuts, bolts, washers shall be of steel having minimum tensile
strength of 400 N/mm2 hot dipped galvanised or cadmium plated.
Nuts and bolts shall be suitable for the pressure rating specified in
the Particular Specification. Nuts and bolts shall be to ISO 4014 and
4032 and washers to ISO 887.
c. Restrained Joints
1) D.I. pipes and fittings with restrained coupling shall be utilised

where pipelines have to cross roads through existing ducts or in ar-
eas with restricted accessibility where the use of concrete anchor
blocks is prohibited, or as directed by ENGINEER. The CONTRACTOR
shall submit with his bid full details of the type of restrained cou-
pling he proposes to use.
2) Whenever in the course of work the CONTRACTOR intends to utilise
restrained couplings he shall obtain prior approval from ENGINEER.
3) Calculation of the number of pipe lengths with restrained coupling
required shall follow the manufacturer's recommendation and shall
be subject to ENGINEER approval.
4) Restrained joints shall be designed to resist the axial thrust forces
but maintaining flexibility and angular deflection. Restrained joints
shall be designed in accordance with ISO 10804- 1. The joint shall be
capable of withstanding the greater of the test pressure or the ser-
vice pressure + the surge pressure
5) The type of restrained joint shall be subject to ENGINEER approval
6) The thrust resisting mechanism shall be separated from the sealing
action of the gasket and shall not be in contact with potable water
in the pipeline.
9. Polyethylene Sleeves
a. Protective polyethylene sleeves shall be used with all D.I. pipes and fittings
to be installed in buried condition and shall be in accordance with ISO
8180. The polyethylene sleeve manufacturer shall be ISO 9001: 2000 Qual-
ity Management System certified. The polyethylene sleeve shall be black,
resistant to the effect of ultra violet light; the minimum nominal thickness
of the sleeve shall be not less than 200µm microns with a maximum minus
tolerance of 10%. The material shall be made from a polymer with a melt
flow index as measured according to BS 2782, of 10 or less and a density in
the range of 0.910 to 0.935 g/ml. The sleeve shall be free from pinholes,
gels, undispersed raw materials and particles of foreign matter. The film
may not contain more than 5% by weight of material other than polyeth-
ylene. Polyethylene sleeving shall be stored in cool dry store away from di-
rect sunlight or excessive heat. Rolls shall be supplied individually packed
in black polyethylene sacks and clearly marked according to ISO 8150
clause.
C High Density Polyethylene Pipes
1. General
a. A PE piping material consists of a polyethylene polymer (commonly desig-

nated 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, stor-
age and service. PE piping materials are classified as thermoplastics be-
cause they soften and melt when sufficiently heated and harden when
cooled, a process that is totally reversible and may be repeated. In con-
trast, thermosetting plastics become permanently hard when heat is ap-
plied.
b. 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 tem-
perature above their melting point.
c. PE is also classified as a semi-crystalline polymer. Such polymers (e.g., ny-
lon, polypropylene, polytetrafluoroethylene), in contrast to those that are
essentially amorphous (e.g., polystyrene, polyvinylchloride), have a suffi-
ciently ordered 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.
d. A beneficial consequence of PE’s semi-crystalline nature is a very low glass
transition temperature (Tg), the temperature below which a polymer be-
haves somewhat like a rigid glass and above which it behaves more like a
rubbery solid.
e. In the case of amorphous polymers, their melting temperature, the tem-
perature at which a transition occurs between the rubbery solid and the
liquid states, is not much higher than their Tg. Also for amorphous poly-
mers, the transition between a rubbery solid and a viscous liquid is not
very emphatic. This contrasts with semi-crystalline polymers, for which
this transition corresponds with the melting of all crystallites, and above
which a highly viscous liquid state is reached. This more emphatic transi-
tion in PE between the semi-crystalline solid and highly viscous liquid
states facilitates manufacture, fabrication and field joining because it al-
lows for more efficient ‘welding’ to be conducted – when in a liquid state
the polymer molecules are able to more effectively 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 liq-
uid viscous state.
f. 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 identi-
fying the most significant engineering properties of a PE pipe material. An
important feature of this designation code is that it identifies the maxi-
mum recommended hydrostatic design stress (HDS) for water, at 73°F
(23°C). Originally, this designation code was devised to only apply to ma-
terials 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 prac-
tice of using this material designation code for quickly identifying all PE
piping materials intended for pipes of solid wall or, of profile wall con-
struction.
g. The pipe shall contain no recycled compound except that generated in the
manufacturers’ own plant
h. 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.
2. Pressure Pipelines
a. Materials used for the manufacture of polyethylene pipe and fittings shall
be made from a PE 3408 high density polyethylene resin compound meet-
ing cell classification 345434C per ASTM D3350; and meeting Type lll,
Class C, Category 5, Grade P34 per ASTM D1238.
b. High Density Polyethylene (HDPE) pipe shall comply with AWWA Specifica-
tions C906.
c. If rework compounds are required, only those generated in the Manufac-

turer’s own plant from resin compounds of the same class and type from
the same raw material supplier shall be used.
d. 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.
e. HDPE pipe and accessories shall be meeting the requirements of Standard
Dimension Ration (SDR) 11 as minimum strength for potable water and
firefighting.
f. The pipe Manufacturer must certify compliance with the above require-
ments.
3. Fittings
a. General:
1. The PE pipe industry has worked diligently to make PE piping systems as

comprehensive as possible. As such, various fittings are produced which
increase the overall use of the PE piping systems. PE fittings may be in-
jection molded, fabricated or thermoformed.
2. The following will briefly describe the operations of each technique.
b. Injection Molded Fittings
1. 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 ser-
vice saddles, and self-tapping saddle tees. Very large parts may exceed
common injection molding equipment capacities, so these are usually fab-
ricated.
2. 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 oc-
casionally 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 Engineer.
c. Fabricated Fittings
1) Fully pressure-rated, full bore fabricated fittings are available from

select fittings fabricators. Fabricated fittings are constructed by join-
ing sections of pipe, machined blocks, or molded fittings together to
produce the desired configuration.
2) Components can be joined by butt or socket heat fusion, electro fu-
sion, hot gas welding or extrusion welding techniques. It is not rec-
ommended 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.
3) Fabricated fittings designed for full pressure service are joined by
heat fusion and must be designed with additional material in re-
gions 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, heavier 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 operating 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 con-
crete, with steel reinforcement or rebar, is also used for the same
purpose. Contact the fitting manufacturer for specific recommenda-
tions.
4) Very large diameter fittings require special handling during shipping,
unloading, and installation. Precautions should be taken to prevent
bending 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 fiber-
glass, for protection.
d. Thermoformed Fittings
1) Thermoformed fittings are manufactured by heating a section of

pipe and then using a forming tool to reshape the heated area. Ex-
amples 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.
e. Electro fusion Couplings
1) Electro fusion couplings and fittings are manufactured by either

molding in a similar manner as that previously described for butt
and socket fusion fittings or manufactured from pipe stock. A wide
variety of couplings and other associated fittings are available from
½” CTS thru 28” IPS. Fittings are also available for ductile iron sized
PE pipe. These couplings are rated as high as FM 200. Electro fusion
fittings are manufactured with a coil-like integral heating element.
These fittings are installed utilizing a fusion processor, which pro-
vides 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.
f. Injection Molded Couplings

1) Some mechanical couplings are manufactured by injection molding
in a similar manner as previously described for butt and socket fu-
sion fittings. 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 de-
pending upon the design. A wide variety of coupling configurations
are available including tees, ells, caps, reducers, and repair cou-
plings. 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.
4. Jointing
a. General
1. PE pipe or fittings are joined to each other by heat fusion or with mechan-
ical fittings. PE pipe may be joined to other pipe materials by means of
compression fittings, flanges, or other qualified types of manufactured
transition fittings. There are many types and styles of fittings available
from which the user may choose. Each offers its particular advantages and
limitations for each joining 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:-
b. Thermal Heat Fusion Methods
1) There are three types of conventional heat fusion joints currently

used in the industry; Butt, Saddle, and Socket Fusion. Additionally,
electro fusion (EF) joining is available with special EF couplings and
saddle fittings.
2) The principle of heat fusion is to heat two surfaces to a designated
temperature, and then fuse them together by application of a suffi-
cient force. This force causes the melted materials to flow and mix,
thereby resulting in fusion. When fused according to the pipe
and/or fitting manufacturers’ procedures, the joint area becomes as
strong as, or stronger than, the pipe itself in both tensile and pres-
sure properties and properly fused joints are absolutely leak proof.
As soon as the joint cools to near ambient temperature, it is ready
for handling. The following sections of this chapter provide a gen-
eral procedural guideline for each of these heat fusion methods.
c. Butt Fusion
1) 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 technique produces a permanent, economical and flow-
efficient connection. Quality butt fusion joints are produced by us-
ing trained operators and quality butt fusion machines in good con-
dition.
2) The butt fusion machine should be capable of:

a) Aligning the pipe ends
b) Clamping the pipes
c) Facing the pipe ends parallel and square to the centerline
d) Heating the pipe ends
e) Applying the proper fusion force
d. Saddle/Conventional Fusion
1) The conventional technique to join a saddle to the side of a pipe

consists of simultaneously heating both the external surface of the
pipe and the matching surface of the “saddle” type fitting with con-
cave and convex shaped heating tools until both surfaces reach
proper fusion temperature. This may be accomplished by using a
saddle fusion machine that has been designed for this purpose.
2) Saddle fusion using a properly designed machine, provides the op-
erator 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 un-
less hand fusion is expressly allowed by the pipe and/or fitting man-
ufacturer.
3) 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 proce-
dure for PE pipe and ASTM 2620.
e. Socket Fusion
1) This technique consists of simultaneously heating both the external

surface 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 re-
quired and to assist in alignment. Most pipe manufacturers have de-
tailed written procedures to follow. The majority refer to ASTM F
2620.
2) Electro fusion (EF): This technique of heat fusion joining is some-
what different from the conventional fusion joining thus far de-
scribed. The main difference between conventional heat fusion and
electro fusion is the method by which the heat is applied. In conven-
tional 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 require the use of electro fu-
sion couplings.
3) General steps to be followed when performing electro fusion joining
are:
a) Prepare the pipe (scrape, clean)

b) Mark the pipe
c) Align and restrain pipe and fitting per manufacturer’s rec-
ommendations
d) Apply the electric current
e) Cool and remove the clamps
f) Document the fusion process
g) Mechanical Connections:
4) As in the heat fusion methods, many types of mechanical connec-

tion styles and methods are available. This section is a general de-
scription of these types of fittings based on a variety of specifica-
tions such as ASTM F1924, F1973, and AWWA C219.
a) Mechanical Compression Couplings for Small Diameter Pipes
i. This style of fitting comes in many forms and materials.

The components, are generally a body; a threaded com-
pression 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, affecting a pres-
sure-tight seal and, in most designs, providing pullout re-
sistance which exceeds the yield strength of the PE pipe. It
is important that the inside of the pipe wall be supported
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 gripping of the pipe for pullout resistance. This
fitting style is normally used in service lines for gas or wa-
ter 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 second provides
a seal and some restraint from pullout and a third provides
a seal plus full pipe restraint against pullout.
f. Mechanical Bolt Type Couplings
1. 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.
2. 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.

3. 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.
g. Flanged Connections
1. 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)
2. 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 serrations 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.
3. 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.
4. 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.
5. 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 VALVES
1. GATE VALVES
a. Valve Features, General
- All valves employed shall be suitable for water application and internally
epoxy coated.
- Valve Design: Non-Rising stem valves shall be used.
- Pressure and Temperature Ratings: As specified hereinafter.
- Sizes: Same size as pipe, unless otherwise indicated on Drawings.

b. Gate Valves, 50 mm and Smaller:
- Class 125, cast, bronze body and union bonnet conforming to ASTM B62;
with threaded ends, "Teflon" impregnated packing and two-piece packing
gland assembly, solid wedge type gate-high tensile forged bronze spindle
engaging a gunmetal nut at the top of the gate, malleable iron spindle caps
and hand wheels.
c. Gate Valves, 60 mm and Larger:
1. Type:
- Resilient seated, non-rising stem, operated by hand wheels, and closing

clockwise with direction of operation clearly casted on the hand wheel.
- The nominal operating torque of closure and opening shall be appropriate

for manual operation using T- Key. All valves shall be provided with exten-
sion spindles
- The valve shall be designed for no leakage under flow from either direction
at a differential pressure across the gate of 10.1 times the rated working
pressure. The valve shall be capable of being operated under the maximum
unbalanced pressure that may occur.
- Face to Face Dimensions shall conform to ISO 5752 / 15.
- Buried Valves shall have flanged ends, whereas valves inside different struc-
tures shall be flanged.
- When connected to Ductile Iron Pipes, Flanged and socketed ends shall con-
form to ISO 2531.
2. Material: Shall be as follows:
- The valve Body, Bonnet, and wedge body shall be Ductile Iron to DIN 1693
– GGG 40/50.
- The wedge shall be completely encapsulated with an EPDM rubber. The
rubber coating thickness shall be a minimum of 2 mm on the flow surfaces
and 4 mm on sealing surfaces.
- The stem (spindle) shall be Stainless steel 316 L to DIN 17400 - 1.4028. The
stem nut shall be of resistant Brass, CZ 132 to BS 2872 forged integral with
the wedge. Pins, clamps, screws and other means of attachment are not
acceptable.
- All Sealing rings of the bonnet and the stem shall be of EPDM with outside
plastic bearings.
- The Bonnet bolts shall be of Stainless steel 1.4401. Nuts, bolts, and
washers for Flanges shall be of high tensile steel, hot dipped galvanized to
BS 729.
- The valve Body and Bonnet shall be internally and externally coated with
non- toxic fusion bonded epoxy powder coat with a minimum dry film
thickness of 250 micron.

3. Rating: Shall be as follows:
 Working pressure:
For transmission line 30 bars.

For distribution network 16 bars.
Test pressure equals to 1.5 working pressure
D. buried gate valves accessories
1. Surface Box Materials
- Surface box shall be manufactured from ductile iron materials (Spheroidal

Graphite Iron) and complying with BS EN 124: 1994.
- Casting shall be smooth, true to pattern and free from projections, sand
holes, blowholes or other distortions. Surface Box shall meet or exceed mini-
mum wheel loading requirements as defined for CLASS D 400.
- The manufacturer/supplier shall forward his proposal to achieve water -
tightness. 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 lift-
ing. The marking 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.
2. Surface Box Base
- Reinforced concrete base, according to Division 03, Section 033000 Concrete

Cast-in-place”, shall be constructed according to drawings.
3. Extension Spindle:
- The extension spindle shall be in one piece i. e. the main spindle shall be extend-
ed without connecting coupling. Alternatively, extension spindle with connecting
coupling shall be supplied.
- 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.

- The PVC pipe piece shall be 100mm diameter 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 water-
tight adaptor. The top of PVC pipe shall be cut up to bottom of frame of man-
hole cover, at site.
- 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.
4. Extra Coating:
- Since valve is to be buried fully below ground, extra protection is required over
epoxy coating. Only epoxy coating is not acceptable.
- Following are to be applied / wrapped except spigot portion of valve where F. C.

joint is to be fixed.
- Mastic or tape filler or molding putty, if required, shall be applied by hand press-
ing to fill the angled / concave section so that exterior surface shall be smooth
and free of projection.
- Immediately after filling with mastic, self-adhesive bituminous wrap or recom-

mended by manufacturer and approved by Engineer shall be wrapped as per
manufacturer recommendation.
- Over the wrapping, self-adhesive thin plastic outer wrap shall be applied.
2. AUTOMATIC AIR RELIEF AND VACUUM VALVES
a. Type:
- Dual orifice vented valve, to allow automatic air venting as the network is being
filled with water, permanent degassing and rapid air ingress when network has
been emptied to avoid vacuum conditions.
- The Valve shall be equipped with isolating valve to allow maintenance of the air
valve without shutting off the main.
- Unless otherwise stated, the size of the valve shall be selected according to the
following schedule:
Pipeline Bore (mm) 200 300 350 450 600 900 1000*
Air Valve size (mm) 40 50 60 75 100 150 200
Valve shall have flanged end conforming to ISO 2531
b. Material: Shall be as follows:
- The valve Body, Cover, float chamber, and baffle body shall be Ductile Iron to DIN
1693 – GGG 40/50.
- Floating Balls shall be of Stainless Steel 13% chromium or light alloy coated
with EPDM.
- Spindle, Guides, Seats, bushing screws, and other internals shall be of Stain-
less Steel 316 L to DIN 17400 - 1.4401.
- Nuts, bolts, and washers for Flanges shall be of high tensile steel, hot dipped
galvanized to BS 729.
- The valve Body and cover shall be internally and externally coated with non-
toxic fusion bonded epoxy powder coat with a minimum dry film thickness of
250 micron.
c. Rating: shall be as follows:
- Working pressure 30 bars
- Test pressure equals 1.5 working pressure
3. MANUALLY OPERATED BUTTERFLY VALVES
A. Type:
- Valves shall be of the manually operated type, metal seated, with self-
lubricating bearing brushes.
- The body parts shall be circular and the diameter shall not be less than the
nominal pipe diameter. The valve shall be closed by clockwise movement of
the hand wheel and with direction of operation clearly casted on the hand
wheel. All valves shall be provided with extension spindles
- The valve shall have a local integral open/closed indicator to indicate the
valve position as a percentage.
- Face to Face Dimensions shall conform to ISO 5752 / 14.
- Flanged ends shall conform to ISO 2531.
- The disk should be designed to withstand the maximum pressure differential

across the valve in either direction of flow. The disk shall be countered to en-
sure the lowest possible resistance to flow and shall be suitable for throttling
operation with minimum vibration.
Valves shall be provided with suitable stops to prevent movement of the
shaft beyond the limits corresponding to fully open and fully closed positions
of the disk.
B. Material: shall be as follows:
- The valve body, disk, and bearing cover shall be ductile iron to din 1693 –
ggg 40/50.

- The disk shall be sealed with an EPDM rubber.
- The Disk shaft shall be of Stainless steel 316 L to DIN 17400 - 1.4028.
- Shaft Bearings should be self-lubricating PTFE, with sealing rings of EPDM.
- Nuts, bolts, and washers for Flanges shall be of high tensile steel, hot dipped
galvanized to BS 729.
- The valve Body shall be internally and externally coated with non- toxic fusion
bonded epoxy powder coat with a minimum dry film thickness of 250 micron.
c. Ratings: Working pressure
 Working pressure :
 For transmission line 30 bars
 For distribution network 16 bars
 Test pressure equals 1.5 working pressure
4. MOTOR OPERATED BUTTERFLY VALVES:
a. General:
- Butterfly valves with motor actuators are used as a control valve at the inlet of the
water tank. The valve is connected to level control switches inside the tank to
control inlet flow.
- The motor operated butterfly valves shall consist of a butterfly valve as specified
in article 2.5 above coupled with 380/220 V, AC, 50 Hz motor actuator complete
with integral motor starter.
- The motor actuator for valves shall be of a standard, well tested and proven de-
sign which ensures maximum safety to personnel, maximum service reliability and
economic operation. Design and construction shall be simple and well laid-out
and shall provide good accessibility to components and parts.
- The actuators shall be suitable for use on a nominal 380V, 3 phases, or 220 V, 1
phase 50 Hz power supply and are to incorporate motor integral reversing starter,
local control facilities and terminals for remote control and indication connections.
- The actuator shall include a device to ensure that motor runs with the correct ro-
tation for the required direction of valve travel with either phase sequence of the
three phase power supply connected to the actuator or signal the wrong phase
sequence.
b. Actuator sizing:
- The actuator shall be sized to guarantee valve closure at the specified differen-
tial pressure. The safety margin of motor power available for seating and un-
seating the valve shall be sufficient to ensure torque switch trip at maximum
valve torque with the supply voltage 10 % below nominal. The operating speed
shall be such to give valve closing and opening at approximately 10 inches per
minute.
- The actuator shall be one integral unit comprising the following:
 Squirrel cage motor

 Reversing contactor starter
 Local control facilities (Open/Stop/Close)
 Remote control facilities (Open/Stop/Close)
 Remote indication facilities (Open/Stop/Close)
 Terminals and terminal box for incoming and outgoing cables
c. Motor:
- The electric motor shall be 3 phase squirrel cage, class f insulated, with a time rat-
ing of 15 minutes at 40º C or twice the valve stroking time, whichever is longer, at
an average load of at least 3 % of maximum valve torque.
- Electrical and mechanical disconnection of the motor should be possible without

draining the lubricant from the actuator gear case.
- Following protection shall be provided for the motor
 Motor shall be de-energized in the event of a stall when at-

tempting to unseat a jammed valve.
 Motor temperature shall be sensed by a thermostat to protect
against overheating.
 Single phasing and incorrect phase sequence protection.
d. Gearing:
- The actuator gearing shall be totally enclosed in an oil or grease-filled gear case
suitable for operation at any angle. All gearing must be of metal construction. The
drive shall incorporate a lost-motion hammer blow feature. The output shaft shall
be hollow to accept a rising stem, and incorporate thrust bearing of the ball or
roller type at the base of the actuator. The design shall be such as to permit the
gear case to be opened for inspection or disassembled without releasing the stem
thrust or taking the valve out of service.
e. Rating: shall be as follows:
 Working pressure :
 For transmission line 30 bars

 For distribution network 16 bars
 Test pressure equals 1.5 working pressure

5. ALTITUDE VALVES
- The altitude valves shall be of the globe type and shall comply with the general
requirements of the specifications. The valve must be capable of bubble tight
sealing against 16 bar operating pressure unless mentioned otherwise. The end
flanges shall be rated and drilled in accordance with the standards indicated in
the Data Sheet.
- The altitude valves shall be of the straight through type. The operation of the
float operated pilot valve shall be through a chamber, which is separated with a
plunger from the body. The altitude valves shall be fitted with external hydraulic
relay system designed to automatically close the valve at reservoir high level and
reopen the valve at pre-set minimum level. The valve shall be suitable for drop
tight shut off by having full-face sealing.
- The relay control system shall consist of a three way float operated pilot valve,
orifice and strainer block, pilot control valves and interconnecting small bore pip-
ing. The float operated pilot valve shall be manufactured completely in 316 stain-
less steel.
- The orifice/strainer unit shall have a body and internals of stainless steel. The pi-
lot control valves and control piping shall be constructed in 316 stainless steel.
- The altitude valve shall be designed such that the hydraulic relay system can be
inspected, maintained or replaced without isolating the supply.
- The pressure setting shall be capable of being adjusted on site by turning the pi-
lot valve screw. The opening and closing speeds shall also be field adjustable by
adjusting the flow regulation screw.
- The minimum upstream pressure from the valve must exceed 0.4 bars. The dis-
tance between the main valve and the pilot valve should not exceed 50 m for
proper functioning of the valve.
- The globe valve shall be designed to provide the necessary loss of head and shall
operate smoothly without hunting.
- The valve shall be coated to a minimum dry film thickness of 300 microns (at any
point) internally with non-toxic fusion bonded epoxy coating system and exter-
nally with fusion bonded epoxy coating system. The maximum dry film thickness
shall be as per paint manufacturer recommendations.
MATERIAL SPECIFICATION (AT A GLANCE)
 Body : Ductile Iron EN 1563, EN-GJS-400-15, EN-GJS-500-7

 Trims Ported guide & seat ring : Gunmetal to BS 1400 LG 2C
 Seating on plunger : Rubber
 Plunger : Ductile Iron EN 1563, EN-GJS-400-15, EN-GJS-500-7

 Pilot valve : Stainless Steel 316
 Pilot parts : Stainless Steel 316
 Indicating rod : Stainless Steel 316
2.5 FLOATING VALVE (FOR WATER TANK)
a. Type:
- Float valves shall be of the elbow type, installed at the end of the inlet pipe, totally
closed when the float is at the end of its travel.
- The valve shall be able to connect at an extension pipe to its outlet.
- The valve shall have flanged end conforming to ISO2531, and shall be able to con-
nect an extension pipe to its outlet
Description Material Norms

Body Ductile cast iron GGG 50 DIN EN 1563(DIN
1693)
Bonnet Ductile cast iron GGG 50 DIN EN 1563(DIN
1693)
Obturator Ductile cast iron GGG 50 DIN EN 1563(DIN
1693)
Sealing Ring Natural rubber
Membrane Neoprene Rubber 22102
Shaft Stainless steel(1) AISI 303
Control Arm Ductile cast iron GGG 50 DIN EN 1563(DIN
1693)
Floating Shaft Stainless steel AISI 304
Adjusting arm Stainless steel AISI 304
Float PVC
Bolts/Nuts Stainless steel A2 AISI 304
And washers
Painting Epoxy Paint Potable (2) DIN 30677
Recicoat
9000 R4 Blue-HJF01R
2.6 FLOAT CONTROL MODULATED VALVE (FOR WATER TANKS)
a. General:
- The control valve SERIES 420 Modulating Float Level.

- Control Valve maintains a constant water level in a reservoir by compensating
for variations in supply or demand.
- It can be installed to control the flow into or out of the reservoir by closing on
rising level or opening on decreasing level.
- Recommended typical assembly for control valve automatic control valves
- The H-Strainer AQUA 90-501 combined with the "anti-shock" air release & vacu-
um break valve AQUA 70-506 are added system products for the best control
valve regulation.
- The control valve is a self-stabilizing Modulating Float Level Control Valve which
maintains a constant liquid level.
- Slight change in liquid level moves the Float Control which makes the main valve
to seek a new position.
b. Standard equipment:
Description Qty Type

Main valve hytrol AE/GE/NGE 1 100-01
Isolation ball valve 2 Rb-117
Strainer 1 X43
Modulating valve position stem con- 1 X74-B3
trol
2-way modulating float valve control 1 CFM-7
c. Optical features:
Description Qty Type

Remote sensing 1 -
Drain to main valve outlet 1 Rb-117
Isolating ball valve 1 Rb-117
High capacity Strainer 1 X43/80-EP
d. Installation
- Servo-controlled hydro-mechanical float pilot CFM-7 or CFM-7A:

- Float control must be installed in the reservoir above the maximum water level;
when closed, the float ball position must
- Be set in order to correspond to the desired maximum level of the reservoir (ad-
justment by means of the two stop collars, which must always maintain the float
ball firmly together with the float rod).
- The connecting pipe between the main valve chamber and the inlet of the float
pilot, not included in the control valve.
- Equipment must be sized in G 3/4" if its length is smaller than 5 m or in G 1" if its
length is bigger than 5m.
- If it presents highpoint(s), this (these) one "S" should be equipped with venting
cock(s) or automatic air release valve(s).

- The discharging pipe between the outlet of float pilot and the reservoir/outlet of
main valve must be sized the same way; the discharging pipe should avoid any
turbulence in the reservoir, in order to insure a quiet action of the float pilot
(stilling tube for the float ball can be recommended).
2.7 GLOBE VALVES
a. Globe valves, 50 mm and smaller:
- Globe valves 50 mm and smaller class 125; body and screwed bonnet of ASTM b
62 cast bronze, with threaded ends, replaceable composition disc, copper-silicon
alloy stem, bronze packing gland, "Teflon" impregnated packing and malleable
iron hand wheel.
2.8 BALL VALVES
- ball valves 25 mm and smaller: rated for 10 bars; two-piece construction; with
bronze body conforming to ASTM b 62, standard (or regular) port, chrome-
plated brass ball, replaceable "Teflon" or "TFE" seats and seals, blowout-proof
stem, and vinyl-covered steel handle with threaded ends.
- ball valves 35 mm to 50 mm: rated for 10 bars; 3-piece construction; with
bronze body conforming to ASTM b 62, conventional port, chrome-plated brass
ball, replaceable "Teflon" or "TFE" seats and seals, blowout proof stem and vinyl-
covered steel handle with threaded ends.
2.9 STOP VALVES (FOR WATER TANKS)
- Stop valves shall be screw down pattern, with chrome plated gunmetal bodies
and screwed connections.
2.10 DRAIN COCKS (FOR WATER TANKS)
- Drain cocks shall be plug type with hose union connector, loose key and gun-
metal body.
2.11 NUTS AND BOLTS WITH WASHERS
- 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 other
items) shall be Type 316 with a mill finish
2.12 FLEXIBLE - COUPLING AND FLANGE ADAPTORS
- 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.
- Flexible couplings and flange adaptors shall be capable of withstanding the test
pressure appropriate to the pipes for which they are supplied.

Nominal pressure(PN) PN10 as per item description
Rilsan Nylon coating to full unit including

Surface Protection internal & ex- studs, nuts, bolts and suitable to for fit in
ternal protection contact with potable water (certificate to
be attached ) minimum thickness - 250
microns
minimum thickness 50 microns

(End ring / flange adaptor body /
center sleeves / spigot) Studs /
Nuts / Bolts / Tie Bolts
BS 4504 PN10 pattern for PN 10 item.

Drilling of hole BS4504 PN16 pattern for PN16 item.
Details of couplings for incorporation in the works shall be submitted to the Engi-
neer for approval
2.13 DISMANTLING JOINTS
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 detailed
drawing to facilitate future removal of valves and other equipment for servic-
ing/replacement.
The dismantling joints shall be of the tied/restrained type having the following spec-
ifications:
Dismantling Joint Body: Steel to DIN EN 10025
End Ring: Malleable Cast Iron or Ductile Iron or Steel as for

Body
Gasket: EPDM
Studs & Tie Bolts: Stainless Steel 316
Coating: Rilsan nylon 11.D.F.T. of 300 microns with maximum

low tolerance of 10%
OR
Approved non-toxic ceramic enamel with min. DGT of

300 microns internally and approved cer- Met-enamel with additional epoxy resin
min. DFT 300 microns externally.
Ratings: Working pressure 16 bars for all valves in distribution

network & 30 bars for transmission lines.
Test pressure shall be 1.5 working pressure.

2.14 WATER METER FOR HOUSE CONNECTIONS
1. Water Meters
a. Water meter shall be manufactured from an approved factory by the min-

istry of water and electricity. The meters shall comply with the interna-
tional standards (ISO 4064-1) or American standards (AWWA) or SASO 238
and shall be accompanied by test certificate, certificate of origin and shall
comply with the following requirements:
b. The water meter shall be of the metrological category Class- C. The dimen-
sioning of the water meter shall comply with the international dimension-
ing standards and shall be installed into two positions vertical and hori-
zontal and the reading precision shall not be less then Class-C.
c. The water meter shall be made of non-corrosive brass solder or bronze
and shall not be affected by temperature and bronze percentage shall not
be less than 60%.
d. All internal and external parts shall be salt and temperature resistant and
temperature should be between 0 and 60 degrees and accompanied by a
certificate and all submerged parts shall be made of non-poisoned materi-
al so that water properties (quality, taste and odor) are maintained.
e. The water meter shall be resistant to high pressures (10 to 16 bars).
f. Water meter shall be isolated from water line and evacuated from air and
be of dry type.
g. Water meter glass shall be firmly treated against breakage and scratch and
color change.
h. Each water meter shall have an external number that will be the meter
number which will be inscribed on the metal part of the meter and the
year of manufacture shall be shown.
i. The water meter shall be measured in meter cube and should not be less
than 5 digits in addition to 3 decimal places in different colors.
j. The water meter material should be weather resistant and internal parts
of meter should be resistant to sand and water impurities.
k. There shall be a guarantee for the availability of spare parts of the meter
and its parts for a period not less than 10 years; during this period any
part of the meter or its base or measuring chamber could be exchanged.
l. The meter should be read clearly in addition to the possibility of being
read remotely as per the Ministry circulation No. 545/1 on 04/06/1428 h.
m. It should be printed on either side of the meter with big letters and num-
bers water meter size and the flow direction with an arrow. Also the pins
of the entrance shall be different than the exit. This will ensure that the
meter will not be installed wrongly.
n. It should be ensured that the meter shall not be affected by the cut of wa-
ter supply or being dry for a long time.
o. Each meter shall have a non-corrosive screen installed at the meter en-
trance before the measuring instrument and shall have a removable flap
valve after the measuring instrument.
p. The readings gears shall be fixed in a manner that is not affected by inter-
nal and external factors and shall be suitable for the water quality and
temperature that reach 60o C.
q. All meter sizes up to 4 inch shall be available and the meter box shall be
fixed with a lock that can be opened only with a special key to avoid van-

dalism.
2. Water Meters Boxes
a. Meter box body shall be made of fiberglass (25% glass).

b. Box cover: the metal hinges are made of stainless steel that allows open-
ing the box with an angle of 18 o.
c. Reading opening made up of thermally treated glass to allow of taking
clear readings with a guarantee that the color will not change and shall be
against scratch and resist temperature effects.
d. Box Key: the locking pin of the box cover shall be of stainless steel which
does not rust, and shall be opened by a special key (imported quantity
equal 5% of number of imported boxes) and the key shall be of stainless
steel.
e. Water pipe opening shall be 50 mm diameter in addition to two gaskets to
fix the entering and exiting pipes.
f. A circular opening to fix the reading instrument by a touching system with
a 40 mm diameter.
g. Ministry of water and electricity logo.
h. Bills collector fixed on the exterior side of the box made of polycarbonate,
transparent and anti-breakage or scratch or color change.
i. Box color is white (RAL9010). Box thickness is 6mm for all surfaces. Sur-
faces shall be resisting for all environmental deteriorating factors and sun-
light with a guarantee that color will not change or that the surface will
not deteriorate.
j. Ground water meter shall be put in ground boxes as shown in drawings.
The frame and cover shall be prepared to be locked and resist a load of 10
tons and shall be coated to specifications. And shall secure keys to open
and close these frames, one key for every 50 boxes.
3. Magnetic Flow meters
1. General
a. Magnetic flow meters shall use the principle of electro-magnetic induction

to produce a DC voltage proportional to the rate of liquid flow. Coil excita-
tion shall be DC. The coils shall generate a magnetic field which in turn in-
duces a voltage in the flowing liquid which is sensed by a pair of elec-
trodes in contact with the fluid.
b. The magnetic flow meter shall utilize DC bi-polar pulsed coil excitation, au-
tomatically re-zeroing after every cycle. The coils shall be protected from
contact with the liquid and the electrodes shall be made of AISI type 316
stainless steel and shall be provided with a minimum preamplifier input
impedance of 1 x 106 mega ohms to reduce errors due to electrode coat-
ing to almost zero. Any form of electrode cleaning is not acceptable. Re-
placeable electrodes are also not acceptable.
c. The electronics shall be remote mounted and the flow meter transmitter
shall retain IP 67 rating. The transmitter shall be furnished with integral
universal wall/pipe stand mounting bracket and 30 meters of cable mini-
mum. Additional lengths of cable shall be provided as required for a com-
plete and operable installation at no extra cost.
d. The Flow Meter sensor shall retain IP 68 rating at 10 meters depth indefi-
nitely. The metering tube shall be suitably lined to withstand abrasion of
the fluid and suitable for use in potable water.
e. The flow meter shall have a switching power supply of 24 VDC + 33% to -
25% w/Backup battery & charger taking power from 220vAC 1∅ 50/60 Hz.
Power consumption shall not exceed 11 VA. All printed circuit boards shall
be contained in a single easy plug-in, easy plug-out type module and be in-
terchangeable for any size without requiring testing. In addition to the in-
ternal EEPROM or RAM built-in with the flow transmitters, the magnetic
flow meters shall have a dedicated sensor memory which will contain all
the characteristics of the sensor (i.e., calibration factor, correction factor,
excitation frequency, etc.) as well as the user configured parameters on
site. It shall be an electrically programmable/erasable memory specifically
configured for each sensor. This memory shall facilitate automatic transfer
of pre-programmed data to the new electronics in an event of transmitter
fault, without requiring renewed calibration or commissioning. A 2 x 16-
character alphanumeric display shall indicate user-defined flow units and
total flow. All menu advice and commands shall be viewed on this display.
f. Each magnetic flow meter system shall have accuracy within + 0.3 percent
of the flow rate over the application operating range when the velocity is
within 0.3 m/s to 10 m/s. Meters shall have a repeatability of 0.1 percent
of full scale.
g. Accuracy shall be maintained for an ambient temperature range of 0 de-
gree to 50 degrees C and liquid temperature of 60 degrees C. Accuracy
shall be verified by calibration in a flow laboratory approved by the Engi-
neer.
h. Outputs shall be isolated 4-20mA dc into 800 ohms plus frequency output
selectable from:
1) 25/50 ms, 24 Vdc pulse, o-10 Hz max. 150 ohm min., or

2) 50-50 duty cycle 15V peak to peak, 0-1000 Hz max. or
3) Either (a) or (b) above with open collector.
4) Two flow alarms
5) RS232 Communication
6) Positive Zero Return for external relay contacts.
i. The flow meter shall be inherently bi-directional, and should total forward
and reverse flow separately.
j. Inter-connection between meters and signal converters shall be by cable
furnished by the manufacturer at no extra cost.
k. Magnetic flow meter shall incorporate a detector to constantly monitor
whether the pipe is full and all electronics, electrodes, sensors and cable
connections are operating correctly. Any fault shall be indicated immedi-
ately via a relay to any remote device, such as alarm, or signal or to the
motor actuator of a valve or pump to open or close as directed by the En-
gineer.
l. The flow meter shall incorporate a feature allowing a menu selection and
program changes to be made from outside the housing via hall-effect sen-
sors. It shall not be necessary to remove covers, panels or fasteners to ac-
complish calibration or program changes. The meter software shall incor-
porate a password, preventing inadvertent program changes. A hand-held
programmer is not acceptable.

m. Field selectable and adjustable circuitry is to be provided as follows:
1) Low flow cut-off, field adjustable from 0-9% of the full scale.
2) Current damping to modulate peaks and troughs for the 4-20mA
output signal in the event the output signals are spasmodically re-
ceived.
3) Noise suppression to cut-off the inaccuracy in magnetic field and
current due to noise created by the liquid flow.
4) Display damping to steady the reading of the flow rate and total.
5) Totalized flow and programmed configuration shall be maintained
in memory for up to 10 years.
2. Construction
a. The magnetic flow meters shall be of short-form type. Meters shall be de-
signed with end connections of NP 16 flanges. Field coils shall be either
completely encapsulated in the meter lining material or the meter tube
shall be 304 stainless steel with a suitable liner.
b. A suitable protective shield shall be provided at each end of the liner to

withstand the scouring velocities of the process fluid at the maximum flow
rates. The flow meter shall be robust & fully welded type to prevent entry
of moisture to the coils.
c. Sensor of shell-type enclosure with gaskets in between the shells is not ac-
ceptable.
3. Grounding
a. The flow meter shall be equipped with built-in grounding electrodes of the
same materials as the sensing electrode. In addition, each magnetic flow
meter shall be provided with two (2) numbers full-bore stainless steel
grounding rings installed at both ends of the sensor thus providing a
grounding circuit for each magnetic meter.
4. Manufacturer
a. Flow meter shall be manufactured by a company who has had several

years of Experience in the manufacture of flow meters of the DC pulse
type suitable for potable water and shall have a fully equipped technical,
marketing.
b. The manufacturer of the flow meters shall confirm the particular applica-
tion of the flow meters for the intended use and shall provide a warranty
of minimum 5 years based on a replacement basis including labor and ma-
terial at no extra cost.
5. Rating:
a. Working pressure is 16 bars

b. Test pressure equals to 1.5 working pressure

2.15 VALVE CHAMBERS
1. Aggregate
a. Fine Aggregate
- The grading of fine aggregate shall be within the limits of Table (5) BS 882.
- Fine aggregate shall be of such uniformity that the fineness modulus as de-
fined 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 de-
sign.
- The sand equivalent for fine aggregate (AASHTO T176) shall be a minimum of
70.
- The water absorption of fine aggregates (ASTM C128) or (AASHTO T84) shall
not exceed 2 percent.
b. Coarse Aggregate
- 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 ag-
gregate 20 mm to 5 mm.
- 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 ex-
ceed 25 percent.
- The water absorption of coarse aggregate (ASTM C127) shall not exceed 2
percent.
2. Cement
- Ordinary Portland cement and rapid-hardening Portland cement shall comply

with the requirements of BS 12 or ASTM C150 Type II.
- Sulphate Resisting Portland Cement shall comply with the requirements of BS
4027 or ASTM C 150 type V.
- Super sulphated Cement shall comply with the requirements of BS 4248 or
ASTM C 150 type V.
- Shall conform to Division-7 Section 03300 "Cast-in-Place Concrete"
3. Water
- Water for concrete, mortar and curing shall comply with BS 3148.
- All water used in concrete & mortar shall be clear, fresh water free from oil,
acids, alkali, sugar, vegetable substances, or any other contaminating agent.
- If required by the Engineer, Contractor shall provide water quality test re-
sults.
- Non-potable water shall not be used in concrete unless written approval to
do so is granted by the Engineer.
4. Concrete Blocks
- Concrete blocks shall be hard, durable, sound, clean, well defined edges and
free from cracks, flaws or other defects. They shall comply with the require-
ments of ASTM C140.
- All mortar shall consist of one part masonry cement to three parts loose sand
complying with the following requirements.
- Sand complying with ASTM C144, grading and coloring suitable for type of
masonry and as approved by the Engineer.
- Sulphate Resisting Portland Cement shall comply with the requirements of BS
4027 or ASTM C150 type V.
- Water Complying with water for Concrete Mixes and curing, of the Specifica-
tions Section 03300 "Cast-in-Place Concrete"
5. Reinforcing
- Reinforcing Bars. Plain and deformed bars shall conform to BS 4449.

- Mesh reinforcement shall conform to the specifications of ASTM designation
A 185
- 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 Designated; the gauge shall be American steel and wire
gauge.
- All testing of reinforcing steel bars shall be carried out in accordance with BS
4449 and BS 4482.
6. Frame And covers
- Valve Chambers Covers and Frames: 600 x 600 mm opening ductile iron kite
marked to BS EN124 Class C250 with mesh type safety grid and two (2) slot
head stainless steel countersunk screws, (25) tone test load, warm applied
black bitumen coat to BS 3416 and special coats for protecting covers in sani-
tary manholes.
- The cover should be equipped with an integrated lifting and locking handle.
The handle should be fixed to the frame with an integrated hinge allowing
- The cover to be freely removed from the frame at suitable opening angle.
The cover should be also equipped with a safety mechanism to maintain the
cover safety locked when opened at suitable vertical angle.
Each cover should be badged with:
 The name and/or identification mark of the manufacturer

 The marking of the standard
 The appropriate class
 The badge of the project and usage subject to engineer’s approval
7. Valve Chamber Step Irons:
- Step ironing rising main valve chambers shall be galvanized malleable cast iron, shall
conform to BS 1247, and shall be of general purpose type.
- The tail length shall be 230 mm unless the well into which the tail is to be cast is
less than 290 mm thick.
- Step irons in house connection chambers shall be galvanized malleable cast iron and
epoxy coated in accordance with BS 1247, and shall be of general purpose type.
- The tail length shall be 230 mm unless the w all into which the tail is cast is less than
290 mm thick.
8. Valve Chamber ladders:
a. Steel ladders
Galvanized steel ladders shall be to the form and dimensions shown on the Draw-
ings, and as specified below:
 Ladders shall comply with BS 539 5, Part 3.

 Ladders greater than 6000 m shall be provided with an intermediate platform
 Stringers shall be solid flat sections of minimum size 65 mm by 13 mm
 Fixing brackets shall be at maximum 2500 mm centers
 rungs shall be
 solid sections of minimum 20 mm diameter

 at 250 mm centers
 minimum 400 mm wide between stringers
 minimum 200 mm from adjacent walls
 capable of withstanding a point load of 5000 N applied at the center of the rung
and close to one end
b. GRP Ladders:
a) GRP material for ladders shall be fabricated from structural quality fiberglass
shapes with chemical and ultraviolet resistance. Resin shall be all vinyl ester.
Glass shall be all ECR and GRP thickness shall be a minimum 5 mm. The top
surface shall be provided with a non-slip silica sand finish. The structural
components shall have Class I fire retardance, with an ASTM E84 flame
spread rating of 25 maximum. Fiberglass components shall have an ultimate
tensile strength of 20 7 MPa, an ultimate compressive strength of 207 MPa, a
modulus of elasticity of 20.7 GPa, and a Barcol hardness of 50.
b) All cut or trimmed edges of the GRP ladder and braces shall be flow coated
with an approved vinyl ester resin. Glass fibres shall not be exposed.
9. Protective Coating:
- Shall conform to the requirements of Division-7, “Corrosion Protection And Odor

Control ".
10. Erosion-Resistant Anchoring Cement:

- Factory-prepackaged, non-shrink, no staining, hydraulic controlled expansion
cement formulation for mixing with water at Project Site to create pourable an-
choring, patching and grouting compound.
- Provide formulation that is resistant to erosion from water exposure without

need for protection by a sealer or waterproof coating and is recommended for
exterior use by manufacturer.
11. Mortar for Setting Covers:
- Mortar shall consist of one (1) part of cement to two (2) parts of sand, by volume.
2.16 FIRE HYDRANT
1. Fire hydrants shall meet or exceed the latest revisions of ANSI/AWWA standard
C502 and shall be UL listed and FM approved.
2. Fire hydrants shall be rated for 250 psig operating pressure and 500 psig test
pressure.
3. Fire hydrants shall be 4.25” valve opening and shall be of the compression type,
opening against the pressure and closing with the pressure.
4. The operating nut shall be ductile iron and also serve as a weather shield. The op
nut shall be pinned to a bronze revolving nut that engages the stem. An anti-
friction washer shall be in place above the revolving nut thrust collar and below
the bronze hold down nut. The hold nut shall have an Allen head locking screw.
The hydrant bonnet shall have a directional arrow cast on it. Bonnet lubrication
shall be grease.
5. The bonnet shall be attached to the upper barrel using the bayonet connection
and then secured by stainless steel screw.
6. Fire hydrant nozzles shall thread counterclockwise into the upper barrel and uti-
lize the O-ring seals. A suitable nozzle lock shall be in place to prevent inadvert-
ent nozzle removal. The Nozzle shall be as specified as follows:
a. One pipe nozzle 115mm.

b. Two hose nozzle 63mm.
7. Hydrant shall be a “Traffic- Model” having upper and lower barriers joined at the
ground line by breakable flange providing 360o rotation of upper barrel for
proper nozzle facing the flange shall employ two stainless steel bolts and nuts for
easy repair.
8. The operating stem shall be 1.25” diameter steel (excluding threaded or ma-
chined areas) and be connected by a stainless steel safety coupling. Screw pins,
bolts, or fasteners used in conjunction with the stem couplings steel. The top of
the lower stem shall be recessed 2” below the safety flange to prevent water
hammer in the event of a “drive over”.
9. The lower barrel shall be an integrally cast unit. The use of threaded on or me-
chanically attached flanges is deemed unacceptable. The ground line shall be
cast on the lower barrel.
10. An O-ring bronze seat ring shall be threaded into a bronze drain ring and have
two drain holes allowed drainage of the hydrant. To control drainage the drain
valve shall be an integral part of the one-piece bronze upper valve plate. They
shall operate without the use of springs, toggles, levers or other intricate syn-
chronizing mechanisms.
11. The shoe inlet size and connection type shall be as specified (Flanged, MJ, etc…).
12. The interior of the shoe including the lower valve plate shall have a protective
coating that meets the requirements of AWWA C550.
13. Hydrants shall be warranted by the manufacturer against defects in materials or
workmanship for a period of ten (10) years from the date of manufacture. The
manufacturing facility for the hydrant must have current ISO certification.
14. Material:
a. Stand pipe upper Ductile Iron

b. Stand pipe upper Ductile Iron
c. Shoe including sub- seat and plastic drain Bronze
d. Role liner Ductile Iron
e. Nozzles Bronze
f. Nozzles cap Ductile Iron
g. Valve rod Steel
h. Valve top plate Steel
i. Seat ring Bronze
15. Rating:
a. Working pressure is 16 bars

b. Test pressure equals to 1.5 working pressure
16. Accessories: Each hydrant shall be equipped with, buried gate valve with surface
box and extension tube, and horizontal ductile iron pipe connected to the main
pipe. All the above mentioned accessories with all mechanical components
needed for installation as indicated on drawings shall not be measured or paid
for , but shall be considered as a subsidiary obligation of the respective items of
the Bill of Quantities
PART 3 EXECUTION
3.1 GENERAL
- All pipe work, fittings are to be installed in strict accordance with the manufacturer
instructions and in accordance with this specification. The excavation, pipe bed-
ding and back filling shall comply with Section 31 30 00 “Earthwork”
3.2 PIPES, FITTINGS AND ACCESSORIES
A. During Construction and Installation:
 Survey of the Pipeline Route
a. The Contractor shall undertake a survey of the routes of all the pipelines
prior to the commencement of construction work, and shall provide the
Engineer with at least two copies of the results of the survey which shall
be in the same format as the tender drawings, together with the Con-
tractor’s proposals for the pipeline gradient and invert level, location of
air valves, washouts, bends (including co-ordinates),..etc. The survey
shall also show the location, dimensions and level of underground exist-
ing services or obstructions in the pipeline route and shall conform to
the following:
1. The length of the route shall be accurately measured. The route

thus marked shall be agreed with Engineer prior to commence-
ment of level surveying.
2. Using a total station or GPS system (accuracy 50 mm), ground lev-
els shall be taken at route and at significant changes in ground
level and with spacing not less than 50ms.
3. Levels shall relate to an approved datum, and permanent bench
marks shall be established, well clear of the proposed pipeline, at
intervals along the pipeline route.
4. Prior to the survey, the Engineer shall supply the Contractor with a
data copy of the tender drawings. The results of the survey shall
be presented as a modified form of the long section drawings plot-
ted at 1:1000 horizontal and 1:100 vertical scale.
5. At all times the route surveying shall be at least one month ahead
of excavation and pipe laying to enable agreement to be reached
between the Engineer and the Contractor on the lines, levels and
gradients.
6. The Contractor shall be responsible for locating all services cross-
ing or closely paralleling to the route of the trench by consultation
with the concerned authorities. The excavation shall done by hand
with trail holes in advance to main excavation.
7. The Contractor shall survey ahead of the pipe laying and copies of
the results shall be submitted to the Engineer without delay.
 Soil investigation
1. Soil testing
 The Contractor is required to dig trial pits and carry out in-situ and
laboratory soil tests at intervals along the route of the pipelines lo-
cated as directed by the Engineer but not exceeding 500m. The tests
shall be carried out at a sufficient distance ahead of pipe laying that
construction is not held up...
 The Contractor shall carry out laboratory soil tests on selected mate-
rial removed from each trial pit to determine its suitability for trench
back-fill. The tests shall include particle size distribution, Waterberg
limits and dry density moisture content relationship.
 Where the Engineer considers excavated material to be unsuitable
for use as trench backfill, the Contractor shall carry out soil tests on
the material he proposes to import to determine its suitability. If the
Contractor proposes a change in back-fill or fill material, all tests
shall be repeated for the new material.
 The Contractor shall also prepare a survey of the soil resistivity along
each pipeline route at intervals not exceeding 500m and determined
at the depth of the underside of the pipe and at the depth of the top

of the pipe. Soil resistivity values shall be determined by as de-
scribed in 402 of British CP 1013. Results shall be presented in tabu-
lar form in accordance with ANSI A 21.5 (AWW A C 105).
 Soil samples shall be taken from trial pits at a minimum of 1 Kilome-
tre spacing along the route of the pipeline as directed by the Engi-
neer. Soil samples shall be tested for PH -value, redox potential,
moisture content, chloride content and sulphide content, and the
results presented in tabular form in accordance .with ANSI A 21.5
(AWWA C105).
2. Resistivity survey
 Whilst undertaking the conventional survey of the pipeline route the

Contractor shall undertake a resistivity survey in accordance with
the requirements of BS 1377 Part 9.
 Resistivity measurements shall be carried out at not more than 500
m spacing along the pipeline route and at all wadi crossings. The re-
sults of the resisitvity survey shall be presented in a tabular report
format to be approved by the engineer. As a minimum, the report
should list the following information for each measurement.
 Date and time

 WGS 84 grid reference
 Brief description of location
 Resisitivity values at depths of 1.5,2 and 3 m
 The resistivity survey report for each section of pipeline shall be pre-
sented to the engineer at the same time as the conventional survey
drawings.
3. Interaction testing
 The Contractor shall carry out interaction testing in accordance with

BS 7;61 Part 1:1991 at all locations where the pipelines cross exist-
ing cathodically protected pipelines.
 The results of the testing shall be submitted to the Engineer togeth-
er with proposals for remedial measures where the positive poten-
tial change exceeds 20mV.
 Testing shall be carried out by qualified persons approved by the En-
gineer.
B. Excavation
- The requirements of “Earthwork” Section shall be applied, except as otherwise spec-

ified in this Clause.

C. Line And Grade
- 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 bench-
marks, base line and pints of reference are disturbed, lost or destroyed. The Con-
tractor shall be charged the cost necessary to replace and relocate all bench
marks, base line and points of reference so disturbed, lost or destroyed.
- 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, equip-
ment, labor, stakes, templates, batter boards, material and supplies necessary
for the laying out of the work and maintenance thereof.
- 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 En-
gineer.
- 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.
D. Pipe Distribution
- 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.
E. Pipe Preparation And Handling
- 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 thor-
oughly. Remove foreign matter and dirt from inside of pipe and keep clean dur-
ing and after laying.
- 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.
- 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 physical
damage to it. Remove all damaged pipe from the Site. Do not drop or dump pipe
into trench under any circumstances.
F. Underground Warning Tape
- Warning tapes shall be laid above all utility pipes. Tapes shall be durable and de-
tectable 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.
- Warning tapes shall be placed in compacted backfill material, approximately 300

mm below finish grade and as indicated on drawings.
- The tapes shall be flexible and subject to the Engineer’s approval. Width of the
tape shall be at least 6” (150 mm).
- Tapes shall have different colors for different utilities and with black text in Ara-
bic 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 max-
imum interval of two (2) meters.
- 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.
- Warning tape shall not be separately measured or paid for, but shall be consid-
ered as a subsidiary obligation under the respective items included in the Bill of
Quantities.
G. 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 material or creep of the
gasketed joints.
- If groundwater exists, take all precaution necessary to prevent the “uplift” or
floating of the line prior to the completion of the backfilling operation.
- 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.
- When pipe is laid within a movable trench shield, take necessary precautions to
prevent pipe joints from pulling apart when moving the shield ahead.
- Temporary Plugs: Watertight plug and timber bulkhead or gasketed steel plug.
- Temporary plugs shall be removable without damage to pipe stubouts and shall
be capable of withstanding internal pressure, external loads and external pres-
sures without leakage.
- Where pipelines are to be laid in ducts, the Contractor shall propose for the En-
gineer'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.
- The Contractor's installation system shall ensure that no damage occurs to the
pipe, linings or coatings to the pipe, or to the duct.
- 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 Engi-
neer's Representative.
A. INSPECTION
- Pre-Construction: Inspections and tests begin before construction. Jobsite condi-

tions dictate how piping may be installed and what equipment is appropriate 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 ma-
terials in accordance with project specifications.
- The installer should carefully review contract specifications and plans. Different
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 lia-
bilities. Good documents also set minimum installation quality requirements,
and the testing and inspection requirements that apply during the job.
Cleaning Before Joining
- All field connection methods and procedures require component ends to be

clean, dry, and free of detrimental surface defects before the connection is
made. Contamination and unsuitable surface conditions usually produce an un-
satisfactory connection. Casketed joints may require appropriate lubrication.
Cleaning component ends before joining may require removing surface deposits
to planning (facing), abrading or scraping the pipe surface. Surface dust and light
soil may be removed by wiping the surfaces with clean, dry, lint free cloths.
- Heavier soil may be washed or scrubbed off with soap and water solutions, fol-
lowed by thorough rinsing with clear water, and drying with dry, clean, lint-free
cloths.
- Before using chemical cleaning solvents, the user should know the potential risks
and hazards and appropriate safety precautions should be taken. Hazard infor-
mation is available from chemical manufacturer’s instructions for the chemical.
- Surface damage that could detrimentally affect sealing or pipe performance
generally requires removing the damaged section.
Joining and Connections
- For satisfactory material and product performance, system designs and installa-
tion 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 conditions.
- Joining and connection methods will vary depending upon requirements for in-
ternal or external pressure, leak tightness, restraint against longitudinal move-
ment (thrust load capacity), application and operation conditions, construction
and installation requirements, and the products being joined.
- Before using a joining or connection method, the limitations of the joining or
connection method must be taken into account. Where a joining or connection
method is suitable, the manufacturer’s joining procedures, tools and compo-
nents required to construct and install joints in accordance with manufacturer’s
recommendations should always be used.
- The Spigot and socket to be joined shall be carefully examined for any damage
which would impair the jointing procedure. Particular attention shall be paid to
the spigot chamfer and to the sealing ring. The pipes shall be chamfered to a
depth of half the wall thickness and at an inclination angle of 150 to the pipe ax-
is.
- If pipes are cut on site they shall be cut square to the pipe axis with a fine
toothed saw and chamfered to half the pipe wall thickness with a coarse file or
surform tool.
- The chamfered spigot shall clean and free from swarf and burrs. The sealing ring
shall be correctly seated in the insert ring. The sealing portion of the ring must
be free from damage of any sort. Joints containing damaged or incorrectly fitted
rings must not be used.
- The spigot insertion depths shall be measured as the depth from the mouth to
the shoulder of the socket. Pipes shall be supplied with the spigot insertion
depth marked on the spigot end. The spigots of cut pipes shall be marked simi-
larly using an indelible crayon. If an allowance for expansion is required (e.g.
where changes in operating temperatures are anticipated), this shall be deduct-
ed from the spigot insertion depth.
- The spigot and socket shall be thoroughly cleaned. All grease, dirt, swarf and
other foreign matter shall be removed from the sealing areas. The spigot end
and triple seal portion of the sealing ring shall be roughly lubricated with the lub-
ricant. The spigot shall be lubricated to the full insertion depth and around its
complete circumference, paying particular attention to the chamfer area. The
triple seal shall be lubricated around its complete circumference. The guiding
principle shall be applied for a liberal quality of lubricant to avoid 'dry' areas on
the sealing surfaces.
- Immediately after lubrication, the spigot shall be brought into contact with the
socket. The spigot pipe and parent joint shall be accurately aligned so that the
axes of the pipes are precisely in line. The spigot shall be hand fed into the sock-
et until resistance from the inner sealing section is felt. Correct alignment at this
stage is essential to ensure that the rubber sealing ring is not pinched or torn.
- The joint can now be completed by one of the methods described below:
a. Leverage Method
- Sizes up to DN 200 mm, can normally be joined by applying leverage with a crow
bar at the following socket end. A stout timber shall be inserted between the
crow bar and the pipe socket to prevent damage to the latter. The leverage shall
be applied in a steady, continuous manner until the spigot insertion depth mark
coincides with the mouth of the socket being jointed. If any undue resistance is
felt and the spigot cannot be levered, the joint shall be disassembled and exam-
ined to determine possible cause (e.g. lack of lubrication and prinched or
trapped sealing ring). The procedure shall then be repeated as described previ-
ously.
b. Joint Clamps
For sizes above DN 200mm specially designed joined clamps shall be used with
UPVC Pressure Pipes. These are particularly useful where bends are to be installed
in the pipeline.
The clamps shall be positioned so that one clamp is adjacent to the socket shoulder
and the other close to, but not overlapping the depth insertion mark.

Once assembled with the steel tie wires in place, a simple ratchet action will draw
the spigot into the socket mouth.
The spigot shall be correctly aligned as described above and drawn into the socket
until the spigot insertion depth mark coincides with the mouth of the socket being
jointed. No further pulling shall take place.
The clamps incorporate protective pads to prevent gouging and scratching of the
pipe surface. The clamps must not be used without the protective pads.
B. ANCHORAGE
- Anchorage lugs shall be provided for socket and spigot fittings and socket clamps
and tie rods used where there is a possibility of pulling the joint under pressure.
Concrete thrust blocks shall be used in lieu of the above where socket and spigot
pipe is used below ground. The Contractor shall submit, for the Engineer’s ap-
proval, working drawings and information demonstrating the adequacy of anchor-
age systems other than thrust blocks or other systems shown on the Contract
Drawings.
C. DURING CONSTRUCTION AND INSTALLATION:
- Tests and inspections performed during construction may include damage In-
spections, butt fusion joint quality tests, soil tests, pipe deflection tests for ID
controlled products such as extruded profile wall pipe, or pressure leak tests.
2. Damage Inspections
- Damage such as cuts, scrapes, gouges, tears, cracks, punctures, and the like may
occur during handling and installation. Damage may affect joint integrity or seal-
ing, or may compromise pipeline performance. The following guidelines may be
used to assess surface damage significance.
- For UPVC pipelines, damage should not exceed about 10% of the minimum wall
thickness required for the pipeline’s operating pressure or the minimum wall
thickness required to meet structural design requirements. Excessive damage
generally requires removing the damaged section or reinforcement with a full
encirclement repair clamp..
- 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.
- Damage such as punctures and tears will generally require cutting the pipe to
remove the damaged section and replacement with undamaged pipe. Small
punctures may occasionally be repaired with patching saddles that are saddle
fused or electrofused over the puncture.
3. Soil Tests
- During buried pipe installation, work should be checked throughout the construction
period by an inspector who is thoroughly familiar with the jobsite, contract specifi-
cations, materials, and installation procedures. Inspections should reasonably en-
sure that signify cant factors such as trench depth, grade, pipe foundation (if re-
quired), quality and compaction of embedment backfill, and safety are in compli-
ance with contract specifications and other requirements. To evaluate soil stabil-
ity, density and compaction, appropriate ASTM tests may be required in the con-
tract specifications.
4. Deflection Tests for ID controlled Pipes
- Deflection tests are typically based on an allowable percent vertical deflection of

the pipe inside diameter.
- Improperly embedded pipe can develop significant deflection in a short time,

thus alerting the installer and the inspector to investigate the problem.
- Inspection should be performed as the job progresses, so errors in the installa-

tion procedure can be identified and corrected.
- Initial deflection checks of ID controlled extruded profile pipe may be performed

after embedment materials have been placed and compacted. The inside diame-
ter of the pipe is measured after backfill materials have been placed to the pipe
crown, and compacted. Then final backfill materials are placed and compacted,
and the pipe inside diameter is measured again at the exact location where the
prior measurement was taken.
- 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 allow-
able deflection, the mandrel is blocked.
- To properly size the mandrel, the allowable vertical diameter of the pipe must be
established. It is necessary to account for pipe ID manufacturing tolerances and
any ovality that may occur during shipping. Pipe base ID dimensions and toler-
ances should be obtained from the manufacturer.
3.3 VALVES INSTALLATION
A. General
1. Valves shall be suitable for continuous operation as well as for intermittent op-
eration. All ferrous parts of the valves shall be coated, except for the finished or
bearing surfaces. The type of the internal and external coating shall be as speci-
fied on the respective data sheets for each type of valve.
2. Valves, strainers and other devices mounted in underground pipelines shall be
installed in reinforced concrete chambers complete with all accessories and pro-
tection systems as per the project specifications and drawings.
3. Valves, strainers 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.
4. The valves shall be supplied complete with all the required joint accessories, ap-
proved gaskets, bolts, nuts and washers etc. for both flanges of each valve. All
valves shall have the name of the manufacturer, working pressure, diameter and
cast number on the body.
5. 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 ac-
ceptable comparison statement. The CONTRACTOR shall attach to his offer the
English text of Standards as applicable.
6. The valves must be accompanied with a certificate guaranteeing their water
tightness and satisfactory operation for a period of not less than 10 years.
7. Contractors shall provide Material Certificates issued by the Manufacturers in
accordance with the requirements of EN 10204 and any other requirements is-
sued by the Client.
8. Contractor shall ensure that all material in contact with potable water shall not
adversely affect the potable water quality requirement of Regulation & Supervi-
sion Bureau Regulation which refers to WHO.
9. Butterfly valves of 1000 mm diameter and larger shall be of double eccentric ex-
ecution according to ISO 5752 series 14 and the flanges shall be in accordance
with the relevant ISO/BS/DIN standards.
b. EXAMINATION
1. Inspection and Testing at Manufacturer's Premises
- CLIENT/ENGINEER and/or third party Inspection Authority reserve the right for
stage inspection of material, manufacturing process, testing, etc. by their author-
ized representatives. Such inspection shall not relieve the CONTRACTOR of the
responsibility for suitable design and workmanship.
- 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 applica-
ble material specification.
- The material certificate indicating above details shall be inspected and certified
by CLIENT/ENGINEER's inspectors prior to starting shop tests of the valve.
- The Manufacturer/CONTRACTOR shall provide full assistance and co-operation

for any such inspection, when required by CLIENT/ENGINEER.
- CLIENT/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.
- The program for the tests shall be prepared by the CONTRACTOR and shall be
subject to CLIENT/ENGINEER approval.
- The below mentioned certificate requirements shall apply to the quality Control
Plan.
 Certificate of compliance for Valve body, disk/wedge, and shaft shall be issued
for the following criteria in accordance to EN 10204 - Type 2.2 - For mass pro-
duced valves and Type 3.1 for Butterfly, Control Valves and other valves which
are not mass produced.
 Heat treatment after coating (if required)
 Chemical analysis
 Physical properties
 Certification of compliance for the following tests shall be issued by the manu-
facturer according to EN 10204 – Type 3.1
 Functional tests
 Strength test for the body
 Leak test for the disk /seat
 Rubber lining checks after vulcanization
 Coating thickness checks (internally & externally)
 Dimensional checks
The above certificates shall be reviewed and certified by the respective inspection
authority.
The Rubber lining checks after vulcanization shall include the following:
 Visual inspection
 Adhesion test
 Dielectric test
 Shore D hardness test
 Thickness test by electronic device
 Non Toxicity Certificate for material in contact with potable water
- The CONTRACTOR/MANUFACTURER shall make suitable provisions for testing and
inform CLIENT/ENGINEER sufficiently (at least one month) in advance to enable
their representatives to witness the test. If witnessing of any tests is not satisfacto-
ry and a retest is required, the cost of the witnessed retests shall be borne by the
CONTRACTOR.
- MANUFACTURER shall ensure that all the applicable codes and standards are
available at their works for CLIENT/ENGINEER's reference during their visit to
manufacturer's works for shop inspection/tests.
- Testing shall be carried out in accordance with applicable codes and standards for
the particular valves. Besides mechanical operation tests, each valve shall be sub-
jected 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 be-
fore leaving the manufacturer's works. Tests shall be witnessed by
CLIENT/ENGINEER as specified and each valve shall be accompanied by manufac-
turer's test certificates.
- 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 CLIENT/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 CLIENT/ENGINEER.
- If any defect is detected during the tests before completion or during the warranty
period, the faulty equipment shall then be rectified immediately by the
VENDOR/CONTRACTOR at his expense. If the fault cannot be rectified, the
VENDOR/CONTRACTOR must then replace the defective equipment which must al-
so be proven to be free from defect.
2. Manufacturing Data Record Books
- The test certificates, material certificates and mill certificates shall be entered into
the manufacturing data record books, as an ongoing procedure and must not be
left until the end of the manufacturing program.
- The manufacturing data record books including the witnessed tests documents
shall be submitted to CLIENT/ENGINEER prior to the dispatch of the materials.
3. INSTALLATION
- Locate valves for easy access and provide separate support where necessary.
Install valves in horizontal piping with stem at or above the center of the pipe.
- Install valves in a position to allow full stem movement.
- Install swing check valves for proper direction of flow with hinge pin level.
- Locate flow meter as recommended by manufacturer with respect to other piping
components to ensure flow meter will meet specified accuracy.
- Flanged Connections: Align flange surfaces parallel. Assemble joints by sequenc-
ing 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.
- All exposed bolts nuts shall be heavily coated with 2 coats of bituminous paint.
- All valves shall be equipped with dismantling joint to enable removal and installa-
tion of flanged valves as shown on Drawings. Dismantling joint shall be DI and suit-
able for valves pressure rating.
- Install buried gate valve complete with valve box and install valves inside valve
chambers complete with hand wheels.
- 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 polyethylene material damaged during
construction.
4. Cleaning of valves:
- Clean mill scale, grease and protective coatings from exterior of valves and prepare
valves to receive finish painting or insulation.
- Install valve chambers in places indicated on drawings as per Standard specifications.
All buried valves shall be provided with a surface service box for operation.
5. Testing valves:
- After piping systems have been tested and put into service, but before final adjust-
ing and balancing, inspect valves for leaks. Adjust or replace packing to stop leaks;
replace valve if leak persists.
3.2 VALVE CHAMBER
Valve chamber shall be cast-in-situ Reinforced concrete valve chamber of dimen-

sions and depths as indicated on Drawings.
The requirements of Section 03300 "Cast-in-Place Concrete"
Section shall be applied, except as otherwise specified in this Clause.
All dirt, chips, sawdust, nails, and other foreign materials shall be completely re-
moved from forms before any concrete deposited therein. Forms previously used
shall be thoroughly cleaned of all dirt, mortar and foreign material before being re-
used. Before concrete is placed in forms, all inside surfaces of the forms shall be
thoroughly coated with commercial quality form oil or other equivalent coating
which will permit the ready release of the forms and will not discolor the concrete.
Forms may be removed at the convenience of the Contractor and with the prior ap-
proval of the Engineer after the concrete has hardened. The concrete surfaces ex-
posed by removing forms shall be protected from damage.
All concrete shall be used while fresh and before it has taken an initial set. Re-
tampering of partially hardened concrete with additional water will not be permit-
ted. A surface on which concrete is to be placed shall be thoroughly moistened with
water immediately before placing concrete.
Mixed concrete, after being deposited, shall be consolidated until all voids are filled
and free mortar just appears on the surface. The concrete shall be placed as nearly
as possible in its final position and the use of vibrators for shifting of the mass of
fresh concrete will not be permitted. Fresh concrete shall not be permitted to fall
from a height greater than 2 meters without the use of adjustable length pipes of
"elephant trunks", double belting may be used in lieu of adjustable pipes or "ele-
phant trunks".
All concrete shall be compacted by means of high frequency internal vibrators with-
in 15 minutes after it is deposited in the forms. The vibrators shall not be attached
to or held against the forms or the reinforcing steel. The location, manner and dura-
tion of the application of the vibrators shall be such as to secure maximum consoli-
dation of the concrete without causing segregation of the mortar and coarse aggre-
gate, and without causing water to flush to the surface. Fresh concrete shall be
spread in horizontal layers in so far as practicable and the thickness of the layers
shall not be greater than can be satisfactorily consolidated with the vibrators. If ad-
ditional concrete is to be placed, care shall be taken to remove all laitance and to
roughen the surfaces of the concrete to ensure that fresh concrete is deposited up-
on sound concrete surfaces. Layers of concrete shall not be tapered off in wedge-
shaped slopes, but shall be placed with square ends and level tops.
Joints in the concrete due to stopping work shall be avoided as far as possible. Such
joints, when necessary, shall be constructed as directed by the Engineer.
Construction joints shall be made only where located on the plans, shown in the

placing schedule and/or as approved by the Engineer.
Construction joints shall be made without keys, except when keys are shown on the
plans.
All newly placed concrete shall be cured in accordance with the following provi-
sions. The concrete shall be kept continuously wet by the application of water for a
minimum period of 7 days after the concrete has been placed. Cotton mats, rugs,
carpets or sand blankets may be used as a curing medium to retain the moisture but
not prevent evaporation.
The moisture from the nozzle shall not be applied under pressure directly upon the
concrete and shall not be allowed to accumulate on the concrete in a quantity suffi-
cient to cause a flow or ash the surface.
Finish exposed walls to produce a uniform flat surface.
After concrete has attained the required characteristic strength and all surfaces
have been finished and accepted by the Engineer, apply protective coating as per
the requirements of section “Division 7 " Corrosion Protection And Odor Control"
Chambers shall be watertight with external tanking.
Unless otherwise indicated, top surfaces of walls supporting cover slabs shall be to
true line and level and painted with two coats of approved bituminous paint as a
bond breaker.
Lifting holes or eyes in precast components are to be provided as shown on the

Drawings or as directed by the Engineer.
All valve chambers shall be backfilled to crown of pipe level or as directed by the
Engineer with concrete grade SRC 20 against undisturbed ground to resist thrust.
Use epoxy compound as interface between concrete and piping materials.
All valve chambers shall be tested for leakage prior to backfilling.
Backfill around all piping and valve chamber will be in accordance with the applica-
ble requirements of Section 02310 "Earthwork".
Where pipes pass through a concrete wall or structure they shall unless otherwise
shown on the Drawings project from the external face of the structure by 300 mm
for pipes with nominal bore of 500mm or less and by 600mm for pipes with nominal
bores in excess of 600mm and the surface of such pipes shall be prepared to the
approval of the Engineer to ensure a satisfactory bond between pipes and concrete
forming the wall. A puddle or thrust flange shall be incorporated on each pipe pass-
ing through a wall as shown on the drawings.
Any excavation beneath the formation line of a pipe trench adjacent to a structure
shall be backfilled to the formation line of the pipe trench with concrete grade SRC
20. The concrete shall extend at least 500mm beyond the extremities of the pipe on
each side.

Unless otherwise indicated in the drawings a flexible coupling or restrained joint will
be installed to each wall piece outlet spigot (puddle flange), in addition a short
length of either spigot and socket or double spigot to suit the flow direction will be
installed. The length of this pipe shall be one and half times the nominal bore or 600
mm whichever is the greater or as shown on the Drawings.
TANKING
Apply protective coating as per the requirements of Division 7 "Corrosion Protection

And Odor Control" except as otherwise specified in this Clause.
All underground external concrete surfaces shall be tanked, with the tanking ex-
tending 150 mm above finished ground level.
Tanking of all external faces of concrete shall be carried out by wrapping with a pre-
formed strong impervious self-adhesive laminated bitumen/ polythene membrane
which shall be capable of withstanding cracking of the substrate up to a crack width
of 0.6 millimeters and shall be subject to the approval of the Engineer's
All surfaces shall be dry and dust free and surfaces painted with a coat of primer as
recommended and supplied by the same manufacturer as the membrane. The
membrane shall have a 75 mm minimum overlap at the joints. The concrete blind-
ing shall be extended outside the wall line by at least 100 mm to enable overlapping
and fixing of the membrane.
The tanking membrane shall be applied in two layers and laps shall be staggered
from one layer to the next.
Horizontal tanking applied over the concrete blinding shall as soon as practicable af-
ter laying be protected from damage by the application overall of a 50mm screed of
Concrete Grade SRC 20.
Tanking to all other surfaces up to finished ground level shall be protected with a
12mm minimum thickness of bitumen bonded cork board which shall be subject to
the approval of the Engineer's Representative. The protective board shall be placed
against the tanking and held in position by temporary struts or other means while
the backfilling is being placed care being taken to prevent loose stones damaging
the membrane or the protective board. Tanking above finished ground level shall be
protected by an aluminum flashing as indicated on the drawings.
All application details for the tanking membrane shall be in accordance with the
membrane manufacturer's details.
The Engineer's Representative may at his discretion approve alternative methods

and materials for tanking purposes.
Exposed tanking shall be protected by flashing fabricated from aluminum alloy at

least 1.6 mm thick to BS 1470.

3.3 VALVE CHAMBER STEP IRONS & LADDERS
General
The wall that supports access rungs or ladder shall be 90 degrees vertical from the
floor of structure to manhole cover.
Install steps and ladders per the manufacturer’s recommendations. Steps and lad-
ders shall not move or flex when used. All loose steps and ladders shall be replaced
by the Contractor.
Step Iron
Steps shall be thoroughly cleaned and given a protective coal tar epoxy coating. The
cleaning shall be done by suitable means to ensure that the surfaces to be coated
are free from foreign matters. After the steps have been cleaned, rinsed and dried,
apply the coating and allow drying before installing in concrete.
Installation of step irons shall not begin until concrete receiving them has attained
its sufficient strength. Embedment into walls shall be as recommended by the man-
ufacturer; non-shrink cement formulation shall be used for pointing.
Steps shall be located to provide a continuous vertical ladder from the valve cham-
ber rim to the top surface of the bottom slab at intervals of 300 mm, plus or minus
40 mm and shall be installed in a manner to be capable of withstanding a force of
160 kg applied on the step at any place and in any direction with no permanent de-
formation.
Steel Ladders
When supported horizontally over a span of 1.0 m with the climbing face uppermost
and with a load of 1000 N applied at the center of the span, the ladder shall not de-
flect more than 15 mm at the point of application of the load and shall show no
permanent deflection after removal of the load. Each ladder fixing shall be capable
of withstanding shear and pull - out loads of 5000 N
Safety cages shall be provided where indicated and where the distance between
landings exceeds 3500 mm. These shall be constructed of three vertical flat sec-
tions, minimum size 50 mm by 8 mm supported by flat hoops with a diameter of
750 mm. The hoops shall be at a maximum of 900 mm centers and the first hoop
shall be 2400 mm above lowest platform level. No single hoop shall be used
All welds shall be ground flush and smoothed and ladders hot - dip galvanized after
fabrication. Connections to concrete or masonry walls shall be secure with accu-
rately positioned stainless steel anchor bolts. Ladders shall be mounted to produce
a finished appearance that is plumb, straight and true to dimensions.
c. GRP ladders
1) GRP ladders shall be of an approved pattern and purpose made to suit the depth
of each location and shall be installed as shown on the Drawings. They shall be
white (or near white) in colour and shall be formed from a laminate of ‘ECR’ type
chopped strand mat and vinylester resin throughout, having a mould face one side
and a finish of a tissue and final resin flow coat on the other, (after the hardwood
inserts). For full support hardwood stiffeners shall be provided inside both the
rungs and the side rails as a former, and shall be fully covered with GRP laminate.
2) The wall thickness of the laminate shall be not less than 5 mm at any point and
there shall be no sharp edges. The support fixing brackets shall be GRP continuous-
ly moulded with the main lamination and they shall be not more than 500 mm apart
(every 2 steps/rungs). The rungs shall be 250 mm apart with the upper face finished
with a non -slip surface.
3) The support fixing brackets shall be put through the liner wall, and be designed
to be totally encapsulated by concrete. The ladder brackets shall be laminated to
the outside of the liner.
4) Each rung shall be able to withstand a point load of 5000 N.
5) When supported horizontally over a span of 1.0 m with the climbing face up-
permost and with a load of 1000 N applied at the centre of the span the ladder shall
not deflect more than 15 mm at the point of application of the load and shall show
no permanent deflection after removal of the load. Each ladder fixing shall be ca-
pable of withstanding shear and pull -out loads of 5000 N.
3.4 VALVE CHAMBER FRAMES AND COVERS
Install frames and covers on top of valve chambers to positively prevent all infiltration
of surface or ground water into valve chambers. 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. Employ bricks conforming to this
specification built with cement sand mortar, to adjust cover level as required.
3.5 TESTS
Unless otherwise approved by the Engineer, water-retaining structures on the pipe-

lines, which are not tested, with the pipelines shall be separately tested in the pres-
ence of the Engineer for water tightness.
The structures shall be filled with water to ground level, the underside of the cover
slab, or to give a head over the pipeline of 2 m whichever is the less. After a period to
the approval of the Engineer to allow for absorption of water by the structure, there
shall be no discernible loss of water over a period of 30 minutes as measured by a ver-
nier gauge or other approved device
3.6 FIRE HYDRANTS
A Set center of each hydrant not less than 600 mm no more than 1800 mm back of edge
of road or face of curb. Fire apparatus connection shall face road with center of nozzle
450 mm above finished grade. Set barrel flange not more than 50 mm above finished
grade.
B Set each hydrant on a slab of stone or concrete not less than 100 mm thick and 375
mm square. The service line to the hydrant, between the tee and the shoe of the hy-
drant, shall be fully restrained.
C Set bases in not less than 0.4 cubic meter of crushed rock or gravel placed entirely be-
low hydrant drainage device.
D Clean interiors of hydrants of all foreign matter before installation.
3.7 CLEANING AND DISINFECTION
Disinfecting Water Mains
Applicable procedures for disinfecting new and repaired potable water mains are pre-
sented in standards such as ANSI/AWWA C651 that uses liquid chlorine, sodium hypo-
chlorite, or calcium hypochlorite to chemically disinfect the main.
Disinfecting solutions containing chlorine should not exceed 12% active chlorine, be-
cause greater concentration can chemically attack and degrade plastic pipe.
Cleaning
Pipelines operating at low flow rates (around 2 ft/sec or less) may allow solids to settle
in the pipe invert. Plastic pipe has a smooth, non-wetting surface that resists the ad-
herence of sedimentation deposits. If the pipeline is occasionally subject to higher flow
rates, much of the sedimentation will be flushed from the system during these peak
flows. If cleaning is required, sedimentation deposits can usually be flushed from the
system with high pressure water.
Water-jet cleaning is available from commercial services. It usually employs high pres-
sure water sprays from a nozzle that is drawn through the pipe system with a cable.
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 Plastic pipe. Scraping finger type or bucket type pigs may severely
damage a Plastic pipe and must not be used.
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.
The main flow is into the tee branch and out through a run outlet. The opposite tee run
outlet is used to launch the pig. The pig is fitted into the opposite tee run; then the run
behind the pig is pressurized to move the pig into the pipeline and downstream. In the
removable pipe spool, the pig is loaded into the spool, the spool is installed into the
pipeline, and then the pig is forced downstream. (Note – Fully pressure rated wyes
suitable for pig launching are generally not available.)
A pig may discharge from the pipeline with considerable velocity and force. The pig
catcher is a basket or other device at the end of the line to safely receive or catch the
pig when it discharges from the pipeline.
Testing
The intent of leak testing is to find unacceptable joint leakage in pressure or no pres-
sure piping systems. If leaks exist, they may manifest themselves by leakage or rupture.
Leak tests of pressure systems generally involve filling the system or a section of the
system with a liquid or gaseous fluid and applying internal pressure to determine re-
sistance to leakage. Leak tests of non-pressure systems typically involve testing sec-
tions of the system or individual joints using end plugs or bulkheads to determine re-
sistance to leakage.
Conduct tests before backfilling over pipes to allow for inspection and conduct initial
service leak test
Where any section of pipe is provided with concrete reaction blocking (thrust block),
do not make the pressure test until at least seven (7) days have elapsed after the con-
crete thrust blocking is casted.
Test Pressure: The test pressure shall be 1.5 working pressure.
Duration: The duration of each pressure test shall be sixty (60) minutes minimum, un-
less otherwise directed by the Engineer.
Safety is of paramount importance when conducting pressurized internal fluid leak

tests. Although routinely performed, leak tests may be the very first time a newly in-
stalled system or repair will be subjected to stress.
Even at relatively low internal pressures, leak testing with a pressurized internal fluid
can generate very high forces that can be dangerous or even fatal if suddenly released
by the failure of a joint or a system component or a testing component.
 Always take safety precautions when conducting pressurized fluid leak tests.
 Restrain pipe, components and test equipment against movement in the event
of failure.
 Joints may be exposed for leakage inspection provided that restraint is main-
tained.
 Keep persons not involved in testing a safe distance away while testing is being
conducted.
Liquids such as water are preferred as test fluids because less energy is released if
something in the test section fails catastrophically. During a pressure leak test, energy
(internal pressure) is applied to stress the test section. If the test fluid is an incompress-
ible liquid such as water, the energy applied to pressurize the liquid transfers primarily
to the pipe and components in the test section. However, if the test fluid is a compress-
ible gas, energy is applied to compress the gas as well as to stress the piping section. If
a catastrophic failure occurs during a pressurized liquid leak test, the overall applied
energy is much lower, and energy dissipation is rapid.
However, if catastrophic failure occurs during a pressurized gas test, energy release is
many times greater, much more forceful and longer duration
All of the required tests shall follow the following standards:
 Hydrostatic pressure leak tests of plastic pressure piping systems should be con-
ducted in accordance with ASTM F 2164. The preferred hydrostatic testing liquid
is clean water. Other non-hazardous liquids may be acceptable
 Pressure System Leak Testing – Pneumatic testing should not be considered un-
less one of the following conditions exists:
1. The piping system is so designed that it cannot be filled with a liquid;

2. The piping system service cannot tolerate traces of liquid testing medium.
3. The pressurizing gas should be non-flammable and non-toxic.
Expel all air from the pipe. Apply and maintain the specified test pressure by continu-
ous pumping if necessary for the entire test period. The test pressure shall be calculat-
ed for the point of lowest elevation or as directed by the Engineer. The pump suction
shall be in a barrel or similar device, or metered so that the amount of water required
maintaining the test pressure may be measured accurately.
Leakage shall be defined as the quantity of water necessary to hold the specified test
pressure for the duration of the test period. No pipe installation shall be accepted if the
leakage is greater than 0.90 liter per mm of pipe diameter per kilometer of pipe length
per day.
Correction of Excessive Leakage: Should any test of pipe laid reveal leakage greater
than that allowed, locate and repair or replace the defective joints or pipe until the
leakage of a subsequent test is within the specified allowance. Repairing and replacing
of defective joints or pipes shall be conducted in a manner approved by the Engineer at
no additional cost to the Employer.
Test Records: Records shall be made for each leakage test.
Records shall include:
 Date and time of test. Name of Engineer’s observer

 Description, identification, size and length of piping tested
 Allowable leakage
 Date of filling tested pipe with water
 Applied test pressure and duration
 Measured leakage
 Remarks, as aforementioned for gravity pipes
Subsequent Failure
Infiltration of groundwater in an amount greater than 18.5 liters per day per millimeter
of pipe diameter per kilometer of pipeline, following 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 ap-
proved by the Engineer at no additional cost to the Employer.
Final Inspection
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.
The Engineer reserves the right to employ any means to accomplish the final inspection
including the use of television inspection equipment.
The Contractor shall provide necessary lamps, ropes, bulkheads, plugs, temporary
pumping, ventilation equipment, ladders and other equipment to allow the Engineer to
properly and safely inspect the work.
BACKFILLING
The requirements of “31 30 00Earthwork” Section shall be applied, except as otherwise

specified in this Clause.
Backfilling shall normally be carried out using selected excavated materials similar to
the in situ materials in which the trench or structure is being constructed. Where the
Engineer's Representative designates the excavated material as unsuitable, suitable
material shall be imported, at no extra cost.
Material for backfilling may be selected from any part of the site and methods of selec-
tion may include sieving to remove large particles or methods of hand or machine sort-
ing.
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.
Backfilling shall be carried our as defined below.
Cohesive Soils
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.
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 excavation. It is to be noted that the
cohesive soils or hard materials from excavations shall be broken down to suitable siz-
es to be used for, backfilling, of the top two layers for stability or as per Engineer’s in-
structions at no extra cost.
Granular Soils
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 vibrating hammer compaction test when the test
is carried out on the same soil at the same moisture content in accordance with rele-
vant BS specification.
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 opti-
mum moisture content determined in the vibrating hammer compaction test.
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%. Dur-
ing compaction the soil shall be made as wet as practicable.

Testing of Backfill
The Contractor shall provide at his own cost the services of approved and backfilled soil
properties and shall maintain with a copy to the Engineer, a daily log of tests carried
out.
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 form-
ing 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 formation 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.
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 di-
ameter as those in the existing drain. Before any further backfilling is done the Con-
tractor 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 min-
imum thickness of 150mm before further backfilling.
Site Tests
After installation and before commissioning, the CONTRACTOR shall carry out site
tests, to be witnessed by ENGINEER representatives as well as valves manufacturer's
representative.
Test certificates shall be issued immediately after site testing and copies of the same
should be incorporated in the O&M manuals.
Any problems/defects detected during these tests shall be promptly remedied / recti-
fied by the CONTRACTOR/Manufacturer at no additional cost to ENGINEER.


ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP SANITARY SEWERAGE UTILITIES
KSA 333000 – 2970 1

CONTENTS
SECTION 333000
SANITARY SEWERAGE UTILITIES
Page
PART 1 GENERAL 2
1.4 Submittals 9
PART 2 PRODUCTS 13
2.1 Warning Tapes 13
2.2 Geotextile 15
2.3 Pipe And Fittings 15
2.4 Anchorage 34
2.5 Grout 35
2.6 Sewage Structures 35
PART 3 EXECUTION 40
3.1 General 40
3.2 Joints 43
3.3 Pipe Laying 44
3.4 Manholes And Special Structures 48
3.5 Building Service Lines 55
3.6 Inspection Of Sewers 55
3.7 Testing 55
Sanitary Sewerage Utilities Section 333000

SECTION 333000 – SANITARY SEWERAGE UTILITIES
PART 1 GENERAL

Section.
B. Related Sections:
1. Division 03 Section 032100 "Concrete and Reinforced Concrete”

2. Division 03 Section 033000 "Concrete Cast-in-place"
3. Division 04 Section 042000 “Unit Masonry Assemblies”
4. Division 31 Section 310000 "Earth Work"
5. Division 07 Section 071000 "Corrosion Protection and Odor Control"
A This section covers gravity pipes, pressure pipes work for the conveyance of
wastewater as indicated on Drawings and specified here in addition to all types of
sewage structure such as manholes, slow down chambers and inspection chambers
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
A The work shall be performed in strict accordance with the stipulations of the
National Water Company (NWC) Latest Edition, the British Standard Specifications
(BS) or the American Standards (ASTM) as noted herein below or other equivalent
approved Standards and Sound Practice.
UPVC pipe and fittings

BS No.
BS 2494 Elastomeric seals for joints in pipework and pipelines

BS 2782 Methods of testing plastics
BS 3063 Dimensions of gaskets for pipe flanges
BS 3532 Method of specifying unsaturated polyester resin systems
BS 4346 Joints and fittings for use with un-plasticised PVC pressure pipe
BS 4660 Un-plasticised polyvinyl chloride (PVC-U) pipes and plastics
fittings of nominal sizes 110 and 160 for below ground gravity

drainage and sewerage
BS 5481 Un-plasticised PVC pipe and fittings for gravity sewers
BS 5556 General requirements for dimensions and pressure ratings for
pipe of thermoplastic materials
BS 5955 Code of practice for plastic pipework (thermoplastic materials)
(International organization for standardization)
ISO NO.
ISO 4633 Rubber seals-Joint rings for water supply, drainage and sewerage
pipelines -- Specification for materials
ISO 4435 Unplasticized poly (vinyl chloride) (PVC-U) pipes and fittings for
buried drainage and sewerage systems – Specifications
ASTM NO.
ASTM D 2583 Indentation hardness of rigid plastics by means of a Barcol
Impresser.
ASTM D 638 Standard Test Method for tensile properties of Plastics.
D2466 Specifications for Poly Vinyl Chloride (PVC) plastic Pipe Fittings,
Schedule 40
D1784 Standard specification for rigid Poly Vinyl Chloride (PVC)

compounds and chlorinated poly Vinyl Chloride (CPVC)
D2321 Standard practice for underground installation of

thermoplastic pipe for sewer plastic pipes using flexible
elastomeric seals.
D3034 Standard specifications for type PSM (PVC) sewer pipe and
fittings.
D2412 Determination for External Loading Characteristics of Plastic

Pipe by Parallel Plate Loading.
F477 Elastomeric Seals (Gaskets) for Jointing Plastic Pipes

F789 Standard specification of type PS-46 (PVC) plastic gravity flow
sewer pipe and fittings.
AWWA C908 2001 PVC self-tapping saddle trees for use on PVC pipe
(revision of ANSI/AWWA C908-97)
AWWA C909 Standard for Molecularly Oriented Polyvinyl Chloride (PVCO)
Pressure Pipe, 4 In. Through 24 In. (100 mm Through 600
mm), for Wastewater Service

GRP pipe and fittings

BS No.
BS 7159 Code of practice for design and construction of glass

reinforced plastics (GRP) piping systems for individual plants or
sites.
BS 3749 Specification for E glass fiber woven roving fabrics for
reinforcement of polyester and epoxy resin systems.
BS 3396 Woven glass fiber fabrics for plastics reinforcement.
BS 3496 Specifications for E glass fiber chopped strand mat for
reinforcement of polyester and other liquid laminating
systems.
BS 3532 Method of specifying unsaturated polyester resin systems.
BS 3691 Specification for E glass fiber roving for reinforcement of
polyester and epoxy resin systems.
BS 4504 Sect. 3.1 Circular flanges for pipes valves and fittings (PN
Designated)
ASTM NO.
AWWA C 950 Glass Fiber Reinforced Thermosetting Resin Pressure Pipe.
AWWA M 45 Manual of water supply practiced. Fiber glass pipe design.
VC pipe and fittings

BS No.
BS 65 - 1991 Vitrified clay pipes, fittings and ducts, also flexible mechanical
joints for use solely with surface water pipes and fittings
BS EN 295-5:1994 Vitrified clay pipes and fittings and pipe joints for drains and
sewers.
ASTM NO.
ASTM C 425 Specification for Compression Joints for Vitrified Clay Pipes and
Fittings.
ASTM C 700 Specification for Vitrified Clay Pipes Extra Strength, Standard
Strength and Perforated
ASTM C 479 Standard Specification for Vitrified Clay Liner Plates

RC pipe and fittings
BS No.
BS 4027, Sulphate-resisting Portland cement

BS 5178, Specifications for pre-stressed concrete pipes for drainage
and sewerage
ASTM NO.
A82 Specification for Steel Wire, Plain, for Concrete Reinforcement
A185 Specification for Steel Welded Wire, Fabric, Plain, for Concrete
Reinforcement
A496 Specification for Steel Wire, Deformed, for Concrete

Reinforcement
A497 Specification for Steel WELDED wire Fabric, Deformed for

Concrete Reinforcement
A615/A615 Specification for Deformed and Plain Billet-Steel Bars for

Concrete Reinforcement
C14M Specification for Concrete Sewer, Storm Drain, and Culvert

Pipe (Metric)
C33 Specification for Concrete Aggregates
C39 Test Method -from compressive Strength of Cylindrical

Concrete Specimens
C150 Specification for Portland Cement
C309 Specification for Liquid Membrane-Forming Compounds for

Curing Concrete
C497M Test Methods for Concrete Pipe, Manhole Sections or Tile

(metric)
C595/ C595M Specification for Blended Hydraulic Cements
C618 Specification for Fly Ash and Raw or Calcined Natural Pozzolan
for Use as a Mineral Admixture in Concrete
C822 Terminology Relating to Concrete Pipe and Related Products
C1116 Specification for Fiber-Reinforced Concrete and Shoterete

ASTM NO.
IS0 4633, Rubber Seals - Joint Rings For Water Supply, Drainage and
Sewage Pipelines - Specification for Materials.
AWWA 651 Disinfecting water mains
ASTM D 2412 Standard Test Method for Determination of External loading
characteristics of Plastic pipe by Parallel plate loading.
ASTM D 2290 Standard Test Method for Apparent Tensile Strength of ring or
tubular plastics and reinforced plastics by Split Disk Method.
ASTM D 2584 Standard Test Method for Ignition Loss of cured Reinforced
Resins.
ASTM D 3517 Specification for Fiberglass Pressure Pipe
HDPE PIPES AND FITTINGS:
ASTM NO.
ASTM D1599 Standard Test Method for Resistance to Short-Time Hydraulic

Pressure of Plastic Pipe, Tubing, and Fittings
ASTM D2412 Determination for External Loading Characteristics of Plastic Pipe
by Parallel Plate Loading
ASTM D2657 Standard Practice for Heat Fusion Joining of Polyolefin Pipe
and Fittings
ASTM D 3350 Standard Specification for PE Pipe & Fittings Materials
ASTM D 3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
ASTM D 3035 Standard Spec for PE Pipe (DR-PR) Based on Controlled
Outside Diameter
ASTM F 894 Specification for Polyethylene (PE) Large Diameter Profile Wall

BS No.


BS 5556 General Requirements for dimensions and pressure ratings for pipe of
thermoplastic materials
BS 6437 Polyethylene pipes (type 50) in metric diameters for general purpose
BS 6076 Tubular Polyethylene film for use a protective sleeving for buried iron
pipes and fittings
BS EN 681 part 1- Elastomeric Seals
BS EN 1092 part 2- Circular flanges for pipes, valves, fittings and accessories
BE EN 1515 part 1- Flanges and their joints- Bolting: selection of bolting
ISO No.
ISO 11414 Plastics pipes and fittings -- Preparation of polyethylene (PE)

pipe/pipe or pipe/fitting test piece assemblies by butt fusion
ISO 161-1 Thermoplastics pipes for the transport of fluids -- Nominal outside
diameters and nominal pressures -- Part 1: Metric series
ISO 3458 Mechanical joint fittings for use with polyethylene pressure pipes
for irrigation purposes
ISO 4427 Plastics Piping Systems -- Polyethylene (PE) pipes and fittings for
water supply -- Part 1: General, Part 2: Pipes and Part 3: Fittings
ISO 4633 Rubber Seals – Joint Rings for Water Supply, Drainage and
Sewage Pipelines – Specification for Materials
ISO 1167 Thermoplastics pipes for the conveyance of fluids - Resistance to
internal pressure - Test method
ISO 2505-1 Thermoplastics pipes - Longitudinal reversion - Part 1:
Determination methods.
ISO 2505-2 Thermoplastics pipes - Longitudinal reversion - Part 2: Determination
parameters.
ISO 3126 Plastic pipes - Measurement of dimensions.
ISO 4065 Thermoplastic pipes - Universal wall thickness table.
ISO 4607 Plastics - Methods of exposure to natural weathering.
ISO 6259 Thermoplastics pipes - Determination of tensile properties - Part 1
General test method.

Polyolefin pipes.
ISO 6964 Polyolefin pipes end fittings - Determination of carbon black
content by calcination and pyrolysis- Test method and basic
specification.
ISO 1183 Plastic - Methods for determining the density and relative
density of non-cellular plastic.
ISO 1133 Plastic - Determination of the melt mass flow rate (MFR) melt
Volume rate (MVR) of thermoplastics.
ISO/TR 9080 Thermoplastics pipes for the transport of fluids - Methods of
extrapolation of hydrostatic stress rupture data to determine the
long-term hydrostatic strength of thermoplastics pipe materials.
ISO/TR 10837 Determination of the thermal stability of polyethylene (PE) for
use in gas pipes and fittings.
ISO 11420 Method for the assessment of the degree of carbon black
dispersion in polyolefin pipes, fittings and compounds.
ISO 11922-1 Thermoplastics pipes for the conveyance of fluids - Dimensions
and tolerances Part1: Metric series.
ISO 12162 Thermoplastics materials for pipes and fittings for pressure
Applications -Classification and designation - Overall service
(design) coefficient.
ISO 13761 Plastics pipes and fittings - Pressure reduction factors for
polyethylene pipeline systems for use at temperatures above
20°C.
ISO 13949 Method for the assessment of the degree. of pigment dispersion
in polyolefin pipes, fittings and compounds.
PPI TR-4 Plastic Pipe Institute, Technical Report No. 4
BS 8005- PART 1 Guide to New sewerage construction.
CHAMBERS AND STRUCTURE COVERS AND FRAMES
BS No.
BS 8005 Sewerage Guide to New Sewerage Construction
BS 5750 Quality assurance in productions and installation
BS 5911 Specification For Inspection chamber and street gullies
BS EN 124 Manhole Covers, Road Gully Grating and Frames
BS 1247 Manhole Step Irons

1.4 SUBMITTALS
A Submit the following in accordance with Conditions of the Contract and Division-1
B Literature and Data: Submit the following as one package:
1. Pipe, Fittings, and, Appurtenances.

2. Jointing Material.
3. Manhole and Structure Material.
4. Frames and Covers.
5. Steps and Ladders.
C Pipes
1. Material technical specifications list and manufacturer’s data of the pipes

include its jointing material (rubber gaskets), fittings/ accessories, bedding
material and geo-textiles.
2. Material Certificates of compliance.
3. Materials Sample.
4. Method statement of pipelines construction.
5. Shop drawings.
6. Record drawings.
7. Maintenance data.
8. Certificates of origin.
D Sewage Structure
1. Detailed design and calculations for different types of sewage structures and
sewage chambers.
2. Shop drawings for all types of cast-in-situ concrete structures and chambers
3. Materials list, original catalogue, certificate of origin and manufacturer's data
sheet of the ductile iron frames, covers, steps, grout, waterproofing of the
manhole outside and plastic liner inside the manholes.
4. Representative samples of the ductile iron frames, covers and steps.
5. Method statement of the manholes construction.
6. Shop drawings of the ductile iron frames and covers installation.
7. Shop drawings of the manhole steps installation.
8. Record drawings of the manholes.
A. Products Criteria
1. Multiple Units: When two or more units of the same type or class of materials
or equipment are required, these units shall be products of one manufacturer
2. Nameplates: Nameplate bearing manufacturer's name, or identifiable
trademark, including model number, securely affixed in a conspicuous place on
equipment, or name or trademark, including model number cast integrally
with equipment, stamped, or otherwise permanently marked on each item of

equipment.
3. Comply with the rules and regulations of the National Water Company having
jurisdiction over the connection to Public Sanitary Sewer lines and the
extension, and/or modifications to Public Utility Systems.
E Inspection
jurisdiction over the connection to Public Sanitary Sewer lines and the
extension, and/or modifications to Public Utility Systems.
2. Inspection and Test by the Manufacturer: Pipe and fittings shall be thoroughly
inspected by the manufacturer before delivery. The manufacturer shall make
all tests as specified herein and the results of the tests shall be furnished to
the Contractor upon request in accordance with mutually acceptable
arrangements. The manufacturer may use his own or other suitable facilities
for the performance of the inspection and test requirements specified herein.
On the sample pieces selected for inspection, the inside diameter of the spigot
end shall be checked by suitable gauges. Fittings shall be suitably inspected for
soundness and brittleness.
3. Inspection and Test by the Contractor: Inspection and tests may be made at
the manufacturer plant or at other suitable facilities. If made at the place of
manufacture, the manufacturer shall provide, without charge, all reasonable
facilities to be determined that the material is in accordance with this
specification.
4. Contractor's Responsibility: The Contractor shall furnish materials, equipment,
transportation services and skilled experienced. Laborers necessary to
complete the work as indicated or as required. The Contractor shall be
responsible to complete the work in accordance with the Specifications and
Drawings including details related to this section and necessary works for
complying with requirements contained therein. Contractor shall grantee and
be responsible for keeping all other existing utilities working in healthy
conditions. Any damage –caused by the contractor- to the existing utilities
shall be repaired on the contractor cost. Moreover, contractor shall be
claimed accordingly.
F Testing:
1. Materials and installed work may require testing and retesting at any time
during the progress of work. Tests, including retesting of rejected materials or
installed work, shall be done at the Contractor's expense.
G Rejection:
1. Materials, fabricated parts and pipes that are discovered to be defective or

that are not conforming to requirements shall be subjected to rejection at any
time. Rejected materials and pipes shall be removed from the site.
A General

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
2. 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
3. The Engineer shall be permitted at all reasonable times to visit places of

manufacture to witness tests.
4. Transport, handling and storage of pipes and fittings 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 and fittings.
B During transport
1. Pipes and fittings shall be well secured and adequately supported along their
length
2. Bolsters and binding of approved type shall be used
3. Nesting of pipes (placing a smaller pipe inside a larger) may be permitted for
pipes of certain materials and size provided that methods statements
demonstrate that effective precautions will be taken to protect all pipe
surfaces and coatings from damage
4. No pipe shall overhang the end of a vehicle
5. Pipes and fittings of plastic materials shall be covered.
C Handling shall be carried out as follows:
1. Pipes should be lifted singly and not handled as bunches

2. Pipes shall be handled only by means of approved hooks, curved plate fit the
curvature of the pipe, on ends of sections
3. Fabric slings not less than 250 mm wide
4. Other methods approved for the pipe used
5. Use of wire rope, chains and fork lift trucks will not be permitted
6. For strings of pipe longer than the standard length precautions shall be taken
to avoid curvature and longitudinal stress in excess of allowable limits
7. Pipes and fittings of plastic materials

a. Smaller than 300 mm diameter may be handled manually
b. 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
c. There should be enough slack in the slings to keep the hook
approximately 600 mm over the pipe
d. Steel chain or hooks shall not come into contact with the pipe
8. Pipes and fittings shall not be dropped or bumped

9. Pipes shall not be dragged over the ground
10. If rolled, pipes shall be rolled only over adequate timber bearers to prevent
damage
11. Where necessary, chocks shall be used to prevent lateral movement of pipes.
D Storage of pipes shall be as follows:
1. All pipes, fittings and materials shall be stored in accordance with the
approved 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 provide 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:
e. In accordance with the manufacturer’s recommendations but
not to a greater number of tiers than the following:
1) Pipes diameter ≥ 900 mm : 2 tiers

2) Pipes diameter < 900 mm ≥ 600 mm: 3 tiers
3) Pipes diameter < 600 mm : 4 tiers
2. Suitable protective packing shall be placed between tiers to the approval of

the Engineer
3. Wrapped pipes shall not be stacked
a. If spigot and socket, stacked so that successive pipe layers have sockets
protruding at opposite ends of the stack
b. With pipes of different sizes and thickness stacked separately
c. With maximum height of stacked pipes not exceeding 2m, or
that recommended by the supplier if less than 2 m.
d. Plastic pipes will be stored under cover and not exposed to the
sunlight.
4. Storage of jointing materials shall be as follows:
a. Under cover

b. Rubber ring gaskets shall
1) Be stored in their original packing

2) Not be exposed to sunlight
3) Protected from exposure to greases and oils
c. Gasket lubricants shall be stored so as to prevent damage to

the container.
5. Pipes and fittings shall be protected in storage to the approval of the Engineer
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.
6. Pipes and fittings shall be subject to visual inspections after off-loading at site
and before installation.
7. 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
Engineer.
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 to the Engineer for approval.
d. No attempt shall be made to repair damage without the Engineer’s
approval
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
expense 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
connections.
B Tapes shall be durable and detectable by electro-magnetic means using low output
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 color 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.
3. Detectability after installation and back filling
a. 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
1) Sewers: Yellow
2) CAUTION: Sewer Below
3) Sewage pressure mains: Yellow
4) CAUTION: Sewage Pressure Main Below

2.2 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
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
D1682.
4. The burst strength as measured by the Diaphragm Method of ASTM D3786
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
2.3 PIPE AND FITTINGS
A Un-plasticized PVC Pipes (according project condition preferred for diameter up to

400 mm)
1. General
a. The material from which pipe, fitting and accessories is produced shall
consist of substantially unplasticized polyvinyl chloride. Only those
additives that are needed may be used for the manufacture of the
polymer, and for its conversion into sound, durable extrusions or
molding of good surface finish, mechanical strength and opacity.
b. UPVC pipes shall not be deteriorated or broken down under the effect
of bacteria or other micro-organisms.
c. Shall be as uniform as commercially practical in color, opacity, density
d. The pipes, fittings and accessories shall have a registered certification
mark on, or in relation to a product, as an assurance that the goods have
been produced under the scheme of supervision control and testing in
accordance with the certification mark scheme. Fittings and accessories
shall comply with ASTM D 2466.
e. Shall be recommended as conduits for the conveyance of potable water

f. Shall have chemical inertness and exceptionally smooth internal surface
g. Shall have long service life, resistance to chemicals and excellent
corrosion resistance.
h. Shall be of great mechanical resistance to external and internal loadings.
i. Shall have the property of absorption of linear expansion or contraction,
j. Shall have absolute tightness at the jointing points regardless of
whether there is an over or under-pressure in the network.
k. Properties of pipes shall meet the requirements of the physical,
chemical and mechanical characteristics as mentioned hereinafter.
2. Properties:
a. Classification of Pipes: Pipes shall be manufactured in accordance with

DIN 9534, DIN 8061 part 1and ASTM D3034 SDR 35 capable to withstand
a working pressure of 6kg/ cm2
b. Dimensions: Pipe shall conform to the outside diameters, inside
diameter and wall thickness specified by the above mentioned standard.
c. Lengths: Pipes shall be supplied in straight lengths, normally of 3 m, 6 m
and 9 m or as denoted in Bill of Quantities and approved by the
Engineer.
d. Cutting to Length and Chamfering: Pipes shall be of such kind that can
be cut to length using fine tooth wood saw or hacksaw and of an end
which can be chamfered with one of the special hard tools developed
for shaping plastics.
e. Physical and Thermo-technical Characteristics:
1) General Properties: UPVC pipes shall be manufactured by

extrusion and shall have low specific gravity.
2) Appearance: The pipes shall be reasonably round, homogeneous
throughout, free from voids, cracks, and other defects that would
impair the performance in service; and as uniform as
commercially practical in color, density, and other physical
properties.
3) Pipe surface shall be free nicks, scratches, and other blemishes.
The joining surfaces of pipe shall be free from gouges and other
imperfections that might cause leakage at joints.
4) The internal and external surface of the pipe shall be smooth,
clean and reasonably free from grooving and other defects. The
ends of the pipes and fittings shall be cleanly cut and square with
the axis of the component. The pipe shall be reasonably straight.
5) Specific Gravity: Specific gravity of pipes shall not be less than
1380 kg/m3 and not more than 1425 kg/m3.
6) Heat Reversion: When tested in accordance with the
manufacturing standards, no point all around the pipe shall have a
length change by more than 5% at 150 ± 2° C. After testing, the
pipe shall show no faults, e.g. cracks, cavities or blisters.
7) Opacity: The pipe shall be full opacity and when tested the wall of

the pipe shall not transmit more than 0.2% of the visible light
falling on to it.
8) Coefficient of Linear Expansion: Expansion shall be 1 mm change
in length at 22°C for each 5°C rise or fall in temperature allowance
for every 1 meter length of pipe when operating at temperature
above ambient.
f. Chemical Characteristics:
1) Water Absorption: Pipes shall be tested for water absorption, a

sample shall be completely immersed in water for 24 hours at
100° C, this test shall meet the requirements of the Standard
Specifications of the country of origin.
2) Resistance to Acetone: Pipes shall not delaminate or disintegrate
after 2 hours immersion in anhydrous acetone at room
temperature, examination at 20 minute intervals.
3) Toxic Substances: Pipes shall conform with the requirements to
toxic substances which shall ensure that the recommendations of
the World Health Organization 1963 concerning toxic
contaminants of drinking water are not exceeded.
4) Resistance to Sulphuric Acid: According to the manufacturing
standards, the mass of the tested specimen shall neither increase
by more than 3.16 g nor decrease by more than 0.13 g.
g. Mechanical Characteristics:
1) Extruded pipes shall have high mechanical characteristics and

shall fulfill the following requirements:
a) Tensile strength: 3.5 kgf/mm2, minimum

b) Modulus of elasticity: 197 kgf/mm2, minimum
c) Impact strength: 3.55 kgf/cm at notch, minimum
d) Deflection temperature under load: minimum: 0.1856
kgf/mm2: 55° C minimum
h. Marking:
1) All pipes shall be indelibly marked at interval of not greater than

3m or as specified in the origin Standards.
2) Pipe markings shall include the following marked continuously:
a) Manufacturer’s Name
b) Nominal Size
c) Class Pressure Rating
d) Identification Code
i. Jointing
1) Solvent Cement: Solvent cement joints are acceptable only up to

size DN 50mm as per the applicable code of practice for the
fittings. The solvent cement shall be of non-toxic quality suitable

for drinking water service. Fittings shall conform to BS 4346 Part
1/BS EN 1452.
2) Push-on Joints: Pipes shall be laid with a gap between the end of
the spigot and the base of the socket. This gap shall not be less
than 10 mm or greater than (1/3) one third of the straight draw of
the pipe joint.
3) Rubber Rings: Rubber sealing rings supplied with pipes or fittings
shall be synthetic rubber rings, shall comply with the
requirements of the Standard Specifications of ASTM F 477 Table
No. 1.
4) Rings shall be smooth and free from air marks and other
blemishes.
5) Rings shall be homogenous, free from porosity, grit, blisters and
visible surface imperfections. The rubber shall not contain more
than one part by weight of paraffin wax per hundred part of
rubber.
6) Rubber rings when tested by immersion in water at a
temperature of 25 ± 1° C for 7 days shall not absorb more than 3%
by weight of water.
7) Rings shall be rapid-installing even in rainy, windy, or hot
weathers.
8) Only tiny deformation of the material while socketing and forming
grooves may be accepted at the discretion of the Engineer.
j. Lubricant
1) Shall be the type recommended by manufacture for use with the

employed pipes and no substitute is allowed.
k. Certification
1) The Contractor shall provide the conformance certification of the

manufacturer, test results or copies of test reports. These reports
shall include all the previously mentioned physical, chemical and
mechanical characteristics concerning the pipes.
B GLASS REINFORCED PLASTIC PIPES (GRP) (according project condition and preferred
from diameter 700 to 900 mm)
1. General
a. The pipe or fitting shall be constructed using chopped and/or

continuous glass filaments, strands or rovings, mats or fabric, synthetic
veils, and polyester resin with or without fillers and if applicable
additives necessary to impart specific properties to the resin. The pipe
or fitting may also incorporate aggregates, and if required, a
thermoplastics liner.
2. Reinforcement:
a. The glass used for the manufacture of the reinforcement shall be one of

the following types:
1) A type 'E' glass, comprising primarily either oxides of Silicon,

Aluminum and Calcium (alumino–calcosilicate glass) or Silicon,
Aluminum and Boron (alumino-borosilicate glass);
2) A type 'C' glass, comprising primarily oxides of Silicon, Sodium,
Potassium, Calcium and Boron (alkalicalcium glass with an
enhanced boron trioxide content) which is intended for
applications requiring enhanced chemical resistance.
b. In either of these types of glass small amounts of oxides of other metals

will be present.
c. The reinforcement shall be made from continuously drawn filaments of
a glass conforming to type E or type C, and shall have a surface
treatment compatible with the resin to be used. It may be used in any
form, e.g. as continuous or chopped filaments, strands or rovings, mat
or fabric.
d. Resin: The resin used in the structural layer shall have a temperature of
deflection of at least 70 °C when
e. the test specimen is tested in accordance with Method A of EN ISO 75-2.
f. Aggregates and fillers: The size of particles in aggregates and fillers shall
not exceed 1/5 of the total wall thickness of the pipe or fitting or 2,5
mm, whichever is the lesser.
g. Elastomers: Each elastomeric material(s) of the sealing component shall
conform to the applicable requirements of EN 681-1.
h. Metals: Where exposed metal components are used, there shall not be
evidence of corrosion of the components after the fitting has been
immersed in an aqueous sodium chloride solution, 30 g/l, for seven days
at (23 ± 2) °C.
3. Wall construction
a. Inner layer
1) The inner layer shall comprise one of the following:
a) A thermosetting resin layer with or without aggregates or

fillers and with or without reinforcement of glass or
synthetic filaments;
b) A thermoplastics liner.
2) NOTE: The thermoplastic liner may require a bonding material

compatible with all other materials used in the pipe construction.
b. Structural layer
1) The structural layer shall consist of glass reinforcement and a

thermosetting resin, with or without aggregates or fillers.
c. 2Outer layer

1) The design of the outer layer of the pipe shall take into account
the environment in which the pipe is to be used. This layer shall
be formed of a thermosetting resin with or without aggregates or
fillers and with or without a reinforcement of glass or synthetic
filaments.
2) The of use special constructions is permitted when the pipe is
expected to be exposed to extreme climatic, environmental or
ground conditions, for example provision for the inclusion of
pigments or inhibitors for extreme climatic conditions or fire
retardation.
d. Appearance
1) Both internal and external surfaces shall be free from

irregularities, which would impair the ability of the component to
conform to the requirements of this European Standard.
4. GRP Pipe Joint
a. Flexible joint
1) Which allows relative movement between the pipes being joined,

these types of joint are:
a) Socket-and-spigot joint with an elastomeric sealing element

(including double socket designs);
b) Locked socket-and-spigot joint with an elastomeric sealing
element (including double socket designs);
c) Mechanical clamped joint e.g. bolted coupling including
joints made from materials other than GRP.
d) End-load-bearing flexible joints have resistance to axial
loading
b. Rigid joint
1) Which does not allow relative movement between the pipes

being joined, these types of joint are:
a) Flanged joint, including integral and loose flanges;

b) Wrapped or cemented joint.
c) Non-end-load-bearing rigid joints do not have resistance to
axial loading
5. GRP Pipe Classifications
a. Categories
1) Pipes and fittings shall be classified according to nominal size

(DN), nominal pressure (PN) and joint type.
2) In addition pipes shall include nominal stiffness (SN) in their
classification.

b. Nominal size
1) The nominal size (DN) of pipes and fittings shall conform to the
appropriate Tables in Clause 5 BS 14364. If a thermoplastics liner
is present, its internal diameter shall be declared by the
manufacturer. The tolerance on the diameter shall be as specified
in Clause 5 BS 14364.
c. Nominal stiffness
1) The nominal stiffness, SN, shall conform to one of those given in

Table 1 (see footnotes a to c).
2) Where special applications require the use of pipes having a
higher nominal stiffness than those given in Below Table, the pipe
shall be marked SN v, where v is the number equal to the pipes
nominal stiffness.
Nominal stiffness’s (SN)
Nominal stiffness’s a b c Nominal stiffness’s a b c

(SN) (SN)
500 2500
630 4000
1000 5000
1250 8000
2000 10000
d. This nominal stiffness’s correspond to the values specified in Clause 5 BS

14364 for the minimum initial specific ring stiffness, in Newton per
square meter (N/m2).
e. Pipes of nominal stiffness less than SN 1000 are not intended for laying
directly in the ground.
f. The selection of pipe stiffness shall be in accordance with the
recommendations given in ENV 1046 based on loading, backfill materials
and native soils.
g. Nominal pressure
1) The nominal pressure (PN) shall conform to one of those given in

Table 2.
2) Where pressure ratings other than the nominal values in below
Table are to be supplied, by agreement between the
manufacturer and the purchaser, the pressure marking PN on the
component shall be replaced by PN v where v is the number equal
to the components nominal pressure.
Nominal pressure
(PN)
1 12.5

2.5 16
4 20
6 25
10 32
NOTE: Components marked PN1 are non-pressure (gravity) components.
1) Stiffness shall be minimum 5000 N/m2 for all pipes but for pipes
to be used in pumping stations and valve chambers the stiffness
shall be minimum 10,000 N/m2 and pipes for use in micro-
tunneling or similar jacking operations the stiffness shall be
minimum 50,000 N/m2 unless enclosed in concrete.
b. Inspection and Testing
1) Test certificates for all type tests and other tests specified in this
Clause shall be submitted to the Engineer.
2) The results of type tests appropriate to the proposed pipes and
fittings shall be used to determine the properties of pipes. Each
type test shall have been carried out on pipes or fittings
representative of the pipes to be used. The following type tests
shall be conducted at the manufacturer’s works in accordance
with the requirements of BS 5480 Part 2 except as noted, and the
tests shall be carried out at 25°C.
Property Test Method
Long-term stiffness and creep

Factor under any deflection
Long-term semi-permanent set Except that test results and ageing

factors shall be extrapolated to 60
years, at
Which time the failure strain must not
be less than 1%
Impact resistance
Long-term hoop tensile
External pressure resistance ASTM D2924
Strain corrosion test ASTM D3681
3) For the strain corrosion type test, samples of pipes representative

of those to be supplied shall be subjected to the strain corrosion
test in the Engineer’s presence if so directed, and evidence of
conformance shall be furnished before commencement of
manufacture. Further regular tests shall be made by the
manufacturer and the results furnished as a feature of his quality
control procedure. Notwithstanding the requirements of ASTM
D3681, any appearance of blisters, delamination, wicking or other

structural blemishes shall be taken to mean that the pipe has
failed and the end point reached.
4) Longitudinal tensile strengths shall be determined in accordance
with BS 5480 and shall be carried out on one pipe in every 100
pipes of each class and diameter manufactured, or as directed by
the Engineer.
5) When subjected to a parallel plate load test in accordance with
ASTM D2412 the pipe shall reveal no evidence of crazing, cracking
at deflection of I0 percent, and no evidence of structural failure at
a deflection of 20 percent.
6) The Barcol hardness test to check resin cure shall be done on
every pipe or fitting at the manufacturer’s work.
7) One pipe in every 25 of each size shall be tested for loss of
ignition in accordance with ASTM D2584.
8) Checks of dimensional accuracy will be carried out by the
Engineer at Site. The Contractor shall destroy or indelibly mark as
rejected and remove from Site any pipes or fittings found at any
time failing to meet dimensional criteria or any of the following
quality criteria:
a) Scratches shall be no deeper than 0.3 mm and no

reinforcing fibers shall be exposed
b) No cracks shall be present on the inside of pipes. Hair
cracks on the outside may be permitted with repair if not
longer than 200 mm circumferentially or 6 mm
longitudinally. Impact cracks shall not affect more than 3 %
of surface area
c) No delamination shall be evident
d) No impact or other damage to pipe ends shall be evident.
The end surface of pipe or fitting shall be completely
covered with resin and free from cracks, porosity, bubbles,
voids, exposed reinforcement or extraneous matter
e) No protruding fibers permitted on or jointing surfaces
f) No other protuberances. Small globules or resin
projections permissible if not more than 25 % of area is
affected. Jointing surfaces shall be completely free of any
such flaws. Ridges formed by resin shall not exceed 1.5 mm
in depth
g) Air voids, blisters, bubbles are not acceptable if greater
than 5 mm diameter or 1mm depth. Subject to the
approval of the Engineer, if less than 0.5 % of internal areas
are affected, such defects may be ground out and repaired
h) Not more than 5 % of the internal or 10 % of the external
surface shall be affected by pitting. No individual pit shall
be more than 1 mm diameter or 0.5 mm depth
i) Wrinkles and indentations shall not be more than 2 mm
deep and not more than 3 % of surface area affected.
Subject to the approval of the Engineer, if not more than 5
mm deep and 0.5 percent of surface area is affected, such
defects may be repaired

j) Any pipe which when resting freely on the ground and not
subjected to any loads other than its own weight exhibits a
deflection of more than 2 %, measured along the diameter,
shall be rejected and removed from the Site. Tests for
deflection of pipes after installation are specified in this
Section.
C REINFORCED CONCRETE PIPES (according project condition) preferred for diameter ≥

1000 mm
1. General:
a. Pipe shall conform to ASTM Standard Specifications for Reinforced

Concrete Culvert, Storm Drain, and Sewer Pipe, Designation C76M, of
the Class and Wall design of D-Load shown on the Drawings. The D-
Load required shall be that load as determined by the results of the
three- edged bearing test to produce a 0.3 mm (0.01 in) crack. The pipe
interior shall be smooth and even, free from roughness, projections,
indentations, offsets, or irregularities of any kind. The concrete mass
shall be dense and uniform.
b. Special design pipe shall be designed and furnished under the
requirements of ASTM C655M, Reinforced Concrete D-Load, Culvert,
Storm Drain and Sewer Pipe. The D-Load required as shown on the
Drawings shall be that load as determined by the results of the three-
edge bearing test to produce a 0.3 mm crack.
c. Sulfate resistant cement conforming to ASTM C150, Type III shall be
used in the manufacture of all concrete pipes.
d. The 28-day compressive strength of the concrete, as indicated by cores
cut from the pipe shall be not less than 420 kg/cm2. The concrete mass
shall be dense and uniform. The average absorption shall not exceed
5.3 percent of the dry weight and no specimen shall exceed 5.5 percent.
Reinforcement shall be circular for all concrete pipe. Quadrant steel
shall not be used. Reinforcement shall be installed in both the bell and
spigot. At least one circumferential reinforcement wire shall be in both
the bell and spigot area, and reinforcement in the bell and spigot shall
be adequate to prevent damage to concrete during shipping, handling
and after installation. Cores indicating reinforcing steel having less than
85 percent bond shall be cause for rejection of the lot of pipes.
e. The pipe shall be clearly marked as required by ASTM C76M and C655M
in a manner acceptable to the Engineer. The markings may be at either
end of the pipe for the convenience of the manufacturer, but for any
one size shall always be at the same end of each pipe length. Pipe shall
not be shipped until the concrete has attained 80 percent of its
compressive strength and not before 7 days after manufacture, and/or
repair, whichever is the longer.
f. Pipe shall have a minimum laying length of approximately 2.5m, except
for closure, wall pipes and other special pieces as satisfactory to the
Engineer. Provide at the site of the work sufficient pipe of various
lengths to effect closure at manholes or structures that cannot be
located to accommodate standard lengths. Short lengths of pipe made

for closure etc. may be used in the pipeline at the end of construction if
properly spaced. The length of the incoming and outgoing concrete
pipe at each structure shall not exceed 1.25 m except where otherwise
noted on the Drawings.
g. The Engineer shall have the right to have cores cut from such pieces of
the finished pipe as he desires for such inspection and tests as he may
wish to apply. Core drilling shall be carried out by the Contractor at his
expense. Holes left by the removal of cores shall be filled in a manner
acceptable to the Engineer and at the expense of the Contractor.
h. The Engineer shall also have the right to take samples of the concrete
after it has been mixed or as it is being placed in the forms or molds,
and to make such inspection and tests thereof as he may wish.
i. At the start of the work, a set of test cylinders shall be taken each day
on which pipe is manufactured for the project or more often if required.
This may ultimately be reduced to one set of three specimens for every
40 cu m. of concrete placed, if the uniformity of results warrants, and if
approved by the Engineer. At the start of the work, a relationship shall
be established between ultimate strength of test cylinders stored in a
standard manner as compared to cylinders cured with the pipe and as
compared to cores taken from the cores ditching finished pipe. At least
five sets of tests shall be made. All concrete shall be tested for chloride
content as specified in Section 03300-CONCRETE. Submit to the
Engineer an aggregate test report as specified in Section 03300-
Concrete.
j. Test cores may be taken for every 150 m of pipe manufactured, but not
less than once each day on which pipe is manufactured for the project.
Cores may be reduced to one set of two per week (or possibly fewer,
but not less than one set for every 450 m) if a satisfactory relationship is
established between cores and cylinders made and cured in the
standard manner. This relationship shall not vary by more than 10 per
cent more or less from the average ratio. Cores may be drilled in any
manner which will provide a smooth core face. All pipe cylinders and
cores shall be 10 cm in diameter. Cores shall be carefully saw-trimmed
and capped in a vertical position with a sulfur cap of minimum thickness,
at least one day before being tested.
k. Core testing shall conform to Standard ASTM Methods.
l. At the time of inspection, the pipe will be carefully examined for
compliance with the appropriate ASTM and project specifications, and
shop drawings. All pipes shall be inspected for general appearance,
dimension, "scratch-strength," blisters, cracks, roughness, soundness,
etc. All pipes will be checked for soundness by being tapped and
scratched over a reasonable portion of the area, at least once on every
400 sq cm of pipe surface. The surface shall be dense and close-
textured. Cores also shall serve as a basis for rejection of pipe,
particularly if lamination or poor bond of reinforcement is apparent.
m. The manufacturer shall use measuring devices to assure joint assembly
is within tolerances of ASTM C361M and these Specifications.
n. Unsatisfactory or damaged pipe will be either permanently rejected or
returned for minor repairs. Only that pipe actually conforming to the
specifications and accepted will be listed for acceptance, shipment and

payment. Acceptable pipe will be so stamped or stenciled on the inside
before it is shipped. All pipe which has been damaged after delivery will
be rejected, and if such pipe already has been laid in the trench, it shall
be acceptably repaired, if permitted, or removed and replaced, entirely
at the Contractor's expense.
o. Pits, blisters, rough spots, breakage, and other imperfections may be
repaired, subject to the satisfaction of the Engineer, after
demonstration by the manufacturer that strong and permanent repairs
result. Repairs shall be carefully inspected before final acceptance.
Non-shrink cement mortar used for repairs shall have a minimum
compressive strength of 420 kg/cm2 at the end of 7 days and at 490
kg/cm2 the end of 28 days. Epoxy mortar may be utilized for repairs
subject to the satisfaction of the Engineer.
p. Pipe for use on curved sections shall be fabricated by beveling one or
both ends sufficient to produce the radius of curvature required. Joint
deflection shall not exceed the limit allowed by ASTM C443M.
2. Joints for Concrete Pipe:
a. Joints shall be formed concrete bell and spigot type, conforming to

section 8 of ASTM C361M except as modified herein. Note the
requirements for bell and spigot geometry. Alternative joint design shall
not be permitted. Gaskets shall have a circular cross section and shall be
confined in a groove in the pipe spigot. Pipe with collars in lieu of
integral bells will not be acceptable.
b. In all concrete joints the manufacturer shall provide sufficient
reinforcement in the bell to resist the hydrostatic, hydrodynamic, and
gasket pressures. The joints shall be designed and tested to withstand a
transverse shear loading equal to 6000 Kilograms of force per meter of
nominal diameter with the gasket in place. Two pairs of pipes of each
pipe diameter shall be tested in this manner.
c. The pipe manufacturer shall furnish information and supervise the
installation of at least the first five joints installed by the Contractor.
The ends of the pipe shall be made true to form and dimension, and the
bell shall be made by casting against steel forms.
d. The manufacturer shall inspect all pipe joint surfaces for out-of-
roundness and pipe ends for squareness. The manufacturer shall furnish
to the Engineer a notarized affidavit stating all pipe meets the
requirements of ASTM C361M, these Specifications and the joint design.
e. The pipe manufacturer shall verify the water-tightness of the joint by
hydro testing the pipes in accordance with ASTM C361M and C497 as
amended herein. The test shall be performed with the joint transversely
loaded to induce sufficient non-uniform gasket compression to induce
the concrete of the bell and spigot to be in contact on one side. This
contract shall be verified with a feeler gage prior to the application of
pressure. The test pressure at the joint shall be one bar.
3. Properties:
a. Classification of Pipes: Reference to ASTM C 76M-97 Pipes classification

shall be from class (II) to class (V) a minimum of Class (III) shall be
acceptable, capable to withstand a working pressure of 1.5 kg/cm2
based on water temperature of 20'C, and also capable to withstand the
load to produce a 0.3mm crack or the ultimate load, as determined by
the three- edge-bearing method, and shall be not less than that
prescribed in Tables H to V for each respective class of pipe, Concrete
pipes internally coated with high density polyethylene smooth liner with
thickness 2.5mm and with additional external protection (paint with not
less than two layers of bituminous)
b. Dimensions: Pipes shall conform to the inside diameters and wall
thickness and length as indicated in the ASTM C 76M-97.
c. Length: Pipes shall be supplied in straight lengths, with a minimum
nominal length of 2.5 m unless shorter length is required.
d. Lining: All pipes shall be internally Lined with one of the following items
conforming to ES No. 268:
1) Pipe shall internally coat with 3 layers (coat) of coal tar epoxy
with thickness not less 450 micron after drying. No solvent
allowed.
2) Pipe shall internally coated with thin layers (coats) of poly
chloride vinyl plastic with thickness not less than 2 mm after
drying and shall be fixed on the total perimeter of the pipe 360
with T-LOCK system.
3) Outside Protection: Pipe and fittings shall be externally coated
with 2 coats of a hygienically harmless factory applied bituminous
varnish (PF4) with thickness not less than 3 5 0 micron after
drying, no solvent is allowed.
4. Materials:
a. Cement: Shall be sea water cement according to ASTM C150 or

conforming to the requirements of ASTM C 595/C 595M, Fly ash shall
conform to the requirements of Class F or Class C of ASTM C 6 1 8.
b. Aggregate: Shall be according to ASTM C33, it shall be clean natural sand
or gravel or crushed stone.
c. Admixture and Blends: Concrete may contain a water reducing
admixture. Engineer must be advised of the type and amount of any
admixture used in the concrete.
d. Steel Reinforcement Bars: Reinforcement shall consist of wire
conforming to ASTM A 82 or ASTM A 496 or of wire fabric conforming to
ASTM A 185 or ASTM A 497 or of bars of Grade 300 steel conforming.
e. Synthetic Fibers: Collated fibrillated virgin polypropylene fibers may be
used, at the manufacturer's option, in concrete pipe as a nonstructural
manufacturing .material. Only Type 111 synthetic fibers designed and
manufactured specifically for use m concrete and conforming to the
requirements of ASTM C 1116 shall be accepted.
5. Reinforcement:
a. Circumferential Reinforcement: A line of circumferential reinforcement

for any given total area may be composed of two layers for pipe with

wall thicknesses of less than 180 mm or three layers for pipe with wall
thicknesses of 180 nun or greater. The layers shall not be separated by
more than the thickness of one longitudinal plus 6 mm. The multiple
layers shall be fastened together to form a single cage.
b. Where one line of circular reinforcement is used- it shall be placed from
35 to 50 % of the wall thickness from the inner surface of the pipe,
except that for wall thicknesses less than 63 mm, the protective cover of
the concrete over the circumferential reinforcement in the wall of the
pipe shall be 19 mm.
c. In pipe having two lines of circular reinforcement, each line shall be so
placed that the protective covering of concrete over the circumferential
reinforcement in the wall, the pipe shall be 25 mm.
d. In pipe having elliptical reinforcement with wall thicknesses 63 mm. Or
greater, the reinforcement in the wall of the pipe shall be so placed that
the protective covering of concrete over the circumferential
reinforcement shall be 25mm from the inner surface of the pipe at the
vertical diameter and 25 mm from the outer surface of the pipe at the
horizontal diameter. In pipe having elliptical reinforcement with wall
thicknesses less than 63 mm, the protective covering of the concrete
shall be 19 mm at the vertical and horizontal diameters.
e. Where reinforcement is in the bell or spigot the minimum and cover on
the last circumferential shall be 13 mm, m the bell or 6 mm the spigot.
f. Longitudinal Reinforcement: Each line of circumferential reinforcement
shall be assembled into a cage that shall contain sufficient longitudinal
bars or members, to maintain the reinforcement in shape and in
position.
g. Joint Reinforcement for Rubber Gasket Joints:
1) The length of the joint as used herein means the inside length of
the bell or the outside length of the spigot from the shoulder to
the end of the pipe section the bell ends shall contain
circumferential reinforcement. This reinforcement shall be an
extension of the outer cage or a single wall cage. Whichever is
less, or may be a separate cage of at least the same area per
meter with longitudinal. If a separate cage is used, the cage shall
Extend into the pipe with the last circumferential wire at least 25
mm past the inside shoulder where the pipe barrel meets the bell
of the joint, where bells require reinforcement, the maximum end
cover on the last circumferential shall be 38 mm.
6. Permissible Variations:
a. Internal Diameter: Permissible variations utilizing S1 units are as

prescribed in the following Table:

Permissible Variation in Internal Diameter
Designated Diameter of Permissible Variation in Internal Diameter of Pipe
Pipe, mm Minimum, mm Maximum, mm
300 300 310
375 375 390
450 450 465
525 525 545
600 600 620
675 675 695
750 750 775
825 825 850
900 900 925
1050 1050 1080
1200 1200 1230
1350 1350 1385
1500 1500 1540
b. Thickness: The wall thickness shall not vary more than shown in the
design or specified wall by more than 5% or 5 mm, whichever is greater.
c. Length of Pipe: The under run in length of a section of pipe shall not be
more than 10 mm/m with a maximum of 13 nun in any length of pipe.
d. Leng1h of Two Opposite Sides: Variations in the laying length of two
opposite sides of the pipe shall not be more than 6 mm for all sizes
through 600-mm internal diameter, and not more than 10 mm/m of
internal diameter for all sizes larger with a maximum of 16 mm in any
length of pipe through 2100-mm internal diameter, and a maximum of
19 nun for 2250-mm internal diameter or larger.
e. Position or Area of Reinforcement: The maximum variation in the
position of the reinforcement shall be ±10 % of the wall thickness or ±13
mm, whichever is greater, shall the cover the circumferential
reinforcement be less than 6 mm as measured to the end of the spigot
or 13 mm as measured to any other surface. The preceding minimum
cover limitations do not apply to mating surfaces of non-rubber gasket
joints or gasket grooves in rubber gasket joints. If convoluted
reinforcement is used, the convoluted circumferential end wire may be
at the, end surface of the joint providing the alternate convolutions
have at least 25 mm cover from the end surface of the joint.
f. Product Marking: The following information shall be legibly marked on
each section of pipe:
1) The pipe class and specification designation

2) The date of manufacture
3) The name or trademark of the manufacturer
4) Identification of plant
5) Reinforcement shall be clearly marked during the process of
manufacturing or immediately thereafter, on the inside and the
outside of opposite walls along the minor axis of the elliptical
reinforcing or along the vertical axis for quadrant reinforcing

6) Markings shall be indented on the pipe section or painted thereon
with waterproof paint.
D (VC) Vitrified Clay Pipe, Extra Strength (according project condition) preferred for
200 mm < diameter < 600 mm
1. General
a. Clay, free clay, shale, and surface clay are as defined in ASTM Definitions
C 43.
b. Vitrified clay pipe shall be manufactured from free clay, shale, surface
clay, or a combination of these materials that, when formed into pipe
and fired to suitable temperatures, yields a product that is strong,
durable, and serviceable, free of objectionable defects, and conforms to
tills specification.
2. Physical Properties
a. Bearing Strength
1) Pipe shall meet the crushing strength requirements of SASO 236;

EN 295; ASTM C 700or as per the below Table.
Nominal Extra Strength

Size, Vitrified Clay Pipe
in. Ibf/linear kN/linear
ft rn
3 2,000 29.2
4 2,000 29.2
6 2,000 29.2
8 2,200 32.1
10 2,400 35 .0
12 2,600 37.9
15 2,900 42.3
18 3,300 48.2
21 3,850 56.2
24 4,400 64.2
27 4,700 68.6
30 5,000 73.0
33 5,500 80.3
36 6,000 87.6
39 6,600 96.3
42 7,000 102.2
2) The number of specimens to be tested shall not exceed 0.5

percent of the number of pipe of each size furnished, except that
no less than two specimens shall be tested.
3) If any of the test specimens fail to meet the requirements, the

manufacturer will be allowed a retest on two additional
specimens for each one that failed. The pipe will be acceptable if
all the specimens for retest meet the requirements.
4) If, subsequent to an initial pipe strength failure, the accuracy of
the machine is questioned, at the request of the manufacturer,
the machine may be recalibrated and a retest made or a retest
may be made upon a machine of known accuracy.
b. Absorption:
1) The absorption of vitrified clay pipe shall not exceed 8 percent.

2) If any of the test specimens fail to meet the absorption
requirements, a retest will be allowed, and the pipe accepted as
already mentioned above in Bearing Strength section
c. Hydrostatic Pressure Test:
1) As an alternative to the absorption test, the manufacturer may, at

his option, apply a hydrostatic pressure test to all of the pipes
subject to test in each size and run of the pipe.
2) When the pipe is subjected to an internal hydrostatic pressure of
10 psi
3) (68.9 kPa) for the elapsed time shown in the following table,
there shall be no leakage on the exterior of the pipe. Moisture
appearing on the surface of the pipe in the form of beads
adhering to the surface shall not be considered leakage. However,
moisture which starts to run on the pipe shall be construed as
leakage regardless of quantity.
Hydrostatic Pressure: Test Times
Thickness Test Time.

of Barrel.
in(mm) min.
. Up to 7
and
including
1 (25)
Over 1 (25) and including 1 ½ 9
(38)
Over 1 ½ (38) and including 2 12
(51)
Over 2 (51) and including 2 ½ 15
(64)
Over 2 ½ (64) and including 3 18
(76)
Over 3 (76) 21
4) If any of the test specimens fail to meet the absorption

requirements, a retest will be allowed, and the pipe accepted as
already mentioned above in Bearing Strength section.
d. Acid Resistance:
1) This test is used to determine the resistance of pipe to the action

of acids encountered in sanitary sewers. The test shall be
performed only when specified.
2) The pipe of each size and shipment shall be acceptable if the acid-
soluble matter, from specimens representing such pipe, does not
exceed 0.25 percent.
3) Failure of any of the specimens to meet the test shall result in the
rejection of the entire pipe represented by the specimen tested.
e. Sizes and Dimensions
1) Sizes and dimensions of pipe areas described in AASHTO

DESIGNATION: M 65-89, (ASTM DESIGNATION: C 700(86)
2) The inside diameter shall not vary from a true circle by more than
3 percent of its nominal diameter.
3) The average inside diameter shall be determined by taking any
two 90°
4) (l.6-rad) opposing measurements and averaging the readings.
f. Straightness
1) Pipe shall not deviate from straight by more than 1/16 in./ft. (5
mm/m) of length when the maximum offset is measured from the
concave side of the pipe.
2) Measurements shall be taken by placing a straightedge on the
concave side of the pipe's full length of the barrel, being sure not
to include spigot joint material or socket, and measuring the
maximum distance between the straightedge and concave side of
the pipe.
g. Glaze
1) Unless otherwise specified, the manufacturer may supply either

glazed or unglazed pipe. On glazed pipe, the glaze shall be a
continuously uniform layer that is substantially free of
imperfections. Not more than 10 percent of the inner surface of
any pipe barrel may be free of glaze. There shall be no well-
defined crazing or hairline cracks.
2) Glazing is not required on the outer surface of the pipe at the
spigot, for a longitudinal distance equal to the depth of the
socket. Glaze may be entirely absent from the inside of the
socket.
3) When a ceramic glaze is used, it need only be applied to the inside
of the pipe.

h. Blisters
1) Pipe of nominal sizes from 3 to 18 in. (76 to 450 mm) shall have
no blister with a dimension exceeding 3 in. (75 mm), and no
blister or pimple shall project more than 1/8 in. (3 mm) above the
surface of the pipe.
2) Pipe of nominal sizes over 18 in. (450 mm) shall have no blister
exceeding 2 in/ft. (166 mm/m) of internal diameter, and no blister
or pimple shall above the surface of the pipe more than 1/8 in.
/ft. (10 mm/m) of internal diameter.
3) Pipe shall have no broken blisters.
i. Fractures and Cracks
1) There shall be no fractures or cracks passing through the barrel or

socket, except that a single crack at the spigot end of the pipe not
exceeding 75 percent of the depth of the socket, or a single
fracture in the socket not exceeding 3 in. (76 mm) around the
circumference nor 2 in. (50 mm) lengthwise may be permitted.
2) Chips or fractures on the interior of the pipe shall not exceed 2 in.
(50 mm) in length, 1 in. (25 mm) in width, and a depth of one
fourth of the thickness of the barrel.
j. Finish of Ends
1) The ends of pipe shall be square with their longitudinal axes,

within the tolerances provided in in AASHTO DESIGNATION: M 65-
89, (ASTM DESIGNATION: C 700(86)
2) The inner surface of the socket and the outer surface of the spigot
shall be scored with triangular or semicircular shaped
circumferential indentations about 1/8 in. (3 mm) in depth. The
minimum number of scorings shall be as follows:
Size of Pipe Number of Scorings
. in mm min
3 to 6 75-150 1
8 and 10 200-250 2
12 to 36 300-900 3
3) Scoring may be eliminated when it is conducive to the proper
application of the joint to be used.
k. Fittings
1) Vitrified clay pipe, spigot and socket type, pipe diameter(s) as

indicated, shall comply with one of the following Standards:
a) SASO 236; EN 295; ASTM C 700,

b) High strength / class A, SASO 236 or equivalent.

c) Jointing: rubber or plastic gasket for push-in joints shall
comply with ASTM C 425; EN 295-4; or equivalent.
1) When connecting two spigot ends, coupling shall be made of a

rubber or elastomeric sealing sleeve with approved stainless steel
clamp ring assembly.
2) Fittings shall correspond in all respects with the dimensions
specified for pipe of the corresponding size. Dimensional
tolerances of fittings shall be the same as for straight pipe. All
fittings shall conform to the requirements for pipe described
above
3) Slants shall have their spigot ends cut at an angle of
approximately 60 deg (1.0 rad) or 45 deg (0.8 rad) with the
longitudinal axis.
4) Curves shall have arcs of approximately 90 deg (1.6 lad), 45 deg
(0.8 rad), 30 deg (0.5 rad), or 22.5 deg (0.4 rad) as required.
5) Fittings shall be made to such lengths as will accommodate the
jointing system provided. Tee and wye fittings shall be furnished
with spurs of the size specified, securely and completely fastened
to the barrel of the fittings in the process of manufacture. The
spurs of tee fittings shall have their axes perpendicular to the
longitudinal axis of the fitting. The spur of the wye fittings shall
have their axes at angles of approximately 60 deg
6) (1.0 rad), or 45 deg (0.8 rad) to the longitudinal axis of the fitting,
measured from the socket or bell end of the fitting. The barrel of
each spur shall be of sufficient length to permit making a proper
joint.
7) Channel pipe and channel fittings shall be approximate half
sections of the corresponding size of straight pipe and fittings.
l. Inspection
1) All pipes shall be subject to inspection by a competent inspector

employed by the purchaser. Inspection may be made promptly at
the factory or at the point of delivery. All pipe accepted may be
plainly marked by the inspector. Rejected pipe shall not be
defaces, but shall be replaced by the manufacturer or seller
without additional cost, with pipe that meets the requirements of
this specification
2.4 ANCHORAGE
A. Anchorage lugs shall be provided for socket and spigot fittings and socket clamps and
tie rods used where there is a possibility of pulling the joint under pressure.
Concrete thrust blocks shall be used in lieu of the above where socket and spigot
pipe is used below ground. The Contractor shall submit, for the Engineer’s approval,
working drawings and information demonstrating the adequacy of anchorage
systems other than thrust blocks or other systems shown on the Contract Drawings.

2.5 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.
2. General purpose non shrink cementations grout.
3. Flow able (Precision) non shrink cementations grout.
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.
2.6 SEWAGE STRUCTURES
A. Cast in Situ Manhole
1. 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 EN 197-1 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
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 032100 "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 032100.
3) Concrete blocks specifications Shall conform to the requirements
of Division 04 Section 042000 “Unit Masonry Assemblies”

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.
B. Precast Concrete Manholes and Chambers
1. General
a. Provide manhole sections, base sections, and related components

conforming to ASTM C 478. Provide base riser section with integral
floors, unless shown otherwise. Provide adjustment rings which are
standard components of manufacturer of manhole sections. Mark date
of manufacture and name or trademark of manufacturer on inside of
barrel.
b. Construct barrels for precast manholes from standard reinforced
concrete manhole sections of diameter indicated on Standard Drawings.
Use various lengths of manhole sections in combination to provide
correct height with fewest joints.
c. For manholes larger than 48-inch diameter, provide precast base
sections with flat slab top precast sections used to transition to 48-inch
diameter manhole access riser sections. Transition can be concentric or
eccentric unless otherwise requested by Engineer. Locate transition to
provide minimum of 7-foot head clearance from base to underside of
transition unless otherwise approved by Engineer.
d. Design Loading Criteria: Manhole walls, transition slabs, cone tops, and
manhole base slab shall be designed, by manufacturer, to requirements
of ASTM C 478 for depth as shown on Standard Drawings and to resist
the following loads :-
1) AASHTO HS-20 vehicle loading applied to manhole cover and

transmitted down to transition and base slabs
2) Unit soil weight of 120 pcf located above portions of manhole,
including base slab projections
3) Lateral soil pressure based on saturated soil conditions producing
an at rest equivalent fluid pressure of 100 pcf
4) Internal liquid pressure based on unit weight of 63 pcf
5) Dead load of manhole sections fully supported by transition and
base slabs
e. Provide joints between sections with o-ring gaskets conforming to ASTM

C 443.

f. When base is cast monolithic with portion of vertical section, extend
reinforcing in vertical section into base.
g. Precast Concrete Base: Suitable cutouts or holes to receive pipe and
connections. Lowest edge of holes or cutouts
1) Sealant Materials
h. A. Provide sealing materials between precast concrete adjustment ring

and manhole cover frame in accordance with ASTM C 443.
C. Drop Connections and Y Connections
1. All manhole drop connections shall be outside drop. Outside drops shall be
provided with same pipe material and classification as sewer main as indicated
in the standard drawings.
2. Y connection shall be provided with same pipe material as sewer main and
with the same pipe classification as indicated in the standard drawings
D. Step Irons & Ladders
1. Step Iron
a. Step ironing rising main valve chambers shall be galvanized malleable

cast iron, shall conform to BS 1247, and shall be of general purpose
type. The tail length shall be 230 mm unless the well into which the tail
is to be cast is less than 290 mm thick.
b. Step irons in house connection chambers shall be galvanized malleable
cast iron and epoxy coated in accordance with BS 1247, and shall be of
general purpose type. The tail length shall be 230 mm unless the w all
into which the tail is cast is less than 290 mm thick.
2. Steel Ladders
a. Galvanized steel ladders shall be to the form and dimensions shown on

the Drawings, and as specified below:
1) Ladders shall comply with BS 539 5, Part 3.

2) Ladders greater than 6000 m shall be provided with an
intermediate platform
3) Stringers shall be solid flat sections of minimum size 65 mm by 13
mm
4) Fixing brackets shall be at maximum 2500 mm centers
5) Rungs shall be:
a) solid sections of minimum 20 mm diameter

b) at 250 mm centers
c) Minimum 400 mm wide between stringers
d) Minimum 200 mm from adjacent walls
e) Capable of withstanding a point load of 5000 N applied at
the center of the rung and close to one end

3. GRP Ladders
a. GRP material for ladders shall be fabricated from structural quality

fiberglass shapes with chemical and ultraviolet resistance. Resin shall be
all vinyl ester. Glass shall be all ECR and GRP thickness shall be a
minimum 5 mm. The top surface shall be provided with a non-slip silica
sand finish. The structural components shall have Class I fire
retardance, with an ASTM E84 flame spread rating of 25 maximum.
Fiberglass components shall have an ultimate tensile strength of 20 7
MPa, an ultimate compressive strength of 207 MPa, a modulus of
elasticity of 20.7 GPa, and a Barcol hardness of 50.
b. All cut or trimmed edges of the GRP ladder and braces shall be flow
coated with an approved vinyl ester resin. Glass fibres shall not be
exposed.
E. Frame and covers
1. Manholes
a. Ductile iron kite marked to BS EN124 Class D400 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. 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.
c. Warm applied black bitumen coat (paint) to BS 3416 and special coats
for protecting covers.
d. All covers shall be non-rock preventing noise and vibration.
e. Clear opening dimensions shall be as indicated on drawings.
f. Each cover should be badged with:
1) The name and/or identification mark of the manufacturer

2) The marking of the standard
3) The appropriate class
4) The badge of the project and usage subject to engineer’s approval
2. Inspection Chamber
a. Ductile iron kite marked to BS EN124 Class D400 when located under
the road and Class C 250 when located under the landscape area 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.

3. Soakaway
a. Ductile iron kite marked to BS EN124 Class C250 solid top circular
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.

F. Protective Coating:
1. Shall conform to the requirements of Section 071000 “CORROSION

PROTECTION AND ODOR CONTROL".
PART 3 EXECUTION
3.1 GENERAL
A. Specialists, Inspection and Testing
1. 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.
2. 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.
3. To the extent ordered by the Engineer, the Contractor shall provide labor,
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.
4. 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.
B. Soil Corrosivity Study
1. 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.
2. Soil resistivity’s 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.
3. 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.
C. Setting Out and Pipeline Alignment
1. 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.
2. Pressure pipelines shall be laid accurately to the lines levels and depths shown
on the approved drawings. Where changes of direction are required,
deflections shall be made in accordance with the manufacturer’s
recommendations.
D. Tools for Installation and Testing
1. The Contractor shall supply all necessary tools for cutting, chamfering, jointing,
and testing and for any other requirement for satisfactory installing the
pipelines.
E. Inspection During Installation
1. Pipes and fittings including any sheathing, inside linings and outside coatings,
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:
a. Material required for the repair of pipe, sheathing, linings and coatings
shall be obtained by the Contractor and shall be used in accordance
with the manufacturers recommendations
b. 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

c. 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.
F. Dewatering
1. All pipeline installation work shall be carried out in the dry.

2. Dewatering shall be carried out as specified in 31 00 00 Earthwork.
G. Closures and Short Sections
1. 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.
H. 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, 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
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.
I. Stringing of Pipes

1. 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.
2. 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.
3. After a pipe has been strung and immediately before being laid, it shall be
cleaned out and inspected for defects. Cast or ductile iron pipes shall be rung
with a light hammer while the pipe is suspended clear of the ground to detect
cracks. Other pipes shall be visually inspected. Any defective, damaged or
unsound pipe shall be rejected. Any damage to the lining or coating of the
pipe shall be repaired or the pipe rejected as directed by the Engineer.
J. Inspection of Trench Formation
1. 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.
3.2 JOINTS
A. Push fit Joints
1. 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.
2. 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.
B. Mechanical Joints
1. 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.
C. Anchorage
1. Anchorage lugs shall be provided for socket and spigot fittings and socket
clamps and tie rods used where there is a possibility of pulling the joint under
pressure. Concrete thrust blocks shall be used in lieu of the above where
socket and spigot pipe is used below ground. The Contractor shall submit, for
the Engineer’s approval, working drawings and information demonstrating the
adequacy of anchorage systems other than thrust blocks or other systems
shown on the Contract Drawings.
3.3 PIPE LAYING
A. General
1. Except as otherwise specified in this Clause, pipe bedding shall conform to the
requirements specified in 31 00 00 EARTHWORK. 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.
2. 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.
3. 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.
4. 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.
5. 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.
6. 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.
7. 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.
8. Whenever work ceases on any pipeline the unfinished end of the pipeline shall
be securely closed with tight fitting plug or cover.
9. 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.
10. 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:
11. 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 colors and be not less than l50 mm deep, straight and
level
12. 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
13. Boning rods and sight rails shall not be removed until the pipeline has been
checked and approved by the Engineer
14. Alternative methods of locating and leveling pipelines may be allowed subject
to the approval of the Engineer
15. Any pipe which is not in true alignment, both vertically and horizontally, or
shows any undue settlement after laying, shall be taken up and relaid correctly
by the Contractor
16. 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
17. The trench shall be kept completely dry
18. In no case shall pipes be jointed before being lowered into position
19. The gasket should be positioned and lubricated.
B. Laying of Rigid and Semi Rigid Pipes
1. In trench pipes with flexible joints except where concrete bed, bed and
surround or protection is required shall be laid on a well compacted bed of
granular material extending for the full width of the trench and with sufficient
material at the sides to permit the pipes to be worked into the granular
material and firmly supported to true line and level. Sufficient space should be
left to enable the joints to be made tested and inspected but the Contractor
shall ensure that at least three quarters of the pipe length is fully supported.
After the pipeline has been tested and approved by the Engineer the trench
shall be carefully filled to 300 mm above the crown of the pipe with granular
material in accordance with the bedding requirements specified in Part 2 of
this Section and as shown on the Drawings.
C. Concrete Protection to Pipe
1. Where shown on the Drawings or directed by the Engineer, pipe shall be

encased, haunches or backfilled with concrete.
D. Service Lateral Connections:

1. Service connection fittings and lines shall in diameter as shown in drawings
and as supplied by the manufacturer of the gravity sewer pipe unless required
otherwise by ENGINEER.
2. All fittings located on the lateral shall be incidental and not be a separate pay
item. Laterals shall be PVC according to ASTM D3034 or ASTM D2751,
respectively, unless otherwise shown. Minimum wall thickness shall be SDR 35
for installations less than 16 feet in depth, and SDR 26 for installations from 16
to 25 feet in depth.
3. Connections of new service laterals to sanitary sewers shall be accomplished
by means of a compression fit service connection. The service connection shall
be specifically designed for this connection. Connections to the sanitary
sewers shall be installed per the manufacturer’s installation instructions.
4. Minimum slope for lateral service lines shall be one percent (1.0%). All
specifications for gravity sewer lines and appurtenances shall apply to lateral
service lines. Unless otherwise shown on the plans or directed by the
ENGINEER, all service laterals shall be installed in a trench with a maximum
width as per this specification.
5. At the locations shown on the plans, or as required by the ENGINEER, service
laterals shall be installed in an encasement pipe by boring and jacking as
shown on the plans. A sufficiently large boring pit shall be excavated to allow
for proper alignment of the drilling equipment and to allow the service lateral
to be pushed through the encasement pipe. The horizontal alignment of the
encasement pipe shall not vary more than two (2) feet at the upstream end of
the service lateral from a line drawn at right angles to the sanitary sewer at
the wye branch or riser.
E. WYE Branches
1. Location: In general, wye branches shall be placed in the main sewer opposite
each lot or property to which a house service may be extended.
2. Existing Sewers: Where a wye branch is to be installed in an existing sewer, the
CONTRACTOR will be permitted to tap the sewer pipe and install the wye as
directed by the ENGINEER. Wyes shall only be installed on the type of pipe for
which they were designed. Wyes shall be approved by the ENGINEER.
3. Wyes shall be of the same material, strength, and joint as the sewer main
pipe.
4. Where the wye branch is not designed for use with PVC service pipe,
appropriate adapters shall be used to connect the lateral to the wye branch.
F. RISER PIPE:
1. Where the cover on the wye branch is in excess of twelve feet below average
ground surface, a 45 degree bend and sufficient riser pipe (also installed at a
45 degree slope) shall be added to terminate at a depth of twelve feet below
the ground surface, provided the property being served will not require
additional depth.
G. CLOSURES
1. Where no riser pipe or lateral is installed with the wye branches, the outlet of

each wye branch shall be securely sealed with a restrained water tight closure
that can be later removed without damage to the outlet.
2. PVC: All closures at the ends of PVC wye branches, risers or service laterals
shall be made by installing a length of PVC pipe to the wye branch, riser or
service lateral and solvent cementing PVC cap to the spigot end. A sufficient
length of pipe should be installed to permit removal of the closure and
extending the line in the future. Mechanical plugs shall not be permitted.
3. All closures shall be capable of passing the sewer leakage test(s).
H. WYE POLES:
1. A wye pole shall be placed at the end of each wye branch, riser, or house
service, as the case may be, extending to a point 6 inches below the end of the
pipe to hold it firmly in position during backfilling. If the wye pole is pulled out,
bent, or broken, the CONTRACTOR shall, at no cost replace or straighten the
pole. The wye pole shall be adjacent to the end of the pipe but not above it or
against it.
2. Material: Wye poles shall be not less than a standard 2 x 4 and shall extend a
minimum of 3 feet above the finished grade. The material used for wye poles
shall be in good condition and shall be straight, sound and free from large or
loose knots
I. Backfilling
1. The requirements of 31 00 00 EARTHWORK shall apply, except as otherwise

J. Deflection at Joints
1. Where the Engineer orders or allows a change of direction to deflect pressure

pipelines from a straight line, either in the vertical or horizontal planes to
avoid obstruction or where long radius curves are permitted, the amount of
deflection allowed shall not exceed that required for satisfactory connection
of the joint and shall be approved by the Engineer. Where a change of
direction cannot be made by deflection at the joints of ordinary straight pipes,
bends shall be used. The locations of such bends and other specials are shown
on the Contract Drawings and their exact positions will be determined by the
Engineer on the Site.
K. Anchor and Thrust Blocks
1. 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.
2. 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.
3. No pressure shall be applied to thrust blocks until the concrete has matured
for at least seven days
L. Connections to Existing Pipelines
1. At locations shown on the Contract Drawings or as instructed by the Engineer,

the Contractor shall connect the new pipelines to the existing pipelines or
structures but not until the said pipelines have passed the final tests.
M. Cleanliness of Pipelines
1. Pipelines and manholes shall at all times be kept free of all silt1 mortar1 debris
and other obstructions. When work is not in progress the open ends of the
pipeline shall be securely plugged with an approved watertight plug or stopper
firmly fixed to resist unauthorized removal. Claw type plugs or any type liable
to damage the pipe shall not be used. All such stoppers1 plugs or caps shall be
provided with a vent incorporating a valve for the purpose of testing whether
the pipeline is under pressure or vacuum and to enable pressures to be
equalized before its removal.
2. The Contractor shall clear the inside of each fitting and pipe length
immediately before jointing and shall swab all fittings and pipe lengths to
remove all dirt1 sand or other matter that may clog the pipeline or
contaminate the fluid to be transported in the pipeline. After j ointing1 the
interior of the pipes shall be freed from any dirt, stones or other matter that
may have entered them. For this purpose, a rubber disc, brush, or other
suitable implement that will not harm the internal lining of the pipe shall be
pulled through the pipe after jointing.
N. Marker Tape
1. All trenches for pressure pipelines, 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.
3.4 MANHOLES AND SPECIAL STRUCTURES
A. General
1. The Contractor shall construct all manholes, chambers, and special structures
including transition chambers and outfall structures as indicated on the
drawings and herein specified.
2. Manholes, chambers, Soakaway and special structures shall conform in shape,
size, dimensions, materials, and other respects to the details indicated on the

drawings or as ordered by the Engineer.
B. Construction of Manholes, Chambers, Soakaway and Special Structures
1. All manholes, chambers, Soakaway and special structures shall have

reinforced-concrete bases as detailed on the drawings. Manhole bases for
storm-sewers less than 600 mm and bases for chambers may be recast or cast
in place at the Contractor's option and as approved by the Engineer. For
precast reinforced-concrete manhole 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 manhole and special structure bases shall be
cast in place as indicated on the drawings.
2. Manhole, Soakaway and chamber cover slabs shall be cast in place reinforced
concrete as marked on the drawings. The ductile iron frames and covers for
manholes and 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.
3. The inverts shall conform accurately to the size of the adjoining pipes. Side
inverts shall be curved and main inverts (where direction changes) shall be laid
out in smooth curves of the longest possible radius which is tangential, within
the manhole, to the centerlines of adjoining pipelines all as indicated on the
drawings and instructed by the Engineer.
4. The ductile iron frames, grates and covers shall be to the BS EN 124 standard
frame, grate and cover as indicated on the drawings and hereinafter specified
in this Section.
5. All benching and channel shall be formed with 30/10 concrete unless shown
otherwise on the drawings.
6. Manhole walls shall be plain Class A concrete formed to the shape and
thickness shown on the drawings by the use of sound formwork material to
give a fair faced finish.
7. GRP lining to walls 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.
8. 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.
9. Pipes entering and leaving manholes, chambers and special structures shall be
laid soffit to soffit unless otherwise shown on the drawings.
10. 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.
11. Manholes and chambers shall be completely constructed as the Works
progress and as each one is reached by the pipe work. Frames and covers shall
be placed immediately after the completion of the manhole and chamber.
12. Soakaways for storm drainage shall be constructed with concrete masonry

bricks.
13. The soakaway shall be surrounded with a graveller hard core backfill to
prevent clogging.
C. Pre Cast Manhole /chamber Installation
1. Examination
a. Verify that lines and grades are correct.

b. Determine if subgrade, when scarified and compacted, can be
compacted to 95 percent of maximum Standard Proctor Density
according to ASTM D 698 prior to placement of foundation material and
base section. When proper density is not reached, moisture condition
subgrade until that density is reached or treat as unstable subgrade.
c. Do not build manholes in ditches, swales, or drainage paths unless
approved by Engineer.
2. Placement
a. Install precast manholes to conform to locations and dimensions as

shown on Construction Drawings.
b. Place sanitary manholes at points of change in alignment, grade, size,
pipe intersections, and end of sewer unless otherwise directed by
Engineer
3. Manhole Base Sections and Foundations
a. Place precast base on 6 inch thick (minimum) foundation of crushed

stone, or concrete foundation slab.
b. Unstable Subgrade Treatment: when unsatisfactory material is
encountered in the manhole subgrade. With Engineer approval, up to
12 inches of additional undercut may be permitted to achieve suitable
foundation. If the additional undercut does not result in a satisfactory
foundation, the Contractor shall obtain a bedding design prepared by a
Geotechnical Engineer licensed in the state in which the project is being
constructed.
4. Precast Manhole Sections
a. Install sections, joints, and gaskets in accordance with manufacturer's

printed recommendations.
b. Install precast adjustment rings above tops of cones or flat-top sections
as required to adjust finished elevation and to support manhole frame.
c. Seal any lifting holes with non-shrink grout.
d. Where fiberglass liners are required, seal joints between sections in
accordance with manufacturer's recommendations.
e. Precast concrete grade rings shall be permitted to achieve the required
grade.
f. Grade rings shall not be permitted to more than 12 inches.
g. External joint wrap all riser joints to ensure seal. No grout is permitted
on the interior of manhole riser joints prior to testing.

h. Concrete base must be dry prior to setting any sections above it.
D. soakaways
1. Soakaways shall be constructed using precast concrete rings. Concrete

works shall comply with the requirements (concrete section) of the
specification. Concrete shall be grade C40 for the precast concrete rings
and the cover slab, using Moderately Sulphate Resisting Portland Cement.
2. The cover slab shall be of the dimensions and contain the reinforcement
as shown on the drawings.
3. The structural concrete shall be designed for durability and shall include
as a minimum the following specification:
 minimum cover 75mm
 all surfaces to be painted with a protective coating meeting the
requirements of section Corrosion Protection and Odor Control
Section
 Any reinforcement shall be epoxy coated in accordance with BS
7295.
4. The soakaways shall have an internal diameter of 1.5 m unless

otherwise designated and shall be of a maximum depth of 2.5 m
unless otherwise designated.
5. The precast concrete rings shall be at least 150 mm thick and shall
have three evenly spaced lifting points.
6. No permanently embedded metal parts shall be left with a cover less
than 40 mm from the surface. The precast rings shall be constructed
with 50 mm diameter holes at 400 mm centres in rows spaced 300
mm apart. The holes shall be alternately offset.
7. The bottom ring shall be founded on in situ blinding concrete 200 mm
deep.
8. The soakaway shall be surrounded by granular material which shall
infill the whole void between the soakaway and the undisturbed
ground around the excavation.
9. The granular material shall be laid in tamps in 150 mm layers and shall
nowhere be less than 225 mm in width.
10. The granular material shall be clean crushed rock from a source
approved by the Engineer.
11. The nominal size shall be 75 mm. The material passing a 0.075mm
sieve shall not exceed 5%.
12. Ductile iron covers and frames shall be to BS EN 124 of the designated
loading class B 125.
13. Filter fabric material lining to the outside of the soakaway excavation
shall be Terram, grade 1000 The placing and laying of the material
shall be in accordance with the manufacturer’s instructions and
14. The geotextile material shall not be left exposed to the sun for a
period greater than 7 days before burying.
E. Building in Pipes to Structures

1. 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.
2. All internal and external protection membranes to the concrete shall be sealed
around the pipe openings as recommended by the membrane manufacturer.
When the pipe is later fixed, the remaining hole shall be re-formed and filled
with non-shrink grout.
3. 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.
4. 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.
5. Where it is impracticable to cast pipes and specials in the concrete, box outs
shall be provided in the formwork. The box shall have six or eight sides,
depending on the pipe diameter, and shall be no larger in size than will give
adequate clearance for the subsequent positioning and grouting in of the pipe.
The sides of the box out shall be provided with a tapered central annular
recess to provide a positive key. The box out shall be provided with a grout
hole and, at the top of the central annular recess a vent hole. The box hole
shall be stripped with the main formwork and the concrete surface thoroughly
cleaned and roughened.
6. Unless otherwise shown on the Contract Drawings, where pipes pass through
a concrete wall or structure they shall be protected with a surround of Grade
20 SRC concrete integral with the external face of the structure. For pipes of
less than 500 mm diameter, the surround shall extend from the wall or
structure by 300 mm and the width and depth of the surround beyond the
outside face of the pipe at its horizontal and vertical diameters shall be a
minimum of 300 mm or as otherwise indicated on the Drawings. For pipes of
500 mm diameter or greater the surround shall extend from the wall or
structure by 500 mm and the width and depth of the surround beyond the
outside face of the pipe at its horizontal and vertical diameters shall be 500
mm or as otherwise indicated on the Drawings.
7. On socket and spigot pipelines except those of GRP or other plastic materials
the socket end of the pipe passing through the wall shall be flush with the
outside face of the concrete surround. On socket of spigot pipelines of GRP or
other plastic materials the socket end of the pipe passing through the wall
shall protrude 300 mm from the concrete surround. A protective synthetic
rubber strip 6 mm thick and 150 mm wide shall be provided around the pipe at
the limit of the concrete surround as shown on the Contract Drawings.
8. On all other flexibly jointed pipes the plain end of the pipe shall protrude from
the concrete surround by a maximum of 300 mm or that distance required to
properly make the joint.
9. The first pipe that is clear of concrete surround beyond the external face of a
concrete wall or structure shall be a short length of either spigot and socket or
double spigot to suit the flow direction and pipe material. The effective length
of this pipe shall be 1.5 times the nominal bore or 600 mm whichever is the
greater.

10. For mechanically jointed pipes the plain end shall protrude from the surround
by a maximum of 300 mm or that distance required properly to make the
joint.
11. Where the structure is tanked, Grade 20 OPC concrete shall be used and the
tanking shall extend to the concrete surround.
F. Property Connections Survey
1. The Contractor shall complete and submit to the Engineer for approval a
standard record sheet of every property connection.
2. The Contractor shall carry out a survey of existing facilities and prepare
individual sketch plans at 1:500 scale for each property for which a sewerage
connection is required. These shall show existing plot boundaries, location of
property and location of all affecting services including septic tanks. These
shall be marked up to show the details of the proposed service connection and
shall be submitted to the Engineer for approval. No service connection work
shall begin before approval to the proposed layout has been received in
writing from the Engineer.
3. In special cases only, an inspection chamber may serve more than one service
connection. Locations of inspection chambers and the layout of service
connections shall be as approved by the Engineer.
4. Service connections shall be laid at sufficient depths to allow for adequate
gradient being continued throughout the properly drainage system without
the pipelines becoming too shallow for adequate cover to be provided over
the pipe.
G. Future House Connections
1. Service connections shall be laid up to the property boundary and an end cap
with a marker post shall be provided at the termination of each service
connections. The Contractor shall produce accurate records of the exact
locations of all service connections.
H. Step Iron and Ladders
1. Steps shall be thoroughly cleaned and given a protective coal tar epoxy
coating. The cleaning shall be done by suitable means to ensure that the
surfaces to be coated are free from foreign matters. After the steps have
been cleaned, rinsed and dried, apply the coating and allow drying before
installing in concrete.
2. Installation of steps shall not begin until concrete receiving them has attained
its sufficient strength. Embedment into walls shall be as recommended by the
manufacturer; no shrink cement formulation shall be used for pointing.
3. Steps shall be located to provide a continuous vertical distance from the
manhole rim to the top surface of the bottom slab at intervals of 300 mm, plus
or minus 40 mm and shall be installed in a manner to be capable of
withstanding a force of 160 kgs applied on the step at any place and in any
direction with no permanent deformation.
I. Inverts for Sanitary Sewers

1. A. Construct invert channels to provide smooth flow transition waterway with
no disruption of flow at pipe-manhole connections. Conform to following
criteria:
a. Slope of invert bench: 1 inch per foot minimum; 1-1/2 inches per foot
maximum
b. Depth of bench to invert:
1) Pipes smaller than 15 inches: one-half of largest pipe diameter

2) Pipes 15 to 24 inches: three-fourths of largest pipe diameter
3) Pipes larger than 24 inches: equal to largest pipe diameter
c. Invert slope through manhole: 0.10 foot drop across manhole with
smooth transition of invert through manhole, unless otherwise
indicated on Construction Drawing.
2. Form invert channels with concrete if not integral with manhole base section.
3. For direction changes of mains, construct channels tangent to mains with
maximum possible radius of curvature. Provide curves for side inlets and
smooth invert fillets for flow transition between pipe inverts.
J. Manhole Covers and Frames
1. Manhole 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. Manhole covers for sewerage, surface water and treated sewage effluent
systems shall have the following words embossed in both English and Arabic,
respectively:
a. Sewage water: Drainage Sewage Water
3. The size of lettering shall be approved by the Engineer.

4. 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
manhole covers shall be of the closed type.
5. 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.
6. 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.
7. 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.

3.5 BUILDING SERVICE LINES
A. Install sanitary sewer service lines to point of connection within approximately 1500
mm outside of buildings where service is required and make connections. Coordinate
the invert and location of the service line with the Contractor installing the building
lines.
B. Connections of service line to building piping shall be made after the new sanitary
sewer system has been constructed, tested, and accepted for operation by the
Resident Engineer. The Contractor shall install all temporary caps or plugs required
for testing.
C. When building services have not been installed at the time when the sanitary sewer
system is complete, provide temporary plugs or caps at the ends of all service lines.
Mark the location and depth of the service lines with continuous warning tape
placed 300 mm above service lines
3.6 INSPECTION OF SEWERS
A. 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. Lips at joints on the inside of gravity sewer lines are not
acceptable.
3.7 TESTING
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. 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.
C. 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.
D. 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.
E. Sewage Pressure Pipeline
1. The pipeline shall be tested between valve chambers or into sections not
exceeding 400 m in length approved otherwise by the Engineer. The section
tests shall be carried out as follows:
a. Each pipeline or section thereof shall be filled with water and all air
removed as far as possible
b. The pressure shall then be raised by pumping in water until the test
pressure is reached and shall be maintained at this level by further
pumping until it is steady
c. Pumping shall then be stopped and the time taken for the observed
pressure to fall by 1.0 m shall be recorded
d. Pumping shall then be resumed and the quantity of water pumped in
order to restore the test pressure shall be recorded
e. If after three hours the test pressure has not fallen by 1.0 m, pumping
shall be resumed at that stage, the time being recorded as three hours
f. The rates of loss shall then be calculated as the recorded quantity
divided by the recorded time
g. The test pump and gauge shall be connected to the pipeline at a
location other than the highest point in the pipeline to facilitate release
of air from the highest point
h. The test pressure shall be such that the entire pipeline or section being
tested is subjected to 1.5 times the working pressure, 1.25 times the
maximum surge pressure or 800 kPa, whichever is the greatest
i. The loss shall not exceed 0.02 liters per mm diameter per kilo meter per
24 hours for each 0.1 MPa of head applied
j. If the pipeline fails to pass the test, the faults shall be located and
repaired and the pipeline retested until it passes the pressure test. All
exposed pipe, fittings, valves and joints shall be visually inspected
during the tests.
2. When all sections have been joined together after completion of section
testing, unless otherwise directed by the Engineer, the entire pipeline shall
than be subjected to final test as follows:
a. All joints between individual test sections shall be left uncovered during
this final test
b. The final test shall be carried out using the same procedure as the
section test
c. In all cases of water tests, where the measured leakage rate exceeds
the allowable, the Contractor shall, at his own expense, make all
necessary repairs and carryout additional testing until a satisfactory
result is obtained
d. Before pressure testing is started the Contractor shall recheck pipes and
valves for cleanliness and shall recheck the operation of all valves. The

“open” ends of the pipeline or sections thereof) shall normally be
stopped off by blank flanges or cap ends additionally secured where
necessary by temporary struts and wedges. All anchor and thrust
blocks shall have been completed and all pipe straps and other devices
intended to prevent the movement of pipes shall have been securely
fastened
e. Since valves cannot be guaranteed to be perfectly drop-tight, testing
against closed valves which are connected to an existing system shall be
prohibited; testing against other closed valves (including air valves) not
so connected, may be attempted if desired, provided the valves are
suitably anchored against thrust. No claims whatsoever will be
entertained on account of leaking valves, or any other difficulties in
closing off lengths of pipework for testing, which shall be entirely an
obligation of the Contractor
f. On successful completion of the final test, the exposed joints shall be
covered and the trench backfilled
F. Testing of Water Retaining Structures
1. All water retaining structures shall be visually inspected to confirm that there
is no infiltration. Where it is required by the Engineer, water retaining
structures shall be tested for water tightness. The structure shall be filled with
fresh water and shall stand for a period of three days, to allow for absorption.
The structure shall be considered satisfactory if, subsequent to this period,
there shall be no fall in level over a period of 24 hours (after making the
allowance for rainfall and evaporation) and there shall be no visible leaks, or
damp surface areas.
2. This shall be carried out before any backfilling and before the application of
any external concrete protection has taken place. Any damages revealed as a
result of such tests shall be made good to the satisfaction of the Engineer.


ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP STROM WATER COLLECTION
KSA NETWORKS 334100- 2970 1

CONTENTS
SECTION 334100
STORM WATER COLLECTION NETWORKS
Page
PART 1 GENERAL 2
1.4 Submittals 8
PART 2 PRODUCTS 13
2.1 Warning Tapes 13
2.2 Geotextile 14
2.3 Pipe And Fittings 14
2.4 Anchorage 22
2.5 Grout 23
2.6 Storm Drainage Structures 23
2.7 Nonpressure-Type Pipe Couplings 29
2.8 Flap Valve 30
2.9 Pitching-Stone Fabrication 31
2.10 High Density Polyethylene Liner (Hdpe) 32
2.11 Pipe Outlets 35
PART 3 EXECUTION 35
3.1 General 35
3.2 Joints 38
3.3 Pipe Laying 39
3.4 Manholes And Special Structures 47
3.5 Testing 54
3.6 Riprap 57
3.7 Storm Water Inlet And Outlet Installation 58
Storm Utility Drainage Piping Section 334100

Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 1 of 58
SECTION 334100 – STORM WATER COLLECTION NETWORKS
PART 1 GENERAL
A Drawings and general provisions of the Contract, including General and Supplemen-
B Related Sections:
1- Division 03 Section 032100 "Concrete and Reinforced Concrete”

2- Division 03 Section 033000 "Concrete Cast-in-place."
3- Division 04 Section 042000 “Unit Masonry Assemblies”
4- Division 07 Section 071000 “Corrosion Protection And Odor Control".
5- Division 31 Section 310000 “Earthwork”.
A This section covers gravity pipes, pressure pipes work for the conveyance of storm
water as indicated on Drawings and specified here in addition to all types of storm
structure such as manholes, slow down chambers, catch basins, soak away and in-
spection chambers as required by the Contract. Extent of these structures is indicat-
ed on Drawings.
B The Contractor shall provide equipment, materials, transportation and labor required
for proper construction of the structures
A The work shall be performed in strict accordance with the stipulations of the National
Water Company (NWC) Latest Edition, British Standard Specifications (BS) and the
American Standards (ASTM) as noted herein below or other equivalent approved
Standards and Sound Practice.
UPVC pipe and fittings

BS No.

BS 3532 Method of specifying unsaturated polyester resin systems
BS 4346 Joints and fittings for use with un-plasticised PVC pressure pipe
BS 4660 Un-plasticised polyvinyl chloride (PVC-U) pipes and plastics fit-
tings of nominal sizes 110 and 160 for below ground gravity
drainage and sewerage

BS 5481 Un-plasticised PVC pipe and fittings for gravity sewers
BS 5556 General requirements for dimensions and pressure ratings for
pipe of thermoplastic materials
ISO NO.
ISO 4633 Rubber seals-Joint rings for water supply, drainage and sewerage
pipelines -- Specification for materials
ISO 4435 Unplasticized poly (vinyl chloride) (PVC-U) pipes and fittings for
buried drainage and sewerage systems – Specifications
ASTM NO.
ASTM D 2583 Indentation hardness of rigid plastics by means of a Barcol Im-
presser.
ASTM D 638 Standard Test Method for tensile properties of Plastics.
D2466 Specifications for Poly Vinyl Chloride (PVC) plastic Pipe Fittings,
Schedule 40
D1784 Standard specification for rigid Poly Vinyl Chloride (PVC) com-
pounds and chlorinated poly Vinyl Chloride (CPVC)
D2321 Standard practice for underground installation of thermo-

plastic pipe for sewer plastic pipes using flexible elastomeric
seals.
D3034 Standard specifications for type PSM (PVC) sewer pipe and fit-
tings.
D2412 Determination for External Loading Characteristics of Plastic

Pipe by Parallel Plate Loading.
F477 Elastomeric Seals (Gaskets) for Jointing Plastic Pipes

F789 Standard specification of type PS-46 (PVC) plastic gravity flow
sewer pipe and fittings.
AWWA C908 2001 PVC self-tapping saddle trees for use on PVC pipe (revi-
sion of ANSI/AWWA C908-97)
AWWA C909 Standard for Molecularly Oriented Polyvinyl Chloride (PVCO)
Pressure Pipe, 4 In. Through 24 In. (100 mm Through 600
mm), for Wastewater Service

GRP pipe and fittings

BS No.
BS 7159 Code of practice for design and construction of glass reinforced

plastics (GRP) piping systems for individual plants or sites.
BS 3749 Specification for E glass fiber woven roving fabrics for rein-
forcement of polyester and epoxy resin systems.
BS 3396 Woven glass fiber fabrics for plastics reinforcement.
BS 3496 Specifications for E glass fiber chopped strand mat for rein-
forcement of polyester and other liquid laminating systems.
BS 3532 Method of specifying unsaturated polyester resin systems.
BS 3691 Specification for E glass fiber roving for reinforcement of poly-
ester and epoxy resin systems.
BS 4504 Sect. 3.1 Circular flanges for pipes valves and fittings (PN Des-
ignated)
ASTM NO.
AWWA C 950 Glass Fiber Reinforced Thermosetting Resin Pressure Pipe.
AWWA M 45 Manual of water supply practiced. Fiber glass pipe design.
VC pipe and fittings

BS No.
BS 65 - 1991 Vitrified clay pipes, fittings and ducts, also flexible mechanical
joints for use solely with surface water pipes and fittings
BS EN 295-5:1994 Vitrified clay pipes and fittings and pipe joints for drains and
sewers.
ASTM NO.
ASTM C 425 Specification for Compression Joints for Vitrified Clay Pipes and
Fittings.
ASTM C 700 Specification for Vitrified Clay Pipes Extra Strength, Standard
Strength and Perforated
ASTM C 479 Standard Specification for Vitrified Clay Liner Plates

RC pipe and fittings
BS No.
BS 4027, Sulphate-resisting Portland cement

BS 5178, Specifications for pre-stressed concrete pipes for drainage
and sewerage
ASTM NO.
A82 Specification for Steel Wire, Plain, for Concrete Reinforcement
A185 Specification for Steel Welded Wire, Fabric, Plain, for Concrete
Reinforcement
A496 Specification for Steel Wire, Deformed, for Concrete Rein-

forcement
A497 Specification for Steel WELDED wire Fabric, Deformed for Con-
crete Reinforcement
A615/A615 Specification for Deformed and Plain Billet-Steel Bars for Con-
crete Reinforcement
C14M Specification for Concrete Sewer, Storm Drain, and Culvert Pipe
(Metric)
C33 Specification for Concrete Aggregates
C39 Test Method -from compressive Strength of Cylindrical Con-

crete Specimens
C150 Specification for Portland Cement
C309 Specification for Liquid Membrane-Forming Compounds for

Curing Concrete
C497M Test Methods for Concrete Pipe, Manhole Sections or Tile

(metric)
C595/ C595M Specification for Blended Hydraulic Cements
C618 Specification for Fly Ash and Raw or Calcined Natural Pozzolan
for Use as a Mineral Admixture in Concrete
C822 Terminology Relating to Concrete Pipe and Related Products
C1116 Specification for Fiber-Reinforced Concrete and Shoterete

ASTM NO.
IS0 4633, Rubber Seals - Joint Rings For Water Supply, Drainage and
Sewage Pipelines - Specification for Materials.
AWWA 651 Disinfecting water mains
ASTM D 2412 Standard Test Method for Determination of External loading
characteristics of Plastic pipe by Parallel plate loading.
ASTM D 2290 Standard Test Method for Apparent Tensile Strength of ring or
tubular plastics and reinforced plastics by Split Disk Method.
ASTM D 2584 Standard Test Method for Ignition Loss of cured Reinforced
Resins.
ASTM D 3517 Specification for Fiberglass Pressure Pipe
HDPE pipes and fittings:
ASTM NO.
ASTM D1599 Standard Test Method for Resistance to Short-Time Hydraulic Pres-
sure of Plastic Pipe, Tubing, and Fittings
ASTM D2412 Determination for External Loading Characteristics of Plastic Pipe by
Parallel Plate Loading
ASTM D2657 Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fit-
tings
ASTM D 3350 Standard Specification for PE Pipe & Fittings Materials
ASTM D 3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
ASTM D 3035 Standard Spec for PE Pipe (DR-PR) Based on Controlled
Outside Diameter
ASTM F 894 Specification for Polyethylene (PE) Large Diameter Profile Wall

BS No.

BS 5556 General Requirements for dimensions and pressure ratings for pipe of
thermoplastic materials
BS 6437 Polyethylene pipes (type 50) in metric diameters for general purpose
BS 6076 Tubular Polyethylene film for use a protective sleeving for buried iron
pipes and fittings
BS EN 681 part 1- Elastomeric Seals
BS EN 1092 part 2- Circular flanges for pipes, valves, fittings and accessories
BE EN 1515 part 1- Flanges and their joints- Bolting: selection of bolting
ISO No.
ISO 11414 Plastics pipes and fittings -- Preparation of polyethylene (PE)

pipe/pipe or pipe/fitting test piece assemblies by butt fusion
ISO 161-1 Thermoplastics pipes for the transport of fluids -- Nominal outside di-
ameters and nominal pressures -- Part 1: Metric series
ISO 3458 Mechanical joint fittings for use with polyethylene pressure pipes for
irrigation purposes
ISO 4427 Plastics Piping Systems -- Polyethylene (PE) pipes and fittings for wa-
ter supply -- Part 1: General, Part 2: Pipes and Part 3: Fittings
ISO 4633 Rubber Seals – Joint Rings for Water Supply, Drainage and Sewage
Pipelines – Specification for Materials
ISO 1167 Thermoplastics pipes for the conveyance of fluids - Resistance to in-
ternal pressure - Test method
methods.
parameters.
ISO 3126 Plastic pipes - Measurement of dimensions.
ISO 4065 Thermoplastic pipes - Universal wall thickness table.
ISO 4607 Plastics - Methods of exposure to natural weathering.
General test method.
ISO 6259 Thermoplastics pipes - Determination of tensile properties - Part 3 Poly-
olefin pipes.
ISO 6964 Polyolefin pipes end fittings - Determination of carbon black content by
calcination and pyrolysis- Test method and basic specification.
ISO 1183 Plastic - Methods for determining the density and relative density of
non-cellular plastic.

ISO 1133 Plastic - Determination of the melt mass flow rate (MFR) melt volume
rate (MVR) of thermoplastics.
ISO/TR 9080 Thermoplastics pipes for the transport of fluids - Methods of
extrapolation of hydrostatic stress rupture data to determine the longterm
hydrostatic strength of thermoplastics pipe materials.
ISO/TR 10837 Determination of the thermal stability of polyethylene (PE) for use in
gas pipes and fittings.
ISO 11420 Method for the assessment of the degree of carbon black dispersion
in polyolefin pipes, fittings and compounds.
ISO 11922-1 Thermoplastics pipes for the conveyance of fluids - Dimensions and
tolerances Part1: Metric series.
ISO 12162 Thermoplastics materials for pipes and fittings for pressure applications
-Classification and designation - Overall service (design) coefficient.
ISO 13761 Plastics pipes and fittings - Pressure reduction factors for polyethylene
pipeline systems for use at temperatures above 20°C.
ISO 13949 Method for the assessment of the degree. of pigment dispersion in
polyolefin pipes, fittings and compounds.
PPI TR-4 Plastic Pipe Institute, Technical Report No. 4
BS 8005- PART 1 Guide to New sewerage construction.
Chambers and structure covers and frames
BS No.
BS 8005 Sewerage Guide to New Sewerage Construction
BS 5750 Quality assurance in productions and installation
BS 5911 Specification For Inspection chamber and street gullies
BS EN 124 Manhole Covers, Road Gully Grating and Frames
BS 1247 Manhole Step Irons
1.4 SUBMITTALS
A Pipes
1. Material technical specifications list and manufacturer’s data of the pipes in-
clude its jointing material (rubber gaskets), fittings/ accessories, bedding ma-
terial and geo-textiles.
2. Material Certificates of compliance.
3. Materials Sample.
4. Method statement of pipelines construction.
5. Shop drawings.
6. Record drawings.
7. Maintenance data.
8. Certificates of origin.
B Storm Structure
1. Detailed design and calculations for different types of storm water structures
and storm water chambers.
2. Shop drawings for all types of cast-in-situ concrete structures and chambers
3. Materials list, original catalogue, certificate of origin and manufacturer's data
sheet of the ductile iron frames, covers, steps, grout, waterproofing of the
storm water structure.
4. Representative samples of the ductile iron frames, covers and steps.
5. Method statement of the storm water structure.
6. Shop drawings of the ductile iron frames and covers installation.
7. Shop drawings of the steps installation.
8. Record drawings of each structure.
A Products Criteria
1. Multiple Units: When two or more units of the same type or class of materials
or equipment are required, these units shall be products of one manufacturer
2. Nameplates: Nameplate bearing manufacturer's name, or identifiable trade-
mark, including model number, securely affixed in a conspicuous place on
equipment, or name or trademark, including model number cast integrally
with equipment, stamped, or otherwise permanently marked on each item of
equipment.
jurisdiction over the connection to Public Sanitary Sewer lines and the exten-
sion, and/or modifications to Public Utility Systems.
B Inspection
1. Inspection and Test by the Manufacturer: Pipe and fittings shall be thoroughly
inspected by the manufacturer before delivery. The manufacturer shall make
all tests as specified herein and the results of the tests shall be furnished to
the Contractor upon request in accordance with mutually acceptable ar-
rangements. The manufacturer may use his own or other suitable facilities for
the performance of the inspection and test requirements specified herein. On
the sample pieces selected for inspection, the inside diameter of the spigot
end shall be checked by suitable gauges. Fittings shall be suitably inspected for
soundness and brittleness.
2. Inspection and Test by the Contractor: Inspection and tests may be made at
the manufacturer plant or at other suitable facilities. If made at the place of
manufacture, the manufacturer shall provide, without charge, all reasonable
facilities to be determined that the material is in accordance with this specifi-
cation.
3. Contractor's Responsibility: The Contractor shall furnish materials, equipment,
transportation services and skilled experienced. Laborers necessary to com-
plete the work as indicated or as required. The Contractor shall be responsible
to complete the work in accordance with the Specifications and Drawings in-
cluding details related to this section and necessary works for complying with
requirements contained therein. Contractor shall grantee and be responsible
for keeping all other existing utilities working in healthy conditions. Any dam-
age –caused by the contractor- to the existing utilities shall be repaired on the
contractor cost. Moreover, contractor shall be claimed accordingly.
C Testing:
1. Materials and installed work may require testing and retesting at any time dur-
ing the progress of work. Tests, including retesting of rejected materials or in-
stalled work, shall be done at the Contractor's expense.
D Rejection:
1. Materials, fabricated parts and pipes that are discovered to be defective or

that are not conforming to requirements shall be subjected to rejection at any
time. Rejected materials and pipes shall be removed from the site.
A Each pipe, fitting and special appurtenance shall be marked with permanent identifi-
cation which shall include but not necessarily limited to the following:
1. Nominal diameter
2. Name or trade mark of manufacturer
3. Serial number
4. Class of pipe, pressure rating in compliance with referenced standards
5. Date of manufacture
6. Type of service
7. Details on fittings such as angle of change and taper
B 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:
1. The manufacturer at the place of manufacturer

2. The Engineer
3. A third party on behalf of the Engineer
C The Engineer shall be permitted at all reasonable times to visit places of manufacture
to witness tests.
D Transport, handling and storage of pipes and fittings shall be carried out as follows:
1. In accordance with the manufacturer’s recommendations subject to the ap-

proval of the Engineer
2. Effective precautions shall be taken to prevent damage to the pipe and fittings.
E During transport

1. Pipes and fittings shall be well secured and adequately supported along their
length.
2. Bolsters and binding of approved type shall be used.
3. Nesting of pipes (placing a smaller pipe inside a larger) may be permitted for
pipes of certain materials and size provided that methods statements demon-
strate that effective precautions will be taken to protect all pipe surfaces and
coatings from damage.
4. No pipe shall overhang the end of a vehicle.
5. Pipes and fittings of plastic materials shall be covered.
F Handling shall be carried out as follows:
1. Pipes should be lifted singly and not handled as bunches.

2. Pipes shall be handled only by means of approved hooks; curved plate fit the
curvature of the pipe, on ends of sections.
3. Fabric slings not less than 250 mm wide.
4. Other methods approved for the pipe used.
5. Use of wire rope, chains and fork lift trucks will not be permitted.
6. For strings of pipe longer than the standard length precautions shall be taken
to avoid curvature and longitudinal stress in excess of allowable limits.
7. Pipes and fittings of plastic materials.
a. Smaller than 300 mm diameter may be handled manually.

b. larger than 300 mm diameter and greater than 4 meters in length shall
be lifted using fabric lifting straps or large diameter rope slings posi-
tioned at a quarter of the pipe length from each end.
c. There should be enough slack in the slings to keep the hook approxi-
mately 600 mm over the pipe.
d. Steel chain or hooks shall not come into contact with the pipe.
8. Pipes and fittings shall not be dropped or bumped.

9. Pipes shall not be dragged over the ground.
10. If rolled, pipes shall be rolled only over adequate timber bearers to prevent
damage.
11. Where necessary, chocks shall be used to prevent lateral movement of pipes.
G Storage of pipes shall be as follows:
1. All pipes, fittings and materials shall be stored in accordance with the ap-
proved 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:
e. In accordance with the manufacturer’s recommendations but not to a
greater number of tiers than the following:
1) Pipes diameter ≥ 900 mm : 2 tiers

2) Pipes diameter < 900 mm ≥ 600 mm : 3 tiers
3) Pipes diameter < 600 mm : 4 tiers
2. Suitable protective packing shall be placed between tiers to the approval of the
Engineer
3. Wrapped pipes shall not be stacked
a. If spigot and sock et, stacked so that successive pipe layers have sockets
protruding at opposite ends of the stack
b. With pipes of different sizes and thickness stacked separately
c. With maximum height of stacked pipes not exceeding 2m, or that rec-
ommended by the supplier if less than 2 m.
d. Plastic pipes will be stored under cover and not exposed to the sunlight.
4. Storage of jointing materials shall be as follows:
a. Under cover
b. Rubber ring gaskets shall
1) Be stored in their original packing

2) Not be exposed to sunlight
3) Protected from exposure to greases and oils
c. Gasket lubricants shall be stored so as to prevent damage to the con-

tainer.
5. Pipes and fittings shall be protected in storage to the approval of the Engineer
by means of an impermeable membrane which shall cover the pipes and fit-
tings and separate them from the ground on which they are supported. The
membrane shall be strong and durable in the prevailing climate conditions.
6. Pipes and fittings shall be subject to visual inspections after off-loading at site
and before installation.
7. 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 to the Engineer for approval.
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 Storm 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
C The tape shall be 150 mm wide and 250 micron thick and produced as a strong com-
posite 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)

2. Tensile strength: According to BS EN ISO 527 – 3
a. Longitudinal (MD) : 160 N (Minimum)

b. Transversal (TD) : 150 N (Minimum)
3. Elongation (PE only): BS EN ISO 527 – 3
a. MD : 450%
b. TD : 550%
4. Tear Strength: BS 2782
a. MD: 640 gram force

b. TD: 700 gram force Minimum
5. Dart Impact: BS 2782 : P3 : 352F : 1000 grams minimum

6. Chemical resistance :
a. The tape shall be remaining legible and color 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 pre-
sent in sub soil and water, oil, 5% Acetic Acid, 5% NaOH and Alcohol mix,
if any.
7. Detectability after installation and back filling
a. Text in Arabic and English indicating the protected services lying below
the tape shall be permanent ink bonded to resist prolonged chemical at-
tack by corrosive acids and alkalis with the message repeated at a maxi-
mum 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
1) Storm Water: Yellow

2) CAUTION: Storm Below
3) Storm pressure mains: Yellow
4) CAUTION: Storm Water Pressure Main Below
2.2 GEOTEXTILE
A Geotextile for Pipe Bedding (Filter Fabric)
1. Geotextile 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 Engi-
neers 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
D1682.
4. The burst strength as measured by the Diaphragm Method of ASTM D3786
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
2.3 PIPE AND FITTINGS
A Un-plasticized PVC Pipes (according project conditions) preferred for diameter up to

315 mm
1. General
a. The material from which pipe, fitting and accessories is produced shall
consist of substantially un-plasticized polyvinyl chloride. Only those ad-
ditives that are needed may be used for the manufacture of the poly-
mer, and for its conversion into sound, durable extrusions or molding of
good surface finish, mechanical strength and opacity.
b. UPVC pipes shall not be deteriorated or broken down under the effect of
bacteria or other micro-organisms.
c. Shall be as uniform as commercially practical in color, opacity, density
d. The pipes, fittings and accessories shall have a registered certification
mark on, or in relation to a product, as an assurance that the goods have
been produced under the scheme of supervision control and testing in
accordance with the certification mark scheme. Fittings and accessories
shall comply with ASTM D 2466.
e. Shall be recommended as conduits for the conveyance of potable water
f. Shall have chemical inertness and exceptionally smooth internal surface
g. Shall have long service life, resistance to chemicals and excellent corro-
sion resistance.
h. Shall be of great mechanical resistance to external and internal loadings.
i. Shall have the property of absorption of linear expansion or contraction,
j. Shall have absolute tightness at the jointing points regardless of whether
there is an over or under-pressure in the network.
k. Properties of pipes shall meet the requirements of the physical, chemi-
cal and mechanical characteristics as mentioned hereinafter.
2. Properties:
a. Classification of Pipes: Pipes shall be manufactured in accordance with

DIN 9534, DIN 8061 part 1andASTM D3034 SDR 35capable to withstand
a working pressure of 6kg/ cm2
b. Dimensions: Pipe shall conform to the outside diameters, inside diame-
ter and wall thickness specified by the above mentioned standard.
c. Lengths: Pipes shall be supplied in straight lengths, normally of 3 m, 6 m
and 9 m or as denoted in Bill of Quantities and approved by the Engi-
neer.
d. Cutting to Length and Chamfering: Pipes shall be of such kind that can be
cut to length using fine tooth wood saw or hacksaw and of an end which
can be chamfered with one of the special hard tools developed for shap-
ing plastics.
e. Physical and Thermo-technical Characteristics:
1) General Properties: UPVC pipes shall be manufactured by extru-

sion and shall have low specific gravity.
2) Appearance: The pipes shall be reasonably round, homogeneous
throughout, free from voids, cracks, and other defects that would
impair the performance in service; and as uniform as commercial-
ly practical in color, density, and other physical properties.
3) Pipe surface shall be free nicks, scratches, and other blemishes.
The joining surfaces of pipe shall be free from gouges and other
imperfections that might cause leakage at joints.
4) The internal and external surface of the pipe shall be smooth,
clean and reasonably free from grooving and other defects. The
ends of the pipes and fittings shall be cleanly cut and square with
the axis of the component. The pipe shall be reasonably straight.
5) Specific Gravity: Specific gravity of pipes shall not be less than
1380 kg/m3 and not more than 1425 kg/m3.
6) Heat Reversion: When tested in accordance with the manufactur-
ing standards, no point all around the pipe shall have a length
change by more than 5% at 150 ± 2° C. After testing, the pipe
shall show no faults, e.g. cracks, cavities or blisters.
7) Opacity: The pipe shall be full opacity and when tested the wall of
the pipe shall not transmit more than 0.2% of the visible light fall-
ing on to it.
8) Coefficient of Linear Expansion: Expansion shall be 1 mm change
in length at 22°C for each 5°C rise or fall in temperature allowance
for every 1 meter length of pipe when operating at temperature
above ambient.
f. Chemical Characteristics:
1) Water Absorption: Pipes shall be tested for water absorption, a

sample shall be completely immersed in water for a 24 hours at
100° C, this test shall meet the requirements of the Standard
Specifications of the country of origin.
2) Resistance to Acetone: Pipes shall not delaminate or disintegrate
after 2 hours immersion in anhydrous acetone at room tempera-
ture, examination at 20 minute intervals.
3) Toxic Substances: Pipes shall conform with the requirements to
toxic substances which shall ensure that the recommendations of
the World Health Organization 1963 concerning toxic contami-
nants of drinking water are not exceeded.
4) Resistance to Sulphuric Acid: According to the manufacturing
standards, the mass of the tested specimen shall neither increase
by more than 3.16 g nor decrease by more than 0.13 g.
g. Mechanical Characteristics:
1) Extruded pipes shall have high mechanical characteristics and

shall fulfill the following requirements:
a) Tensile strength: 3.5 kgf/mm2, minimum

b) Modulus of elasticity: 197 kgf/mm2, minimum
c) Impact strength: 3.55 kgf/cm at notch, minimum
d) Deflection temperature under load: minimum: 0.1856
kgf/mm2: 55° C minimum
3. Marking:
a. All pipes shall be indelibly marked at interval of not greater than 3m or

as specified in the origin Standards.
b. Pipe markings shall include the following marked continuously:
1) Manufacturer’s Name
2) Nominal Size
3) Class Pressure Rating
4) Identification Code
4. Jointing
a. Solvent Cement: Solvent cement joints are acceptable only up to size DN

50mm as per the applicable code of practice for the fittings. The solvent
cement shall be of non-toxic quality suitable for drinking water service.
Fittings shall conform to BS 4346 Part 1/BS EN 1452.
b. Push-on Joints: Pipes shall be laid with a gap between the end of the
spigot and the base of the socket. This gap shall not be less than 10 mm
or greater than (1/3) one third of the straight draw of the pipe joint.
c. Rubber Rings: Rubber sealing rings supplied with pipes or fittings shall
be synthetic rubber rings, shall comply with the requirements of the
Standard Specifications of ASTM F 477 Table No. 1.
d. Rings shall be smooth and free from air marks and other blemishes.
e. Rings shall be homogenous, free from porosity, grit, blisters and visible
surface imperfections. The rubber shall not contain more than one part
by weight of paraffin wax per hundred part of rubber.
f. Rubber rings when tested by immersion in water at a temperature of 25
± 1° C for 7 days shall not absorb more than 3% by weight of water.
g. Rings shall be rapid-installing even in rainy, windy, or hot weathers.
h. Only tiny deformation of the material while socketing and forming
grooves may be accepted at the discretion of the Engineer.
5. Lubricant
a. Shall be the type recommended by manufacture for use with the em-
ployed pipes and no substitute is allowed.
6. Certification
a. The Contractor shall provide the conformance certification of the manu-

facturer, test results or copies of test reports. These reports shall in-
clude all the previously mentioned physical, chemical and mechanical
characteristics concerning the pipes.
B GLASS REINFORCED PLASTIC PIPES (GRP) (according project condition and preferred
for diameter greater than 315 mm)
1. General
a. The pipe or fitting shall be constructed using chopped and/or continuous

glass filaments, strands or rovings, mats or fabric, synthetic veils, and
polyester resin with or without fillers and if applicable additives neces-
sary to impart specific properties to the resin. The pipe or fitting may al-
so incorporate aggregates, and if required, a thermoplastics liner.
2. Reinforcement:
a. The glass used for the manufacture of the reinforcement shall be one of
the following types:
1) A type 'E' glass, comprising primarily either oxides of Silicon, Alu-

minum and Calcium (alumino–calcosilicate glass) or Silicon, Alu-
minum and Boron (alumino-borosilicate glass);
2) A type 'C' glass, comprising primarily oxides of Silicon, Sodium, Po-
tassium, Calcium and Boron (alkalicalcium glass with an enhanced
boron trioxide content) which is intended for applications requir-
ing enhanced chemical resistance.
b. In either of these types of glass small amounts of oxides of other metals

will be present.
c. The reinforcement shall be made from continuously drawn filaments of
a glass conforming to type E or type C, and shall have a surface treat-
ment compatible with the resin to be used. It may be used in any form,
e.g. as continuous or chopped filaments, strands or rovings, mat or fab-
ric.
d. Resin: The resin used in the structural layer shall have a temperature of
deflection of at least 70 °C when
e. The test specimen is tested in accordance with Method A of EN ISO 75-2.
f. Aggregates and fillers: The size of particles in aggregates and fillers shall
not exceed 1/5 of the total wall thickness of the pipe or fitting or 2,5
mm, whichever is the lesser.
g. Elastomers: Each elastomeric material(s) of the sealing component shall
conform to the applicable requirements of EN 681-1.
h. Metals: Where exposed metal components are used, there shall not be
evidence of corrosion of the components after the fitting has been im-
mersed in an aqueous sodium chloride solution, 30 g/l, for seven days at
(23 ± 2) °C.
3. Wall construction
a. Inner layer
1) The inner layer shall comprise one of the following:

a) A thermosetting resin layer with or without aggregates or
fillers and with or without reinforcement of glass or syn-
thetic filaments;
b) A thermoplastics liner.
2) NOTE: The thermoplastic liner may require a bonding material

compatible with all other materials used in the pipe construction.
b. Structural layer
1) The structural layer shall consist of glass reinforcement and a

thermosetting resin, with or without aggregates or fillers.
c. Outer layer
1) The design of the outer layer of the pipe shall take into account
the environment in which the pipe is to be used. This layer shall
be formed of a thermosetting resin with or without aggregates or
fillers and with or without a reinforcement of glass or synthetic
filaments.
2) The of use special constructions is permitted when the pipe is ex-
pected to be exposed to extreme climatic, environmental or
ground conditions, for example provision for the inclusion of pig-
ments or inhibitors for extreme climatic conditions or fire retarda-
tion.
d. Appearance
1) Both internal and external surfaces shall be free from irregulari-

ties, which would impair the ability of the component to conform
to the requirements of this European Standard.
4. GRP Pipe Joint
a. Flexible joint
1) Which allows relative movement between the pipes being joined,

these types of joint are:
a) Socket-and-spigot joint with an elastomeric sealing element

(including double socket designs);
b) Locked socket-and-spigot joint with an elastomeric sealing
element (including double socket designs);
c) Mechanical clamped joint e.g. bolted coupling including
joints made from materials other than GRP.
d) End-load-bearing flexible joints have resistance to axial
loading
b. Rigid joint
1) Which does not allow relative movement between the pipes being
joined, these types of joint are:
a) Flanged joint, including integral and loose flanges;

b) Wrapped or cemented joint.
c) Non-end-load-bearing rigid joints do not have resistance to
axial loading
5. GRP Pipe Classifications
a. Categories
1) Pipes and fittings shall be classified according to nominal size

(DN), nominal pressure (PN) and joint type.
2) In addition pipes shall include nominal stiffness (SN) in their classi-
fication.
b. Nominal size
1) The nominal size (DN) of pipes and fittings shall conform to the
appropriate Tables in Clause 5 BS 14364. If a thermoplastics liner
is present, its internal diameter shall be declared by the manufac-
turer. The tolerance on the diameter shall be as specified in
Clause 5 BS 14364.
c. Nominal stiffness
1) The nominal stiffness, SN, shall conform to one of those given in

Table 1 (see footnotes a to c).
2) Where special applications require the use of pipes having a high-
er nominal stiffness than those given in Below Table, the pipe
shall be marked SN v, where v is the number equal to the pipes
nominal stiffness.
Nominal stiffness’s (SN)
Nominal stiffness’s a b c Nominal stiffness’s a b c

(SN) (SN)
500 2500
630 4000
1000 5000
1250 8000
2000 10000
d. This nominal stiffness’s correspond to the values specified in Clause 5 BS

14364 for the minimum initial specific ring stiffness, in Newton per
square meter (N/m2).
e. Pipes of nominal stiffness less than SN 1000 are not intended for laying
directly in the ground.
f. The selection of pipe stiffness shall be in accordance with the recom-

mendations given in ENV 1046 based on loading, backfill materials and
native soils.
g. Nominal pressure
1) The nominal pressure (PN) shall conform to one of those given in

Table 2.
2) Where pressure ratings other than the nominal values in below
Table are to be supplied, by agreement between the manufactur-
er and the purchaser, the pressure marking PN on the component
shall be replaced by PN v where v is the number equal to the
components nominal pressure.
Nominal pressure
(PN)
1 12.5
2.5 16
4 20
6 25
10 32
NOTE: Components marked PN1 are non-pressure (gravity) components.
3) Stiffness shall be minimum 5000 N/m2 for all pipes but for pipes
to be used in pumping stations and valve chambers the stiffness
shall be minimum 10,000 N/m2 and pipes for use in micro-
tunneling or similar jacking operations the stiffness shall be mini-
mum 50,000 N/m2 unless enclosed in concrete.
h. Inspection and Testing
1) Test certificates for all type tests and other tests specified in this
Clause shall be submitted to the Engineer.
2) The results of type tests appropriate to the proposed pipes and
fittings shall be used to determine the properties of pipes. Each
type test shall have been carried out on pipes or fittings repre-
sentative of the pipes to be used. The following type tests shall be
conducted at the manufacturer’s works in accordance with the
requirements of BS 5480 Part 2 except as noted, and the tests
shall be carried out at 25°C.
Property Test Method
Long-term stiffness and creep

Factor under any deflection
Long-term semi-permanent set Except that test results and ageing

factors shall be extrapolated to 60
years, at
Which time the failure strain must not
be less than 1%
Impact resistance
Long-term hoop tensile
External pressure resistance ASTM D2924
Strain corrosion test ASTM D3681
3) For the strain corrosion type test, samples of pipes representative

of those to be supplied shall be subjected to the strain corrosion
test in the Engineer’s presence if so directed, and evidence of con-
formance shall be furnished before commencement of manufac-
ture. Further regular tests shall be made by the manufacturer and
the results furnished as a feature of his quality control procedure.
Notwithstanding the requirements of ASTM D3681, any appear-
ance of blisters, delamination, wicking or other structural blem-
ishes shall be taken to mean that the pipe has failed and the end
point reached.
4) Longitudinal tensile strengths shall be determined in accordance
with BS 5480 and shall be carried out on one pipe in every 100
pipes of each class and diameter manufactured, or as directed by
the Engineer.
5) When subjected to a parallel plate load test in accordance with
ASTM D2412 the pipe shall reveal no evidence of crazing, cracking
at deflection of I0 percent, and no evidence of structural failure at
a deflection of 20 percent.
6) The Barcol hardness test to check resin cure shall be done on eve-
ry pipe or fitting at the manufacturer’s work.
7) One pipe in every 25 of each size shall be tested for loss of ignition
8) Checks of dimensional accuracy will be carried out by the Engineer
at Site. The Contractor shall destroy or indelibly mark as rejected
and remove from Site any pipes or fittings found at any time fail-
ing to meet dimensional criteria or any of the following quality cri-
teria:
a) Scratches shall be no deeper than 0.3 mm and no reinforc-

ing fibers shall be exposed
b) No cracks shall be present on the inside of pipes. Hair
cracks on the outside may be permitted with repair if not
longer than 200 mm circumferentially or 6 mm longitudinal-
ly. Impact cracks shall not affect more than 3 % of surface
area
c) No delamination shall be evident
d) No impact or other damage to pipe ends shall be evident.
The end surface of pipe or fitting shall be completely cov-
ered with resin and free from cracks, porosity, bubbles,
voids, exposed reinforcement or extraneous matter
e) No protruding fibers permitted on or jointing surfaces
f) No other protuberances. Small globules or resin projections
permissible if not more than 25 % of area is affected. Joint-
ing surfaces shall be completely free of any such flaws.
Ridges formed by resin shall not exceed 1.5 mm in depth
g) Air voids, blisters, bubbles are not acceptable if greater
than 5 mm diameter or 1mm depth. Subject to the approv-
al of the Engineer, if less than 0.5 % of internal areas are af-
fected, such defects may be ground out and repaired
h) Not more than 5 % of the internal or 10 % of the external
surface shall be affected by pitting. No individual pit shall
be more than 1 mm diameter or 0.5 mm depth
i) Wrinkles and indentations shall not be more than 2 mm
deep and not more than 3 % of surface area affected. Sub-
ject to the approval of the Engineer, if not more than 5 mm
deep and 0.5 percent of surface area is affected, such de-
fects may be repaired
j) Any pipe which when resting freely on the ground and not
subjected to any loads other than its own weight exhibits a
deflection of more than 2 %, measured along the diameter,
shall be rejected and removed from the Site. Tests for de-
flection of pipes after installation are specified in this Sec-
tion.
2.4 ANCHORAGE
A. Anchorage lugs shall be provided for socket and spigot fittings and socket clamps and
tie rods used where there is a possibility of pulling the joint under pressure. Con-
crete thrust blocks shall be used in lieu of the above where socket and spigot pipe is
used below ground. The Contractor shall submit, for the Engineer’s approval, work-
ing drawings and information demonstrating the adequacy of anchorage systems
other than thrust blocks or other systems shown on the Contract Drawings.
2.5 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 shrink-
age 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.
2. General purpose non shrink cementations grout.
3. Flow able (Precision) non shrink cementations grout.
B Non shrink Epoxy Grout
1. Non shrink epoxy-based grout shall be a pre-proportioned, three components,

and 100 percent solids system consisting of epoxy resin, hardener, and blend-
ed 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.
2.6 STORM DRAINAGE STRUCTURES
A Cast In Situ manhole and structures
1. 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 modu-
lus as defined in AASHTO M6 or (ASTM C125) shall not vary more
than 0.20 either way from the fineness modulus of the repre-
sentative 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 ac-
cordance 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 ag-
gregates used in Class E concrete no limit shall apply. The abrasion loss
when tested in accordance with ASTM C131 shall not exceed 25 per-
cent.
3) The water absorption of coarse aggregate (ASTM C127) shall not ex-
ceed 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 or ES No.
373
2) Sulphate Resisting Portland Cement shall comply with the require-
ments of BS 4027 or ASTM C 150 type V or ES No. 583
3) Super sulphated Cement shall comply with the requirements of BS
d. Water
1) Water for concrete, mortar and curing shall comply with 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 con-
taminating 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 ap-
proval to do so is granted by the Engineer.
e. Concrete:
1) Shall conform to Section 032100 "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 re-

quirements of BS 4027 or ASTM C150 type V.
c.
Water Complying with water for Concrete Mixes and curing, of the
Specifications Section 032100
g. Reinforcing
1) Reinforcing bars. Plain and deformed bars shall conform to BS 4449.
2) Mesh reinforcement shall conform to the specifications of ASTM des-

ignation 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.
h. Concrete Masonry Units:
1) Shall conform to Division-4 Section 042000 “Unit Masonry Assemblies”
B Precast Concrete Manholes and Chambers:
1. General:
a. Provide manhole sections, base sections, and related components con-

forming to ASTM C 478. Provide base riser section with integral floors,
unless shown otherwise. Provide adjustment rings which are standard
components of manufacturer of manhole sections. Mark date of manu-
facture and name or trade mark of manufacturer on inside of barrel.
b. Construct barrels for precast manholes from standard reinforced con-
crete manhole sections of diameter indicated on Standard Drawings.
Use various lengths of manhole sections in combination to provide cor-
rect height with fewest joints.
c. For manholes larger than 48-inch diameter, provide precast base sec-
tions with flat slab top precast sections used to transition to 48-inch di-
ameter manhole access riser sections. Transition can be concentric or
eccentric unless otherwise requested by Engineer. Locate transition to
provide minimum of 7-foot head clearance from base to underside of
transition unless otherwise approved by Engineer.
d. Design Loading Criteria: Manhole walls, transition slabs, cone tops, and
manhole base slab shall be designed, by manufacturer, to requirements
of ASTMC 478 for depth as shown on Standard Drawings and to resist
the following loads :-
1) AASHTO HS-20 vehicle loading applied to manhole cover and

transmitted down to transition and base slabs
2) Unit soil weight of 120 pcf located above portions of manhole, in-
cluding base slab projections
3) Lateral soil pressure based on saturated soil conditions producing
an atrest equivalent fluid pressure of 100 pcf
4) Internal liquid pressure based on unit weight of 63 pcf
5) Dead load of manhole sections fully supported by transition and
base slabs
e. Provide joints between sections with o-ring gaskets conforming to ASTM

C 443.
f. When base is cast monolithic with portion of vertical section, extend re-
inforcing in vertical section into base.
g. Precast Concrete Base: Suitable cutouts or holes to receive pipe and
connections. Lowest edge of holes or cutouts
2. Sealant Materials:
a. Provide sealing materials between precast concrete adjustment ring and

manhole cover frame in accordance with ASTM C 443.
C Drop Connections and Y Connections:
1. All manhole drop connections shall be outside drop. Outside drops shall be
provided with same pipe material and classification as main pipe lines as indi-
cated in the standard drawings.
2. Y connection shall be provided with same pipe material as main pipe lines and
with the same pipe classification as indicated in the standard drawings
D Step Irons
1. Step Iron
a. Step ironing rising main valve chambers shall be galvanized malleable

cast iron, shall conform to BS 1247, and shall be of general purpose type.
The tail length shall be 230 mm unless the well into which the tail is to
be cast is less than 290 mm thick.
b. Step irons in house connection chambers shall be galvanized malleable
cast iron and epoxy coated in accordance with BS 1247, and shall be of
general purpose type. The tail length shall be 230 mm unless the w all
into which the tail is cast is less than 290 mm thick.
2. Steel Ladders
a. Galvanized steel ladders shall be to the form and dimensions shown on

the Drawings, and as specified below:
1) Ladders shall comply with BS 539 5, Part 3.

2) Ladders greater than 6000 m shall be provided with an intermedi-
ate platform
3) Stringers shall be solid flat sections of minimum size 65 mm by 13
mm
4) Fixing brackets shall be at maximum 2500 mm centers
5) rungs shall be:
a) solid sections of minimum 20 mm diameter

b) at 250 mm centers
c) minimum 400 mm wide between stringers
d) minimum 200 mm from adjacent walls
e) capable of withstanding a point load of 5000 N applied at the
center of the rung and close to one end
3. GRP Ladders
a. GRP material for ladders shall be fabricated from structural quality fiber-
glass shapes with chemical and ultraviolet resistance. Resin shall be all
vinyl ester. Glass shall be all ECR and GRP thickness shall be a minimum
5 mm. The top surface shall be provided with a non-slip silica sand fin-
ish. The structural components shall have Class I fire retardance, with an
ASTM E84 flame spread rating of 25 maximum. Fiberglass components
shall have an ultimate tensile strength of 20 7 MPa, an ultimate com-
pressive strength of 207 MPa, a modulus of elasticity of 20.7 GPa, and a
Barcol hardness of 50.
b. All cut or trimmed edges of the GRP ladder and braces shall be flow
coated with an approved vinyl ester resin. Glass fibres shall not be ex-
posed.
E Frame And covers
1. Manholes:
a. Ductile iron kite marked to BS EN124 Class D400 solid top circular
covers are removable from the frame horizontally or vertically after re-
moving the metal safety pins. Circular frame over all flanged with an-
choring holes that can be used to fix the frame.

2. Soakaway
a. Ductile iron kite marked to BS EN124 Class C250 solid top circular

3. Catch Basin
a. Catch Basin Grating Cover and Frame: Ductile iron kite marked to BS
EN124 Class C 250 Hinged grate inlet type, grating should be of the sin-
gle type without cover. The grating should be fixed to the overall
flanged frame using suitable hinges. The hinges system should allow for
free removing of the grating from frame.
b. Clear opening dimensions shall be as indicated on drawings.
d. The cover should be freely removed from the frame
e. Warm applied black bitumen coat (paint) to BS 3416 and special coats
4. Outfall Manholes covers:
a. Ductile iron kite marked to BS EN124 Class D400 grating top circular
5. Mortar for Setting Covers:
a. Mortar shall consist of 1 part of cement to 2 parts of sand, by volume.
b. Cement shall be ordinary Portland cement to ES No. 373. Sand shall be

clean, hard and siliceous conforming to ES No. 1108.
F Protective Coating:
a. Shall conform to the requirements of Section 071000 “CORROSION

PROTECTION AND ODOR CONTROL".
2.7 NONPRESSURE-TYPE PIPE COUPLINGS
A Comply with ASTM C 1173, elastomeric, sleeve-type, reducing or transition coupling,

for joining underground non pressure piping. Include ends of same sizes as piping to
be joined, and corrosion-resistant-metal tension band and tightening mechanism on
each end.
B Sleeve Materials:
1. For Concrete Pipes: ASTM C 443, rubber.

2. For Plastic Pipes: ASTM F 477, elastomeric seal or ASTM D 5926, PVC.
3. For Dissimilar Pipes: ASTM D 5926, PVC or other material compatible with
pipe materials being joined.
C Unshielded Flexible Couplings: Elastomeric sleeve with stainless-steel shear ring and
corrosion-resistant-metal tension band and tightening mechanism on each end.
D Shielded Flexible Couplings: ASTM C 1460, elastomeric or rubber sleeve with full-
length, corrosion-resistant outer shield and corrosion-resistant-metal tension band
and tightening mechanism on each end.
E Ring-Type Flexible Couplings: Elastomeric compression seal with dimensions to fit in-
side bell of larger pipe and for spigot of smaller pipe to fit inside ring.
F Non pressure-Type Rigid Couplings: ASTM C 1461, sleeve-type reducing- or transi-

tion-type mechanical coupling molded from ASTM C 1440, TPE material with corro-
sion-resistant-metal tension band and tightening mechanism on each end.
G Quality Control and Documentation:
1. Prior to installation commencement of any geo-membrane material, provide

the following information certified by the manufacturer for the delivered geo-
membrane.
2. Origin, identification and production of the resin (supplier's name, brand name
and production plant).
3. Copies of quality control certificates issued by the resin supplier.
4. Manufacturer's certification verifying that the quality of the resin used to
manufacture the geo-membrane meets the specifications.
5. Each roll delivered to the project site shall have the following identification in-
formation:
a. Manufacturer's name
b. Product identification
c. Thickness
d. Roll number
e. Roll dimensions
6. Quality control certificates, signed by the manufacturer's quality assurance

manager. Each certificate shall have roll identification number, sampling pro-
cedures, and frequency and test results. At a minimum the following test re-
sults shall be provided in accordance with test method specified in above ta-
ble.
a. Thickness
b. Density
c. Tensile properties
d. Tear resistance
e. Carbon black content
f. Carbon black dispersion.
H Conformance Testing:
1. Conformance testing shall be performed by an independent Quality Assurance

Laboratory (QAL) approved by the Owner. A Quality Assurance Technician
(QAT) from the QAL shall obtain the samples from the roll, mark the machine
direction and identification number. The following conformance tests shall be
conducted at the laboratory:
a. Thickness
b. Density
c. Tensile properties
d. Tear resistance
e. Carbon black content
2. These conformance tests shall be performed in accordance with the above ta-
ble.
3. All conformance test results shall be reviewed by Engineer and accepted or re-
jected, prior to the placement of the geo-membrane. All test results shall
meet, or exceed, the property values listed in the above table. In case of fail-
ing test results, the manufacturer may request that another sample be retest-
ed by the independent laboratory with manufacturer's technical representa-
tive present during the testing procedures. This retesting shall be paid for by
the manufacturer. The manufacturer may also have the sample retested at
two different laboratories approved by the Owner. If both laboratories report
passing results, the material shall be accepted. If both laboratories do not re-
port passing results, all geo-membrane material from the lot representing the
failing sample will be considered out of specification and rejected.
2.8 FLAP VALVE
A General
1. Flap valves of GRP designed for ease of installation due to their low weight but
with exceptional mechanical strength and durability
2. GRP Flap Valves shall comply with the following:-
a. Resistant to 1bar (10m head) back pressure(Multi-CD 0.8 bar)

b. Most sizes can be handled by one person due to low weight
c. Low weight ensures ease of installation
d. High mechanical strength
e. High resistance to corrosion and ultraviolet degradation
f. Seals at a low level of back pressure
g. Low operating head due to low weight
h. Low maintenance
3. The design of the valve body shall be such that there is adequate clearance
around the back of the door to minimize jamming by rags and debris. Stops
shall be provided to limit the back lift of the disc and shall be positioned to
prevent fouling.
B Material Specification
Body & flap Glass reinforced plastic using a isophtalicpolyester res-

in with surface isophtalic gel coat
Hinge Self-lubricatingErtacetal plastic
Seal Ethylene Propylene Diene Monomer (EPDM)

to BS EN 681
Optional nitrile (NBR) seal available
Fittings Grade 316 austenitic stainless Steel to BS EN 10088-2
1. The CONTRACTOR may propose alternative types of check valves with all nec-
essary data to demonstrate an advantage to ENGINEER. The alternative pro-
posal will be evaluated during tender evaluation
2.9 PITCHING-STONE FABRICATION
A Riprap Slope protection: Stone for loose and grouted riprap shall consist of field
stones furnished in broad flat shapes to the maximum extent practicable and as indi-
cated in the design.
B All stone shall be hard, sound, durable, and highly resistant to weathering and shall
be suitable as protection material for the intended purpose.
C Samples of the stone material proposed for use in the Works shall be submitted to
the Ministry representative for approval prior to its use in the Work.
D The minimum apparent specific gravity shall be 2.5 and the maximum absorption
shall be 6% when tested in accordance with AASHTO T 85. The stone shall have an
abrasion loss not greater than 45% when tested in accordance with AASHTO T 96.
E Unless otherwise specified and approved by the Ministry representative, the weight
of stone for the various classes of riprap shall be as follows:
Weight of Stone (kilograms) % of Total Smaller than

Size Shown
Class A Class B Class C Class D

50 200 1,000 5,000 95-100
20 100 400 2,000 50-100
5 20 100 500 0-50
1 5 20 100 0-10
F Unless otherwise indicated on the Drawings or directed by the ENGINEER representa-

tive, stones for loose and grouted riprap shall conform to class B gradation. Each
stone shall generally weigh between 20 and 70 kg with at least 60% weighing more
than 45 kg.
G Stones for wire fabric enclosed riprap and for gabions, shall conform to Class A grada-
tion.
H Stone for loose riprap shall be quarried, fractured, or otherwise predominantly angu-
lar. Stone for other riprap and gabions may be rounded (boulders) or angular.
I Concrete slope protection: as indicated and as specified in Division 03 “CONCRETE”

and in accordance with Division 31 “EARTHMOVING”.
2.10 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, blis-
ters, undispersed raw materials, or any sign of contamination by foreign mat-
ter. The geo-membrane shall be free of plasticizers and other leachable addi-
tives.
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 Con-
tractor if the product is not suitable.
a. Properties
5. The geo-membrane rolls shall meet the minimum properties as per manufac-
turer recommendation and below table
6. HIGH DENSITY POLYETHYLENE (HDPE) GEOMEMBRANE

TEXTURED SHEET (BOTH SIDES)
Test
2
Property Unit Method Minimum
Thickness
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
(Each Direction) ASTM D638
1. Yield MPa 15.2 (2200 psi)

Strength N/cm min. 231 (132 lb/in)
2. Break MPa 10.3 (1500 psi)

Strength N/cm min. 158 (90 lb/in)
3. Elongation
at Yield % min. 13
4. Elongation
at Break % min. 150
Tear Resistance N/cm min. ASTM D1004 1313 (750 lb/in)

Puncture N 200 (45 lbs)
Resistance N/cm min. ASTM D4833 3152 (1800 lb/in)

N 480 (108 lbs)
Law
Temperature C max. ASTM D746 (-60)
Dimensional
Stability % max. ASTM D1204 +2.0
1 hour @ 1080
Environmental
1
Stress Crack Hours min. ASTM D5297 1500
Carbon Black
Content % range ASTM D4218 2.0 to 3.0
Carbon Black
1
Dispersion N/A rating ASTM D5596 A1, A2, or B1
1) This value represents the minimum acceptable test value for a roll
as tested according to Manufacturing Quality Control Manual.
b. Other Materials
1) Extradite welding rods shall be of the same compound as the geo-

membrane and supplied by the manufacturer and shall be deliv-
ered 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 struc-
tures shall fit snugly around the pipe and/or structure. Prefabri-
cated material shall be designed to fit site specific conditions for
the intended slope and size of pipe and structure.
c. Quality Control and Documentation
1) Prior to installation commencement of any geo-membrane mate-

rial, provide the following information certified by the manufac-
turer for the delivered geo-membrane.
2) Origin, identification and production of the resin (supplier's name,
brand name and production plant).
3) Copies of quality control certificates issued by the resin supplier.
4) Manufacturer's certification verifying that the quality of the resin
used to manufacture the geo-membrane meets the specifications.
5) Each roll delivered to the project site shall have the following
identification information:
a) Manufacturer's name
b) Product identification
c) Thickness
d) Roll number
e) Roll dimensions
6) Quality control certificates, signed by the manufacturer's quality

assurance manager. Each certificate shall have roll identification
number, sampling procedures, and frequency and test results. At
a minimum the following test results shall be provided in accord-
ance with test method specified in above table.
a) Thickness
b) Density
c) Tensile properties
d) Tear resistance
e) Carbon black content
f) Carbon black dispersion.
d. Conformance Testing
1) Conformance testing shall be performed by an independent Quali-

ty Assurance Laboratory (QAL) approved by the Owner. A Quality
Assurance Technician (QAT) from the QAL shall obtain the samples
from the roll, mark the machine direction and identification num-
ber. The following conformance tests shall be conducted at the
laboratory:
a) Thickness
b) Density
c) Tensile properties
d) Tear resistance
e) Carbon black content
2) These conformance tests shall be performed in accordance with

the above table.
3) All conformance test results shall be reviewed by Engineer and ac-
cepted or rejected, prior to the placement of the geo-membrane.
All test results shall meet, or exceed, the property values listed in
the above table. In case of failing test results, the manufacturer
may request that another sample be retested by the independent
laboratory with manufacturer's technical representative present
during the testing procedures. This retesting shall be paid for by
the manufacturer. The manufacturer may also have the sample
retested at two different laboratories approved by the Owner. If
both laboratories report passing results, the material shall be ac-
cepted. If both laboratories do not report passing results, all geo-
membrane material from the lot representing the failing sample
will be considered out of specification and rejected.
2.11 PIPE OUTLETS
A Head Walls: Cast-in-place reinforced concrete, with apron and tapered sides as indi-
cated in the drawing and as per Division 03 Concrete.
B Riprap Basins: Broken, irregular size and shape, graded stone according to NSSGA's
"Quarried Stone for Erosion and Sediment Control."
C Average Size: NSSGA No. R-5, screen opening 127 mm.
D Filter Stone: According to NSSGA's "Quarried Stone for Erosion and Sediment Con-
trol," No. FS-2, No. 4 screen opening, average-size, graded stone.
E Energy Dissipaters: According to NSSGA's "Quarried Stone for Erosion and Sediment
Control," No. A-1, 2700-kg average weight armor stone, unless otherwise indicated
PART 3 EXECUTION
3.1 GENERAL
A Specialists, Inspection and Testing
1. The Employer may employ the services of a specialist firm to assist the Engi-
neer as he may require in any matter connected with pipes, and fitting includ-
ing the inspection of materials and workmanship and the witnessing of tests at
any stage during the execution and maintenance of the Works.
2. 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.
3. To the extent ordered by the Engineer, the Contractor shall provide labour,
plant, tools and materials (but not special testing equipment) for direct assis-
tance 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.
4. The provision of labor, plant and materials a s aforesaid shall be an obligation
of the Contractor where in the Engineer’s opinion the inspection test or fur-
ther investigation shows that materials and workmanship provided by the
Contractor do not comply with the designated requirements.
B Soil Corrosivity Study
1. 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.
2. 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 tak-
en at 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.
3. 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 car-
bonates.
C Setting Out and Pipeline Alignment
1. All storm pipe lines shall be laid accurately to the lines, and levels gradients
shown on the approved drawings so that the pipeline is straight between suc-
cessive manholes in the vertical and horizontal planes.
2. Pressure pipelines shall be laid accurately to the lines levels and depths shown
on the approved drawings. Where changes of direction are required, deflec-
tions shall be made in accordance with the manufacturer’s recommendations.
D Tools for Installation and Testing
1. The Contractor shall supply all necessary tools for cutting, chamfering, jointing,
and testing and for any other requirement for satisfactory installing the pipe-
lines.
E Inspection During Installation
1. Pipes and fittings including any sheathing, inside linings and outside coatings,
shall be inspected by the Contractor immediately before and after installation,
and damage or other imperfection shall be repaired by the Contractor as di-
rected by the Engineer before installation and in accordance with the follow-
ing:
a. Material required for the repair of pipe, sheathing, linings and coatings
shall be obtained by the Contractor and shall be used in accordance with
the manufacturers recommendations
b. 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
c. 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 incorpora-
tion 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.
F Dewatering
1. All pipeline installation work shall be carried out in the dry.

2. Dewatering shall be carried out as specified in 31 00 00 Earthwork.
G Closures and Short Sections
1. For the purpose of reducing the angular deflections at pipe joints, and for clo-
sure 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 Con-
tractor shall be responsible for taking the measurements required to deter-
mine the lengths of cut portions of pipes for insertion as closing lengths in
pipelines.
H 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, 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.
I Stringing of Pipes
1. 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.
2. 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.
3. After a pipe has been strung and immediately before being laid, it shall be
cleaned out and inspected for defects. Cast or ductile iron pipes shall be rung
with a light hammer while the pipe is suspended clear of the ground to detect
cracks. Other pipes shall be visually inspected. Any defective, damaged or un-
sound pipe shall be rejected. Any damage to the lining or coating of the pipe
shall be repaired or the pipe rejected as directed by the Engineer.
J Inspection of Trench Formation
1. After excavations have been completed to the designated levels and, trench
formation compacted, the Contractor shall issue a formal notice to the Engi-
neer that the trench formation is ready between designated points for inspec-
tion. The Engineer will without unreasonable delay inspect the said trench
formation, unless he considers it unnecessary and advises the Contractor ac-
cordingly. Any rejection of trench formation will be confirmed in writing by
the Engineer.
3.2 JOINTS
A Push fit Joints
1. 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 pre-
vent inadvertent use, or the matter reported forthwith to the Engineer. If
more than three successive rings inspected in this way are rejected the Con-
tractor 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.
2. 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 po-
sition 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 en-
sure proper jointing. Care shall be taken to avoid twisting or cutting the ring
when jointing the pipe.
B Mechanical Joints:
1. 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.
C Anchorage:
1. Anchorage lugs shall be provided for socket and spigot fittings and socket
clamps and tie rods used where there is a possibility of pulling the joint under
pressure. Concrete thrust blocks shall be used in lieu of the above where
socket and spigot pipe is used below ground. The Contractor shall submit, for
the Engineer’s approval, working drawings and information demonstrating the
adequacy of anchorage systems other than thrust blocks or other systems
shown on the Contract Drawings.
3.3 PIPE LAYING
A General
1. Except as otherwise specified in this Clause, pipe bedding shall conform to the
requirements specified in 31 00 00 EARTHWORK. 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.
2. Each pipe shall be carefully lowered onto its prepared bed by means of appro-
priate 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.
3. No pipe shall be rolled into place for lowering into the trench except over suit-
able timber planking free from roughness likely to damage any coatings.
4. 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 Con-
tractor. The bench marks shall be approved by the Engineer.
5. 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.
6. 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 in-
terior. The pipeline shall be clean and unobstructed at the time of its installa-
tion and shall be true to the required line and levels.
7. 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.
8. Whenever work ceases on any pipeline the unfinished end of the pipeline shall
be securely closed with tight fitting plug or cover.
9. 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.
10. 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 pipes to regular curves. The placement of pipes shall comply
with the following requirements:
11. Each pipe shall be plumbed to its correct line and directly and accurately sight-
ed 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 colors and be not less than l50 mm deep, straight and level
12. 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
13. Boning rods and sight rails shall not be removed until the pipeline has been
checked and approved by the Engineer
14. Alternative methods of locating and leveling pipelines may be allowed subject
to the approval of the Engineer
15. Any pipe which is not in true alignment, both vertically and horizontally, or
shows any undue settlement after laying, shall be taken up and relaid correct-
ly by the Contractor
16. 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
17. The trench shall be kept completely dry
18. In no case shall pipes be jointed before being lowered into position
19. The gasket should be positioned and lubricated.
B Laying of Flexible Pipes
1. This clause does not apply to GRP pipes for which laying requirements are giv-
en in this Section.
2. All operations involving the laying, bedding, jointing, backfilling etc. of pipes of
plastic materials shall be strictly in accordance with the manufacturer’s rec-
ommendations subject to the approval of the Engineer.
3. 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 Specifica-
tion.
C Laying of Rigid and Semi Rigid Pipes:
1. In trench pipes with flexible joints except where concrete bed, bed and sur-
round or protection is required shall be laid on a well compacted bed of granu-
lar material extending for the full width of the trench and with sufficient mate-
rial at the sides to permit the pipes to be worked into the granular material
and firmly supported to true line and level. Sufficient space should be left to
enable the joints to be made tested and inspected but the Contractor shall en-
sure that at least three quarters of the pipe length is fully supported. After the
pipeline has been tested and approved by the Engineer the trench shall be
carefully filled to 300 mm above the crown of the pipe with granular material
in accordance with the bedding requirements specified in Part 2 of this Section
and as shown on the Drawings.
D Laying of UPVC Pipes
1. If any defective pipe is discovered after it has been laid, it shall be removed
and replaced with a sound pipe in a satisfactory manner by the Contractor, at
his own expense. All pipe and fittings shall be thoroughly cleaned before lay-
ing, 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 in-
stalled in accordance with requirements of the manufacturer except as other-
wise provide 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 permit-
ted. 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 en-
sure that such compaction equipment will not have a damaging effect on the
pipe. Equipment used in compacting the initial 900mm of backfill shall be ap-
proved by the pipe manufacturer's representative prior to use.
2. All pipe 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. Buried PVC pressure pipe shall be snaked along the trench to provide for ex-
pansion and contraction in accordance with manufacturer's recommenda-
tions.
5. The 100 mm PVC perforated pipe shall be installed in a trench with aggregate
filter media to a minimum depth of 500 mm. The aggregate filter media shall
have a minimum of 300 mm in thickness under the pipe and 100 mm over the
top of the pipe. Aggregate filter media shall have no fines smaller than 20 mm
and shall be covered with filter fabric before backfilling with soil.
6. Jointing PVC Pipe
7. Push-on type joints shall be made in strict accordance with the manufacturer's
instructions. Pipe shall be laid with bell ends looking upstream. A rubber gas-
ket shall be inserted in the groove of the bell end of the pipe, and the joint
surfaces cleaned and lubricated. The plain end of the pipe to be entered shall
then be inserted in alignment with the bell of the pipe to which it is to be
joined, and pushed home with a come-along or by other means. Check that
the reference mark on the spigot end is flush with the end of the bell.
a. Laying of Reinforced Concrete Pipes
8. Care shall be taken in loading, transporting, and unloading to prevent injury to

the pipe or fittings and the joint surfaces. Pipe or fittings shall not be dropped.
All pipe or fittings shall be examined before laying, and no piece shall be in-
stalled which is found to be defective.
9. As soon as the excavation is completed to the normal grade of the bottom of
the trench, place filter fabric and crushed stone in the trench, and the pipe
shall be firmly bedded in the crushed stone such that the invert of the pipe is
from 20 to 50mm above the lines and grades indicated on the Drawings.
Blocking under the pipe will not be permitted.
10. The line and grade of each pipe shall be verified after the crushed stone bed-
ding material is placed and before backfilling is started. The line and grade will
be deemed acceptable provided the pipe is installed within the following toler-
ances of the line and grade indicated on the drawings plus 20 mm- 50mm:
Invert Elevation Tolerance
Pipes smaller than 800 mm +10 mm

Pipes from 800 mm to 1200 mm inclusive + 20 mm
Pipes greater than 1200 mm +30 mm
Horizontal Alignment
All pipes + 50 mm
11. Some settlement of the pipe is expected during backfill operations; however,
the Contractor shall take the steps necessary to limit the total settlement from
the installed elevation to a maximum of 3 percent of the internal pipe diame-
ter. Differential settlements shall be limited such that the joints remain sealed,
the pipe or manhole is not damaged and the pipe installation is capable of
meeting the testing requirements specified herein.
12. Crushed stone shall be placed and compacted to give complete vertical and
lateral support for the lower section of the pipe as indicated on the Drawings.
A depression shall be left in the supporting bedding at the joint to prevent con-
tamination of the rubber gasket immediately before being forced home. Be-
fore the pipe is lowered into the trench, the spigot and bell shall be cleaned
and free from dirt. Gasket spigot and bell shall be lubricated by a vegetable
lubricant which is not soluble in water, furnished by the pipe manufacturer,
and harmless to the rubber gasket. The pipe shall be properly aligned in the
trench to avoid any possibility of contact with the side of the trench and foul-
ing the gasket. As soon as the spigot is centered in the bell of the bell of the
previously laid pipe, it shall be forced home with jacks or come-along. After
the gasket is compressed and before the pipe is brought fully home, each gas-
ket shall be carefully checked for proper position around the full circumference
of the joint. Steel inserts shall be used to prevent the pipe from going home
until the feeler gauge is used to check the final position of the gasket. The
jacks or come-along shall be anchored sufficiently back along the pipeline (a
minimum of 5 lengths) so that the pulling force will not dislodge the pieces of
pipe already in place. Only a jack or come-along shall be employed to force the
pipe home smoothly and evenly and hold the pipe while backfilling is in pro-
gress. Under no circumstances shall crowbars be used nor shall any of the mo-
tor driven equipment be used.
13. As soon as the pipe is in place and before the come-along is released, crushed
stone backfill shall be placed as indicated on the Drawings and packed carefully
by hand under the haunch of pipe for the length of pipe. Not until this backfill
is placed shall the come -along be released. If any motion at joints can be de-
tected, a greater amount of backfill shall be placed before pressure is released.
When pipe laying is not in progress, the open ends of the pipe shall be closed
by a watertight plug, bulkhead or other approved means. Precautions shall be
taken during this period to prevent flotation of the pipe.
14. Carefully regulate equipment and construction operations such that the load-
ing of the pipe does not exceed the loads for which the pipe is designed and
manufactured. Any pipe damaged during construction operations shall
promptly and satisfactorily be repaired or replaced at the Contractor's ex-
pense.
15. The interior joints of all pipes shall be filled with non-shrinking grout after the
backfilling and testing is completed. Grout shall consist of one part by volume
of cement, 1-1/2 parts by volume of sand, conforming to ASTM C33 and 1/4
part by volume of EMBECO metallic aggregate or equal. The mixture shall have
a dry, crumbly consistency and shall be pounded into place and toweled to
make a smooth joint.
E Concrete Protection to Pipe
1. Where shown on the Drawings or directed by the Engineer, pipe shall be en-
cased, haunches or backfilled with concrete.
F Deflection Criteria for Flexible Pipelines
1. All flexible pipelines will be subjected to deflection measurements at Site. Sec-

tions of pipe failing to meet the specified deflection criteria shall be removed
from the trench and relaid 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. If the perma-
nent 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 re-
placed by the Contractor.
2. 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 back-
filling, 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 disman-
tled and relaid.
3. 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.
4. Pipes exhibiting a deflection greater than 8% or 1.6 times the calculated allow-
able long term deflection, shall be exhumed, indelibly marked “REJECTED”,
removed from site and not reused.
G Service Lateral Connections:
1. Service connection fittings and lines shall in diameter as shown in drawings

and as supplied by the manufacturer of the gravity pipe unless required oth-
erwise by ENGINEER.
2. All fittings located on the lateral shall be incidental and not be a separate pay
item. Laterals shall be PVC according to ASTM D3034 or ASTM D2751, respec-
tively, unless otherwise shown. Minimum wall thickness shall be SDR 35 for in-
stallations less than 16 feet in depth, and SDR 26 for installations from 16 to
25 feet in depth.
3. Connections of new service laterals to sanitary sewers shall be accomplished
by means of a compression fit service connection. The service connection shall
be specifically designed for this connection. Connections to the sanitary sew-
ers shall be installed per the manufacturer’s installation instructions.
4. Minimum slope for lateral service lines shall be one percent (1.0%). All specifi-
cations for gravity pipe lines and appurtenances shall apply to lateral service
lines. Unless otherwise shown on the plans or directed by the ENGINEER, all
service laterals shall be installed in a trench with a maximum width as per this
specification.
5. At the locations shown on the plans, or as required by the ENGINEER, service
laterals shall be installed in an encasement pipe by boring and jacking as
shown on the plans. A sufficiently large boring pit shall be excavated to allow
for proper alignment of the drilling equipment and to allow the service lateral
to be pushed through the encasement pipe. The horizontal alignment of the
encasement pipe shall not vary more than two (2) feet at the upstream end of
the service lateral from a line drawn at right angles to the sanitary pipe lines at
the wye branch or riser.
6. WYE Branches:
a. Location: In general, wye branches shall be placed in the main storm

pipe line opposite each lot or property to which a house service may be
extended.
b. Existing pipe lines: Where a wye branch is to be installed in an existing
pipe lines, the CONTRACTOR will be permitted to tap the pipe and install
the wye as directed by the ENGINEER. Wyes shall only be installed on
the type of pipe for which they were designed. Wyes shall be approved
by the ENGINEER.
c. Wyes shall be of the same material, strength, and joint as the main pipe.
d. Where the wye branch is not designed for use with PVC service pipe, ap-
propriate adapters shall be used to connect the lateral to the wye
branch.
7. Riser Pipe:
a. Where the cover on the wye branch is in excess of twelve feet below av-
erage ground surface, a 45 degree bend and sufficient riser pipe (also in-
stalled at a 45 degree slope) shall be added to terminate at a depth of
twelve feet below the ground surface, provided the property being
served will not require additional depth.
8. Closures
a. Where no riser pipe or lateral is installed with the wye branches, the
outlet of each wye branch shall be securely sealed with a restrained wa-
ter tight closure that can be later removed without damage to the out-
let.
b. PVC: All closures at the ends of PVC wye branches, risers or service lat-
erals shall be made by installing a length of PVC pipe to the wye branch,
riser or service lateral and solvent cementing PVC cap to the spigot end.
A sufficient length of pipe should be installed to permit removal of the
closure and extending the line in the future. Mechanical plugs shall not
be permitted.
c. All closures shall be capable of passing the storm piping leakage test(s).
9. WYE Poles
a. A wye pole shall be placed at the end of each wye branch, riser, or house
service, as the case may be, extending to a point 6 inches below the end
of the pipe to hold it firmly in position during backfilling. If the wye pole
is pulled out, bent, or broken, the CONTRACTOR shall, at no cost replace
or straighten the pole. The wye pole shall be adjacent to the end of the
pipe but not above it or against it.
b. Material: Wye poles shall be not less than a standard 2 x 4 and shall ex-
tend a minimum of 3 feet above the finished grade. The material used
for wye poles shall be in good condition and shall be straight, sound and
free from large or loose knots
H Backfilling
1. The requirements of 310000 EARTHWORK shall apply, except as otherwise

2. After the pipeline has been tested and approved by the Engineer, the trench
shall be carefully backfilled to 300 mm above the crown of the pipe for rigid
pipes with granular material. Backfilling of the pipe trench should carry out as
designated, or shown on the Contract Drawings.
3. Where concrete bedding or surround is required, the backfill shall not be
placed before the compressive strength of the site concrete has reached 15
MPa.
4. Where concreting to pipeline is specified, a blinding layer of Grade 20 SRC
concrete shall be placed over the full width of the trench or heading to comply
with:
Blinding Layer of Concrete Over Trench Width
Pipe Nominal Bore (mm)

less than greater than greater than
or equal to 600 but less to 900 but less to greater than
600 900 1200 1200
Minimum thickness of
blinding layer (mm) 75 75 75 100
Minimum extent of blinding
each side of pipe barrel (mm) 150 150 230 300

Minimum clearance between
blinding and pipe barrel (mm) 80 150 230 300
5. Pipes to be bedded on or cradled with concrete shall be supported on precast

concrete setting blocks, the top face of each block being covered with a sepa-
ration layer.
6. Concreting to the pipeline shall be either bed or bed and surround as shown
on the Drawings and shall be of Grade 20 SRC concrete along such lengths as
are shown on the Drawings or ordered by the Engineer.
7. The pipe shall be prevented from moving during concreting.
8. Where concrete bed and surround is used with GRP and PVC-U pipes the max-
imum spacing between pipes joints shall be 3 m. For other pipe materials the
maximum spacing shall be as directed by the Engineer.
9. When support of excavations is provided, building paper shall be placed
against that support before concreting to facilitate withdrawal of the support.
Building paper shall comply with BS 1521 Class ‘A2’.
10. In the case of pipes with flexible joints, the concrete at each joint shall be in-
terrupted in a vertical plane at the edge of the socket by a strip of fiberboard
or other material approved by the Engineer and of the following thicknesses:
a. Up to 300 mm nominal bore 13 mm

b. Over 300 mm and up to 600 mm nominal bore 25
mm
c. Over 600 mm and up to 1200 mm nominal bore 38 mm
d. Over 1200 mm and up to 2000 mm nominal bore 50 mm
11. The protection and filling of headings shall be of Grade 20 SRC concrete.
12. Where concrete slab protection to GRP and PVC-U pipelines is required such
protection shall extend a minimum of 200 mm either side of the pipe trench.
The slab shall be of reinforced concrete as shown on the Drawings.
I Deflection at Joints

pipelines from a straight line, either in the vertical or horizontal planes to
avoid obstruction or where long radius curves are permitted, the amount of
deflection allowed shall not exceed that required for satisfactory connection
of the joint and shall be approved by the Engineer. Where a change of direc-
tion cannot be made by deflection at the joints of ordinary straight pipes,
bends shall be used. The locations of such bends and other specials are shown
on the Contract Drawings and their exact positions will be determined by the
Engineer on the Site.
J Cleanliness of Pipelines
firmly fixed to resist unauthorized removal. Claw type plugs or any type liable
the pipeline is under pressure or vacuum and to enable pressures to be equal-
ized before its removal.
2. The Contractor shall clear the inside of each fitting and pipe length immediate-
ly before jointing and shall swab all fittings and pipe lengths to remove all
dirt1 sand or other matter that may clog the pipeline or contaminate the fluid
to be transported in the pipeline. After j ointing1 the interior of the pipes
shall be freed from any dirt, stones or other matter that may have entered
them. For this purpose, a rubber disc, brush, or other suitable implement that
will not harm the internal lining of the pipe shall be pulled through the pipe af-
ter jointing.
K Marker Tape
150 mm placed during backfilling 300 mm below finished surface or as di-
rected by the Engineer.
2. All tapes shall be clearly marked in black lettering with “STORM WATER” All
non-ferrous pipelines shall have marker tape with tracer wire.
3.4 MANHOLES AND SPECIAL STRUCTURES
A General
1. The Contractor shall construct all chambers and special structures as indicated
on the drawings and herein specified.
2. Soakaway, catch basin and special structures shall conform in shape, size, di-
mensions, materials, and other respects to the details indicated on the draw-
ings or as ordered by the Engineer.
B Construction of Soakaway, Catch basin, Chambers, and Special Structures
1. All Soakaway, chambers, catch basin and special structures shall have rein-
forced-concrete bases as detailed on the drawings. Bases for storm-sewers
less than 600 mm and bases for chambers may be recast or cast in place at the
Contractor's option and as approved by the Engineer. For precast reinforced-
concrete manhole bases, openings for pipes if any shall be cast in the base at
the required location during its manufacture. Field cut openings will not be
permitted. All other manhole and special structure bases shall be cast in place
as indicated on the drawings.
2. Soakaway, chambers and catch basin cover slabs shall be cast in place rein-
forced concrete as marked on the drawings. The ductile iron frames and co-
vers for chambers shall be brought to grade by the number of courses of con-
crete blocks shown on the drawings or as instructed by the Engineer and a re-
inforced concrete frame into which the ductile iron frame is embedded.
3. The ductile iron frames, grates and covers shall be to the BS EN 124 standard
frame, grate and cover as indicated on the drawings and hereinafter specified
in this Section.
4. Catch Basin walls shall be plain Class A concrete formed to the shape and
thickness shown on the drawings by the use of sound formwork material to
give a fair faced finish.
5. PVC/GRP lining to internal wall /or with a brush-applied bituminous emulsion
as indicated in the drawing. Lining shall incorporate lugs molded onto the out-
side 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.
6. 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.
7. Pipes entering and leaving manholes, chambers and special structures shall be
laid soffit to soffit unless otherwise shown on the drawings.
8. All construction joints to chambers and special structures shall be perfectly
watertight. Water stop across joints in structures as specified shall be provid-
ed where detailed in the drawings or as directed. Joints shall be fully scrab-
bled.
9. Chambers shall be completely constructed as the Works progress and as each
one is reached by the pipe work. Frames and covers shall be placed immedi-
ately after the completion of the manhole and chamber.
10. Soakaways for storm drainage shall be constructed with concrete masonry
bricks.
11. Vertical joints between the bricks shall be left open and shall not receive any
mortar and shall be according to the dimensions shown in drawings.
12. The soakaway shall be surrounded with a graveller hard core backfill to pre-
vent clogging.
13. The filter shall be protected by a non-woven geotextile membrane of 1.0 mm
minimum thickness as shown on drawings. The membrane shall be of best
quality as per Terram or equivalent.
14. Catch basin shall be according to dimensions and details in Drawings.
15. Catch basin cover slabs shall be surmounted by ductile cast iron grating
top/solid top covers and frames of the quality specified; frame will be rested
on RC slab.
16. Unless otherwise indicated on drawings one cast iron trap shall be installed at
each pipe outlet for the catch basin.
C Pre Cast Manhole/chamber Installation:
1. Examination:
a. Verify that lines and grades are correct.

b. Determine if subgrade, when scarified and compacted, can be compact-
ed to 95percent of maximum Standard Proctor Density according to
ASTM D 698 prior to placement of foundation material and base section.
When proper density is not reached, moisture condition subgrade until
that density is reached or treats a sun stable subgrade.
c. Do not build manholes in ditches, swales, or drainage paths unless ap-
proved by Engineer.
2. Placement:
a. Install precast manholes to conform to locations and dimensions as

shown on Construction Drawings.
b. Place sanitary manholes at points of change in alignment, grade, size,
pipe intersections, and end of storm drain piping unless otherwise di-
rected by Engineer
3. Manhole Base Sections and Foundations:
a. Place precast base on 6 inch thick (minimum) foundation of crushed

stone, or concrete foundation slab.
b. Unstable Subgrade Treatment: when unsatisfactory material is encoun-
tered in the manhole subgrade. With Engineer approval, up to 12 inches
of additional undercut may be permitted to achieve suitable foundation.
If the additional undercut does not result in a satisfactory foundation,
the Contractor shall obtain a bedding design prepared by a Geotechnical
Engineer licensed in the state in which the project is being constructed.
4. Precast Manhole Sections:
a. Install sections, joints, and gaskets in accordance with manufacturer's

printed recommendations.
b. Install precast adjustment rings above tops of cones or flat-top sections
as required to adjust finished elevation and to support manhole frame.
c. Seal any lifting holes with non-shrink grout.
d. Where fiberglass liners are required, seal joints between sections in ac-
cordance with manufacturer's recommendations.
e. Precast concrete grade rings shall be permitted to achieve the required
grade.
f. Grade rings shall not be permitted to more than 12 inches.
g. External joint wrap all riser joints to ensure seal. No grout is permitted
on the interior of manhole riser joints prior to testing.
h. Concrete base must be dry prior to setting any sections above it.
D Soakaways
1. Soakaways shall be constructed using precast concrete rings. Concrete
works shall comply with the requirements (concrete section) of the speci-
fication. Concrete shall be grade C40 for the precast concrete rings and the
cover slab, using Moderately Sulphate Resisting Portland Cement.
2. The cover slab shall be of the dimensions and contain the reinforcement as
shown on the drawings .
3. The structural concrete shall be designed for durability and shall include as
a minimum the following specification:
 minimum cover 75mm

 all surfaces to be painted with a protective coating meeting the re-
quirements of section Corrosion Protection and Odor Control Sec-
tion
 any reinforcement shall be epoxy coated in accordance with BS
7295.

4. The soakaways shall have an internal diameter of 1.5 m unless otherwise
designated and shall be of a maximum depth of 2.5 m unless otherwise
designated.
5. The precast concrete rings shall be at least 150 mm thick and shall have
three evenly spaced lifting points.
6. No permanently embedded metal parts shall be left with a cover less than
40 mm from the surface. The precast rings shall be constructed with 50
mm diameter holes at 400 mm centres in rows spaced 300 mm apart. The
holes shall be alternately offset.
7. The bottom ring shall be founded on in situ blinding concrete 200 mm

deep.
8. The soakaway shall be surrounded by granular material which shall infill

the whole void between the soakaway and the undisturbed ground around
the excavation.
9. The granular material shall be laid in tamps in 150 mm layers and shall
nowhere be less than 225 mm in width.
10. The granular material shall be clean crushed rock from a source approved
by the Engineer.
11. The nominal size shall be 75 mm. The material passing a 0.075mm sieve
shall not exceed 5%.
12. ductile iron covers and frames shall be to BS EN 124 of the designated
loading class B 125.
13. Filter fabric material lining to the outside of the soakaway excavation shall
be Terram, grade 1000 The placing and laying of the material shall be in
accordance with the manufacturer’s instructions and
14. The geotextile material shall not be left exposed to the sun for a period
greater than 7 days before burying.
E Building in Pipes to Structures
1. 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.
2. All internal and external protection membranes to the concrete shall be sealed
around the pipe openings as recommended by the membrane manufacturer.
When the pipe is later fixed, the remaining hole shall be re-formed and filled
with non-shrink grout.
3. 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.
4. Pipes and pipe specials through concrete walls and floors shall as far as possi-
ble be positioned and built in during construction. They shall be located exact-
ly 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.
5. Where it is impracticable to cast pipes and specials in the concrete, box outs
shall be provided in the formwork. The box shall have six or eight sides, de-
pending on the pipe diameter, and shall be no larger in size than will give ade-
quate clearance for the subsequent positioning and grouting in of the pipe.
The sides of the box out shall be provided with a tapered central annular re-
cess to provide a positive key. The box out shall be provided with a grout hole
and, at the top of the central annular recess a vent hole. The box hole shall be
stripped with the main formwork and the concrete surface thoroughly cleaned
and roughened.
6. Unless otherwise shown on the Contract Drawings, where pipes pass through
a concrete wall or structure them shall be protected with a surround of Grade
20 SRC concrete integral with the external face of the structure. For pipes of
less than 500 mm diameter, the surround shall extend from the wall or struc-
ture by 300 mm and the width and depth of the surround beyond the outside
face of the pipe at its horizontal and vertical diameters shall be a minimum of
300 mm or as otherwise indicated on the Drawings. For pipes of 500 mm di-
ameter or greater the surround shall extend from the wall or structure by 500
mm and the width and depth of the surround beyond the outside face of the
pipe at its horizontal and vertical diameters shall be 500 mm or as otherwise
indicated on the Drawings.
7. On socket and spigot pipelines except those of GRP or other plastic materials
the socket end of the pipe passing through the wall shall be flush with the out-
side face of the concrete surround. On socket of spigot pipelines of GRP or
other plastic materials the socket end of the pipe passing through the wall
shall protrude 300 mm from the concrete surround. A protective synthetic
rubber strip 6 mm thick and 150 mm wide shall be provided around the pipe
at the limit of the concrete surround as shown on the Contract Drawings.
8. On all other flexibly jointed pipes the plain end of the pipe shall protrude from
the concrete surround by a maximum of 300 mm or that distance required to
properly making the joint.
9. The first pipe that is clear of concrete surround beyond the external face of a
concrete wall or structure shall be a short length of either spigot and socket or
double spigot to suit the flow direction and pipe material. The effective length
of this pipe shall be 1.5 times the nominal bore or 600 mm whichever is the
greater.
10. For mechanically jointed pipes the plain end shall protrude from the surround
by a maximum of 300 mm or that distance required properly making the joint.
11. Where the structure is tanked, Grade 20 OPC concrete shall be used and the
tanking shall extend to the concrete surround.
F Property Connections Survey
1. The Contractor shall complete and submit to the Engineer for approval a
standard record sheet of every property connection.
2. The Contractor shall carry out a survey of existing facilities and prepare indi-
vidual sketch plans at 1:500 scale for each property for which a sewerage or
storm connection is required. These shall show existing plot boundaries, loca-
tion of property and location of all affecting services. These shall be marked

up to show the details of the proposed service connection and shall be submit-
ted to the Engineer for approval. No service connection work shall begin be-
fore approval to the proposed layout has been received in writing from the En-
gineer.
3. In special cases only, a catch basin may serve more than one service connec-
tion. Locations of catch basin and the layout of service connections shall be as
approved by the Engineer.
4. Service connections shall be laid at sufficient depths to allow for adequate gra-
dient being continued throughout the properly system without the pipelines
becoming too shallow for adequate cover to be provided over the pipe.
A. Future House Connections
1. Service connections shall be laid up to the property boundary and an end cap
with a marker post shall be provided at the termination of each service con-
nections. The Contractor shall produce accurate records of the exact locations
of all service connections.
G Step Iron and Ladders
1. Steps shall be thoroughly cleaned and given a protective coal tar epoxy coat-
ing. The cleaning shall be done by suitable means to ensure that the surfaces
to be coated are free from foreign matters. After the steps have been cleaned,
rinsed and dried, apply the coating and allow drying before installing in con-
crete.
2. Installation of steps shall not begin until concrete receiving them has attained
its sufficient strength. Embedment into walls shall be as recommended by the
manufacturer; no shrink cement formulation shall be used for pointing.
3. Steps shall be located to provide a continuous vertical distance from the man-
hole rim to the top surface of the bottom slab at intervals of 300 mm, plus or
minus 40 mm and shall be installed in a manner to be capable of withstanding
a force of 160 kgs applied on the step at any place and in any direction with no
permanent deformation.
4. GRP ladders of an approved pattern as specified may be purpose made to suit
the depth of each manhole. Fixings for ladders shall be approved stainless
steel stud anchors. Fixing holes shall be grouted with epoxy mortar and sealed
as above. Rungs or treads shall be ribbed to provide a non-slip surface.
H Inverts for Sanitary Sewers:
1. A. Construct invert channels to provide smooth flow transition waterway with

no disruption of flow at pipe-manhole connections. Conform to following crite-
ria:
a. Slope of invert bench: 1 inch per foot minimum; 1-1/2 inches per foot
maximum
b. Depth of bench to invert:
1) Pipes smaller than 15 inches: one-half of largest pipe diameter

2) Pipes 15 to 24 inches: three-fourths of largest pipe diameter
3) Pipes larger than 24 inches: equal to largest pipe diameter

c. Invert slope through manhole: 0.10 foot drop across manhole with
smooth transition of invert through manhole, unless otherwise indicated
on Construction Drawing.
2. Form invert channels with concrete if not integral with manhole base section.
3. For direction changes of mains, construct channels tangent to mains with max-
imum possible radius of curvature. Provide curves for side inlets and smooth
invert fillets for flow transition between pipe inverts.
I Manholes and Chambers Covers and Frames
1. Chambers covers shall be ductile iron and comply with EN 124. Production fa-
cilities shall be quality assessed in accordance with ISO 9000 or EN 29002 BS
5750).
2. Manhole covers for storm, surface water and treated storm effluent systems
shall have the following words embossed in both English and Arabic, respec-
tively:
3. Surface water: Drainage Surface Water
4. The size of lettering shall be approved by the Engineer.
5. 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 appro-
priate design to match the different cover configurations. Keyways in man-
hole covers shall be of the closed type.
6. 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 di-
rected.
7. The covers in paved areas shall be accurately set on precast concrete brick-
work to the level and slopes of the roads or pavements, to adjust cover level
as required.
8. 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.
J Deflection at Joints:

pipelines from a straight line, either in the vertical or horizontal planes to avoid
obstruction or where long radius curves are permitted, the amount of deflec-
tion allowed shall not exceed that required for satisfactory connection of the
joint and shall be approved by the Engineer. Where a change of direction can-
not be made by deflection at the joints of ordinary straight pipes, bends shall
be used. The locations of such bends and other specials are shown on the
Contract Drawings and their exact positions will be determined by the Engineer
on the Site.
K Cleanliness of Pipelines:
firmly fixed to resist un authorized removal. Claw type plugs or any type liable
the pipeline is under pressure or vacuum and to enable pressures to be equal-
ized before its removal.
2. The Contractor shall clear the inside of each fitting and pipe length immediate-
ly before jointing and shall swab all fittings and pipe lengths to remove all dirt1
sand or other matter that may clog the pipeline or contaminate the fluid to be
transported in the pipeline. After j ointing1 the interior of the pipes shall be
freed from any dirt, stones or other matter that may have entered them. For
this purpose, a rubber disc, brush, or other suitable implement that will not
harm the internal lining of the pipe shall be pulled through the pipe after joint-
ing.
L Marker Tape:
150 mm placed during backfilling 300 mm below finished surface or as directed
by the Engineer.
2. All tapes shall be clearly marked in black lettering with “STORM WATER” All
non-ferrous pipelines shall have marker tape with tracer wire.
3.5 TESTING
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 ap-
pointed by the Engineer. Test equipment shall be approved by the Engineer
and calibration certificates when requested by the Engineer shall be submit-
ted. 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 else-
where, 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 exceed-
ing 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 pipe-
line network. The seal should be fitted with a valued vent to allow equaliza-
tion of pressure before removal.
5. All flexible pipelines shall be tested for deflection as per this specification.
6. Storm water Pipelines
a. Each pipeline 600 mm or less in diameter shall be tested by air test.

Should any pipe fail the air test, the Engineer may order a water test to
be carried out. Acceptance of the pipeline will then be based on the re-
sults of the water test. All pipelines up to and including 1200 mm shall
be tested by air test in accordance with the requirements of BS 8005:
Part 1, Section 5.
b. The Contractor shall, at his own expense, furnish all equipment and ma-
terials for making the tests. Each pipeline shall be tested before backfill-
ing and also after backfilling before carrying out road reinstatement or
laying new road surfacing. Where the pipeline is located under a new
road alignment, the pipeline will be tested after sub-base compaction in
complete. All pipelines shall be subjected to pass infiltration tests as
specified herein. All pipes are to be clean and empty at the time of test-
ing. Tests shall be performed in the presence of the Engineer.
B 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 inter-
nal 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.
C Water Test
1. All the joints of the pipeline shall be able to withstand a pressure of a mini-
mum 5 m head of water, above the crown of pipe at the highest point of pipe-
line 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 inspec-
tion for leakage if any. All branches and open ends shall be closed with stop-
pers, 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 un-
der test. The diameter of air vent shall be about one and ha lf times the diam-
eter of water inlet pipe to allow easy escape of air. No entrapped air shall re-
main in the pipeline while testing.
3. A pressure of 5 m head of water shall be maintained for one hour to allow ini-
tial 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.

D Infiltration Test
1. The upper ends of the storm and service connections shall be closed sufficient-
ly to prevent the entry of water and pumping of groundwater shall be discon-
tinued until the groundwater surface reaches its natural level before begin-
ning the infiltration test
2. The dewatering system shall be stopped, but not be removed until the infiltra-
tion 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 storm 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 pro-
posed 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 inspec-
tion, any infiltration is visible.
A. Storm Pressure Pipeline
1. The pipeline shall be tested between valve chambers or into sections not ex-
ceeding 400 m in length approved otherwise by the Engineer. The section
tests shall be carried out as follows:
a. Each pipeline or section thereof shall be filled with water and all air re-
moved as far as possible
b. The pressure shall then be raised by pumping in water until the test
pressure is reached and shall be maintained at this level by further
pumping until it is steady
c. Pumping shall then be stopped and the time taken for the observed
pressure to fall by 1.0 m shall be recorded
d. Pumping shall then be resumed and the quantity of water pumped in
order to restore the test pressure shall be recorded
e. If after three hours the test pressure has not fallen by 1.0 m, pumping
shall be resumed at that stage, the time being recorded as three hours
f. The rates of loss shall then be calculated as the recorded quantity divid-
ed by the recorded time
g. The test pump and gauge shall be connected to the pipeline at a location
other than the highest point in the pipeline to facilitate release of air
from the highest point
h. The test pressure shall be such that the entire pipeline or section being
tested is subjected to 1.5 times the working pressure, 1.25 times the
maximum surge pressure or 800 kPa, whichever is the greatest
i. The loss shall not exceed 0.02 liters per mm diameter per kilo meter per
24 hours for each 0.1 MPa of head applied
j. If the pipeline fails to pass the test, the faults shall be located and re-
paired and the pipeline retested until it passes the pressure test. All ex-
posed pipe, fittings, valves and joints shall be visually inspected during
the tests.

2. When all sections have been joined together after completion of section test-
ing, unless otherwise directed by the Engineer, the entire pipeline shall than be
subjected to final test as follows:
a. All joints between individual test sections shall be left uncovered during
this final test
b. The final test shall be carried out using the same procedure as the sec-
tion test
c. In all cases of water tests, where the measured leakage rate exceeds the
allowable, the Contractor shall, at his own expense, make all necessary
repairs and carryout additional testing until a satisfactory result is ob-
tained
d. Before pressure testing is started the Contractor shall recheck pipes and
valves for cleanliness and shall recheck the operation of all valves. The
“open” ends of the pipeline or sections thereof) shall normally be
stopped off by blank flanges or cap ends additionally secured where
necessary by temporary struts and wedges. All anchor and thrust blocks
shall have been completed and all pipe straps and other devices intend-
ed to prevent the movement of pipes shall have been securely fastened
e. Since valves cannot be guaranteed to be perfectly drop-tight, testing
against closed valves which are connected to an existing system shall be
prohibited; testing against other closed valves (including air valves) not
so connected, may be attempted if desired, provided the valves are suit-
ably anchored against thrust. No claims whatsoever will be entertained
on account of leaking valves, or any other difficulties in closing off
lengths of pipework for testing, which shall be entirely an obligation of
the Contractor
f. On successful completion of the final test, the exposed joints shall be
covered and the trench backfilled
E Testing of Water Retaining Structures
1. All water retaining structures shall be visually inspected to confirm that there
is no infiltration. Where it is required by the Engineer, water retaining struc-
tures shall be tested for water tightness. The structure shall be filled with
fresh water and shall stand for a period of three days, to allow for absorption.
The structure shall be considered satisfactory if, subsequent to this period,
there shall be no fall in level over a period of 24 hours (after making the al-
lowance for rainfall and evaporation) and there shall be no visible leaks, or
damp surface areas.
2. This shall be carried out before any backfilling and before the application of
any external concrete protection has taken place. Any damages revealed as a
result of such tests shall be made good to the satisfaction of the Engineer.
3.6 RIPRAP
A Graded stone bedding shall be placed, graded, and compacted to the thickness
shown on the drawings, to obtain a continuous uninterrupted bed within the limits
required for riprap.
B Light and heavy riprap shall be placed on the prepared bed to the thickness shown on
the drawings. Spaces between stones shall be filled with spalls of suitable size to
construct a solid, stable slope, free from voids and defects which might not protect
the earth slopes against erosion.”
C Riprap shall be placed at locations indicated on the Drawings and other areas as di-
rected by the Engineer.
3.7 STORM WATER INLET AND OUTLET INSTALLATION
A Construct inlet head walls, aprons, and sides of reinforced concrete, as indicated in
the drawing and as per Division 03 Concrete
B Construct riprap of broken stone, as indicated in this specification
C Install outlets that spill onto grade, anchored with concrete, where indicated as indi-
cated on the drawings
D Install outlets that spill onto grade, with flared end sections that match pipe, where
indicated.
E Construct energy dissipaters at outlets, as indicated.


ISSUED FOR
PURCHASE
CONSTRUCTION X

NO. BY BY BY
A Oct. 2021 A.E. C.AMAM C.MYSM 20 ISSUED FOR DETAILED DSIGN
B Oct. 2021 A.E. C.AMAM C.MYSM 20 ISSUED FOR DETAILED DSIGN
0 Jan. 2022 A.E. C.AMAM C.MYSM 20 ISSUED FOR TENDER
1 Feb. 2022 A.E. C.AMAM C.MYSM 20 ISSUED FOR CONSTRUCTION
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP OVERHEAD ELECTRIC CRANES
KSA 412215.10- 2970 1

CONTENTS
SECTION 412215.10
COMMON WORK RESULTS FOR PLUMBING

Page
PART 1 - GENERAL 2
1.1 Summary 2
1.2 Submittals 2
1.3 References 3
1.5 Testing And Inspection 5
1.6 Delivery And Storage 6
1.7 Field Measurements 6
1.8 Stability 6
PART 2 - PRODUCTS 7
2.1 Materials 7
2.2 Structural Materials 7
2.3 Mechanical Equipment 9
2.4 Electrical Components 12
PART 3 – EXECUTION 16
3.1 Erection 16
3.2 Acceptance Testing 17
3.3 Schematic Diagrams 19
3.4 Manufacturer’s Field Service Representative 19
3.5 Field Training 19
3.6 Spare Parts 19
3.7 Acceptance 20
3.8 Equipment Schedule 20
Overhead Electric Cranes Section 412215.10

SECTION 412215.10 – OVERHEAD ELECTRIC CRANES
PART 1 - GENERAL
1.1 SUMMARY
A. Cab or pendant crane controls or a combination of the two can be provided
B. Alternating current or dc control systems can be specified.
C. Crane Terminology
1. Top-running bridge is a bridge gantry, which travels on the top surface of rails
of a fixed runway structure.
2. Top-running Trolley is a trolley which travels on the top surfaces of rails of the
bridge girder(s).
1.2 SUBMITTALS
A. Product Data
a. Crane Design Criteria: A complete list of equipment and materials, including

manufacturer's descriptive data and technical literature, performance charts
and curves, catalog cuts, and installation instructions.
b. Hooks: Hook material and any heat treatment performed, stamped on the
hook shank or documented in certification papers furnished with the hooks.
Crane test data recorded on appropriate test record forms suitable for
retention for the life of the crane.
c. Electric Overhead Cranes: A complete list of equipment and materials,
including manufacturer’s descriptive data and technical literature performance
charts and curves, catalog cuts and installation instructions.
d. Spare Parts: Spare parts data for each different item of material and
equipment specified, after approval of the detail drawings and not later than 3
months prior to the date of beneficial occupancy. The data shall include a
complete list of parts and supplies, with current unit prices and source of
supply.
e. Framed Instructions: Diagrams, instructions and safety requirements
B. Shop Drawings
a. Detail drawings containing complete wiring and schematic diagrams. Diagrams

shall indicate each numbered wire, where wire initiates, where wire
terminates, and any other details required to demonstrate that the system has
been coordinated and will properly function as a unit. Drawings shall show
layout and anchorage of equipment and appurtenances, and equipment
relationship to other parts of the work including clearances for maintenance
and operation.

C. Reports and Equipment Manuals
a. Acceptance Testing: Test reports in booklet form showing all field tests
performed to adjust each component and all field tests performed to prove
compliance with the specified performance criteria, upon completion and
testing of the installed system. The report shall include the information as
required by paragraph ACCEPTANCE TESTING.
b. Operation and Maintenance Data: Operation and Maintenance Manuals six
copies of operation and six copies of maintenance manuals for the equipment
furnished. One complete set prior to performance testing and the remainder
upon acceptance. Operation manuals shall detail the step-by-step procedures
required for system startup, operation and shutdown. Operation manuals shall
include the manufacturer's name, model number, parts list, and brief
description of all equipment and basic operating features. Maintenance
manuals shall list routine maintenance procedures, possible breakdowns and
repairs, and troubleshooting guides. Maintenance manuals shall include piping
and equipment layout and simplified wiring and control diagrams of the
system as installed. Operation and maintenance manuals shall be approved
prior to the field-training course.
1.3 REFERENCES
A. The publications listed below form a part of this specification to the extent
referenced. The publications are referred to within the text by the basic designation
only.
AMERICAN GEAR MANEJFACTURERS ASSOCIATION (AGMA)
AGMA 2000 (1988a) Gear Classification and Inspection Handbook

Tolerances and Measuring Methods for Unassembled Spur and Helical Gears
(Including Metric Equivalents)
AGMA 2001 (2004d) Fundamental Rating Factors and Calculation Methods

for Involute Spur and Helical Gear Teeth
AGMA 2009 (2001b) Bevel Gear Classification, Tolerances and Measuring

Methods
AGMA 2011 (1998a) Cylindrical Worm gearing Tolerance and Inspection

Methods
AGMA 6009 (2000a) Standard for Gear motor shaft Mounted and Screw
Conveyor Drives
AGMA 6010 1997f) Standard for Spur, Helical, Herringbone, and Sevel
Enclosed Drives
AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)
AISC 325 (2005) Manual of Steel Construction

AMERICAN WELDING SOCIETY (AWS)
AWS D1.1/D1.1M (2006; Errata 2006) Structural Welding Code – Steel
AWS D14.1/D14.1M (2005) Welding Industrial and Mill Cranes and Other
Material Handling Equipment
ASME INTERNATIONAL (ASME)
ASME B30.17 (2006) Overhead and Gantry Cranes (Top Running Bridge,
Single Girder, Under hung Hoists)
ASME B30.2 (2005) Overhead and Gantry Cranes (Top Running Bridge,
Single or Multiple Girder, Top Running Trolley Hoist)
ASME HST-1 (1999; R 2004) Performance Standard for Electric Chain Hoists
ASME EST-3 (1999; R 2004) Performance Standard for Manually Lever

Operated Chain Hoists
ASME HST-4 (1999; R 2004) Performance Standard for Overhead Electric

Wire Rope Hoists
ASME HST-5 (1999; R 2004) Performance Standard for Air Chain Hoists
ASME HST-6 (1999; R 2004) Performance Standard for Air Wire Rope Hoists
ASME INTERNATIONAL (ASTE)
ASTM A 325 (2006) Standard Specification for Structural Bolts, Steel, Heat
Treated, 120/105 ksi Minimum Tensile Strength
ASTM A 668/A 668M (2004) Standard Specification for Steel Forgings,

Carbon and Alloy, for General Industrial Use
ASTM B 439 (2007) Standard Specification for Iron-Base Sintered Bearings

(Oi1-Impregnated)
ASTM B 633 (2007) Standard Specification for Electrodeposited Coatings of

Zinc on Iron and Steel
CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)
CMAA 70 (2004) EnviroTop Running and Bridge and Gantry Type

Multiple Girder Electric overhead Traveling Cranes, No. 70
CIAA 74 (2004) Top Running and Under Running Single Girder Electric
Overhead Cranes Utilizing Under Running Trolley Hoist, No. 74
NATIONAL ELECTRICAL MANJFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; Errata 2002; R 2005; Errata 2006) Standard for
Industrial Control and Systems: Controllers, Contractors, and Overload Relays
Rated Not More than 2000 Volts AC or 750 Volts DC: Part B - Disconnect
Devices for Use in Industrial Control Equipment
NEMA ICS 6 (1993; R 2006) Standard for Industrial Controls and Systems
Enclosures
NEMA 14G 1 (2006; Errata 2007) Standard for Motors and Generators
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NAPA 70 (2005; TIA 2005) National Electrical Code
UNDERWRITERS LABORATORIES (UL)
UL 1004 (1994; Rev thru Mar 2006) Electric Motors
UL 489 (2002; Rev thru Jun 2006) Standard for Molded-Case Circuit
Breakers, Molded-Case Switches and Circuit-Breaker Enclosures
UL 943 (2006) Ground – Fault Circuit – Interrupters
A. Electric overhead cranes shall be designed and manufactured by a company with a

minimum of 10 years of specialized experience in designing and manufacturing the
type of overhead crane required to meet requirements of the Contract Documents.
1.5 TESTING AND INSPECTION
A. Pre-Delivery Inspections: Contractor shall be responsible for performance of quality

control inspections, testing and documentation of steel castings, hook assembly and
nuclear safety as follows.
B. Inspection of Steel Castings: Load carrying steel castings shall be visually inspected
and tested using the magnetic-particle inspection method. Allowable degree of
discontinuities shall be referenced to ASTM E125, and shall be related to service
loads and stresses, critical configuration, location and type. Methods of repairing the
discontinuities shall be subject to review by the Contracting Officer.
C. Inspection of Hook Assembly: Hook and nut shall be inspected by a magnetic-particle

type inspection or X-rayed prior to delivery. Documentation of hook inspection shall
be furnished to Contracting Officer at the field operational testing. As part of the
acceptance standard, linear indications will not be allowed. Welding repairs of hook
will not be permitted. A hook showing linear indications, damage or deformation will
not be accepted, and shall be replaced.
1. Classification

a. Class B (Light Service): This service covers cranes which may be used in
repair shops, light assembly operations, service buildings, light
warehousing, etc., where service requirements are light and the speed is
slow. Loads may vary from no load to occasional full rated loads with 2
to 5 lifts per hour, averaging 3 m per lift.
b. Crane shall be designed and constructed to CMAA 70 Class B, light
service requirements for operation in indoor environment with hoist in
accordance with ASME HST-3 and ASME HST-6.
D. Rated Capacity and Speeds: Rated capacity of cranes shall be (2) metric tons or as
per design drawings. Lower load block or assembly of hook, swivel bearing sheaves,
pins and frame suspended by the hoisting ropes shall not be considered part of the
rated capacity. Rated speeds in meters/second for the hoist and trolley at the rated
load shall be as follows:
Rated Speeds
Meters per second
Description Minimum Maximum
Main Hoist 0.10 0.25
Trolley 0.25 0.51
Bridge 0.51 0.89
1.6 DELIVERY AND STORAGE
A. Equipment delivered and placed in storage shall be stored with protection from the
weather, humidity and temperature variations, dirt and dust, and other
contaminants Protect bearings and couplings against damage.
1.7 FIELD MEASUREMENTS
A. Before performing any work, Contractor shall become familiar with all details of the
work, verify all dimensions in the field, and submit a letter describing the results of
this verification including discrepancies to the Contracting Officer and crane
manufacturer.
1.8 STABILITY
A. The gantry crane shall have a minimum factor of safety of 1.25 against overturning
under each condition of loading stated in paragraph 3.3.2.4 of CMAA 70.
Counterweights shall be provided if necessary to obtain the required stability.

PART 2 - PRODUCTS
2.1 MATERIALS
A. General: Materials and equipment shall be standard products of manufacturers

regularly engaged in the fabrication of complete and totally functional & cranes
including necessary ancillary equipment.
B. Nameplates: Nameplates shall be secured to each major component of equipment

with the manufacturer's name, address, type or style, model or catalog number, and
serial number. Two bridge identification plates shall be provided, one for each side of
bridge. Identified plates shall be non-corrosive metal with letters which are easily
read from the floor, showing a separate number such as BC-1, BC-2 for each bridge
crane.
C. Use of Asbestos Products: Materials and products required for designing and
manufacturing cranes shall not contain asbestos.
D. Capacity Plates: Two capacity plates indicating the crane capacity in metric tons and
tons are required, one secured to each side of bridge. Each capacity plate shall be
fabricated of a steel backing plate and exterior quality/fade-resistant stick-on labels
with letters large enough to be easily read from the floor. Capacity plates shall be
placed in a location visible to pendant operator's position after the crane has been
installed.
E. Safety Warnings: Readable warning labels shall be affixed to each lift block or control
pendant in a readable position in accordance with? ASME B30.16, ASME B30.2 and
ASME B30.17. The Contractor shall submit these safety warnings, diagrams and other
framed instructions for display as indicated by the Contractin Officer.
1. The word "WARNING" or other legend shall be designed to bring the label to
the attention of the operator. Warning labels shall be durable type and display
the following information concerning safe-operating procedures: Cautionary
language against lifting more than the rated load; operating the hoist when the
hook is not centered under the hoist; operating hoist with twisted, kinked or
damaged rope; operating damaged or malfunctioning hoist; operating a rope
hoist with a rope that is not properly seated in its hoist drum groove; lifting
people; lifting loads over people; and removing or obscuring the warning label.
2. To avoid operation of crane in the wrong direction, the words "FORWARD" and
"REVERSE" and accompanying directional arrows shall be affixed in a location
on the trolley and bridge which are visible and readable to the operator from
pendant station. The words "FORWARD" and "REVERSE" shall agree with the
markings on control pendant. Directional arrows shall not be indicated on
control pendant.
2.2 STRUCTURAL MATERIALS
A. Bolts, Nuts and Washers: High-strength bolted connections shall utilize SAE Grade 5
bolts with corresponding lockwashers, nuts, etc., conforming to requirements of AISC

325 bolts. Bolts, nuts and washers shall conform to ASTM A 325M ASTM A 325 bolts.
Galvanized bolts are not acceptable. ASTM A 490M ASTM A 490 bolts shall bot be
used.
B. Girders: Bridge girders shall be wide flange beams, standard I-Beams, reinforced
beams or sections fabricated from rolled plates and shapes.
C. Bridge Rails: Trolley runway rails, crane girders and other sections shall be straight
and true. When loaded with motor driven cranes the deflection of rails shall not
exceed 1/800 of the span. The deflection shall be calculated with the worst case of
two loaded bridge cranes located adjacent each other. Rail joints shall be flush and
true without misalignment of running tread and shall be designed to minimize
vibration. The gap between adjacent rail ends and the vertical misalignment of
running treads shall not exceed 1.588 mm. The bridge rail shall be leveled to a plus-
or-minus 3 mm at all rail support joints. Bridge rail shall be fastened to wide flange
or offset near web plate for welded box sections complete with welded clips. Bridge
rail joints shall be bolted using standard joint bars. Rail joints shall be staggered. A
positive stop shall be provided at bridge rail ends to prevent creep.
D. End Ties and Bridge Girder End Connections: Welded steel box sections shall be used
for end ties, full depth diaphragms shall be provided at girder connections and
jacking points. Horizontal gusset plates shall be provided at the elevation of top and
bottom end tie flanges for connection to girder ends. End connections shall be made
with high-strength bolts. Body-bound bolts fitted in drilled and reamed holes shall be
used to maintain the crane square.
E. Bridge End Trucks: End trucks shall be the rotating or fixed axle type fabricated of
structural tubes or from structural steel to provide a rigid box section structure.
Jacking pads shall be provided for removal of wheel assemblies.
F. Trolley Frame: Trolley frame shall consist of two structural steel side frames or trucks
welded together with one or more structural steel load girts to form a one-piece unit.
Pads shall be provided for the use of jacks or wedges when changing truck wheels. All
trolley yokes and load bars shall be of drop forged, cast or rolled steel.
G. Stops and Bumpers: Crane runways and bridge girders shall be fitted with structural
steel end stops. Bridge end trucks and trolley frames shall be fitted with shock-
absorbing, spring type bumpers capable of decelerating and stopping the bridge
and/or trolley within the limits stated by OSHA and MHI CMAA. Trolley end stops
shall be of sufficient strength to withstand the impact of a fully loaded trolley moving
at 50 percent of maximum rated travel speed. When two bridge cranes are on the
same runway, one crane shall be fitted with shock-absorbing bumpers on each end of
each end-truck, and the other crane shall have shock-absorbing bumpers as per
above on one end only of each end-truck, which is the opposite end of the adjacent
crane. The other end of the end-truck shall be fitted with a structural steel stop to
engage the bumpers of the adjacent crane. Bridge bumper stops shall be provided as
specified in Section 05 12 00 STRUCTURAL STEEL. Stops shall be located to permit
maximum bridge and trolley travel.
H. Footwalks

G. Runway Rails: The runway rail size shall be as recommended by crane manufacturer.
2.3 MECHANICAL EQUIPMENT
A. Drives
1. Drives: Bridge drives shall be A-4 drive arrangement as specified in CMAA 70

or CMAA 74. Bridge drive shall consist of a single electric motor mechanically
connected through gear reduction and drive shafts to the drive wheels or
separate drive motors at each end of bridge. Acceleration and deceleration
shall meet the requirements specified in this section. Gears shall conform to
applicable AGMA standards. Gear reducers shall be oil tight and fully enclosed
with pressure or splash type lubrication. Bridge-travel limit-switches are
optional.
2. Trolley Drives: Trolley shall be complete with a drive arrangement with a
minimum of two wheels driven by an integral electric motor. Drive mechanism
shall run in totally enclosed oil bath. Limit switches are optional for drive
mechanism. Acceleration and deceleration controls shall meet requirements
specified in this section
B. Load Blocks
1. Main and Auxiliary Hoist Load Blocks: Load blocks shall be of welded steel
construction. Load blocks shall be provided with hot-rolled or forged steel
fixed crosshead separate from the sheave pin with swivel mounting for forged
steel hook. Each lubrication fitting for sheave pins shall be an independent
type recessed within the sheave pin or adequately guarded to prevent
damage. The pitch diameter of the sheaves shall be not less than 16 times the
rope diameter. Sheaves shall be supported by roller type bearings on steel
sheave pins. Provisions for external lubrication shall be provided to allow
pressure relief and purging of old grease. Sheave blocks shall be constructed to
provide maximum personnel safety and to prevent the hoist rope from leaving
the sheaves under normal operating condition.
2. Hook Assembly: Hooks shall be single barbed and shall be made of forged steel
complying with ASTM A 668/A 668M. Hook dimensions shall be as shown.
Hooks shall be fitted with safety latches designed to preclude inadvertent
displacement of slings from the hook saddle. Painting or welding shall not be
performed on the hook. Hook nut shall be secured with a removable type set
screw or other similar fastener, but shall not be welded. Hooks shall be
designed and commercially rated with safety factors in accordance with MHI
CMAA. The hook shall be free to rotate through 360 degrees when supporting
the rated load.
3. Hoisting Ropes: Hoisting ropes shall be regular lay, performed, uncoated,
improved plow steel, 6 by 37 construction, with independent wire rope core.
Ropes shall be suited to meet the service requirements. Rope socketing or U-
bolt clip connections shall be made in accordance with clip or rope
manufacturer's recommendation, and shall be equal to or greater than the
rope strength. Hoisting ropes shall be the rated capacity load plus the load
block weight divided by the number of rope parts, and shall not exceed 20

percent of the certified breaking strength of rope. Hoisting ropes shall be
secured to hoist drum so that no less than two wraps of rope remain at each
anchorage of hoist drum at the extreme low position (limit switch stop).
4. Sheaves: Sheaves shall be of cast, forged, rolled, or welded structural steel.
Sheave grooves shall be accurately machined, smoothly finished and free of
surface defects.
5. Hoist Drums: Hoist drums shall be of welded rolled structural steel, cast steel,
or seamless steel pipe. Drums shall be machined and provided with right-hand
and left-hand grooves to take the full run of cable for the required lift without
overlapping, plus a minimum of two full wraps of cable when load is on floor.
At least one groove shall remain unused when hook is at the highest position.
Drum grooves shall be cut from solid stock and have sufficient depth for size of
cable required. Drum flanges shall be guarded so that the cable cannot wedge
between drum flange and hoist frame.
6. Gearing: Gearing shall be of the enclosed gear reducers type. Gears and
pinions shall be spur, helical, or herringbone type only, and shall be forged,
cast or rolled steel; open-type gearing is not acceptable. Gears and pinions
shall have adequate strength and durability for the crane service class and shall
be manufactured to AGMA 2001 Quality Class 6 or better precision per AGMA
2011.
a. Gear Reducers: Gear reducers shall be standard items of manufacturers

regularly engaged in the design and manufacture of gear reducers for
Class D and G cranes or shall be integral components of standard hoists
or hoist/trolley units of manufacturers regularly engaged in the design
and manufacture of hoists or hoist/trolley units for Class A, B or C
cranes. Gear reducers shall be designed, manufactured and rated in
accordance with AGMA 6010, (for trolley drives only), as applicable.
Except for final reduction, the gear reduction units shall be fully
enclosed in oil-tight housing. Gearing shall be designed to AGMA
standards and shall operate in an oil bath. Operation shall be smooth
and quiet.
b. Open Gearing: All gears and pinions shall have adequate strength and
durability for the crane service class and manufactured to AGMA 2001
quality class 6 or better precision per AGMA 2001. Open gears shall be
enclosed with safety guards provided with openings with covers for
inspection and access for grease lubrication.
7. Brakes: Brakes shall be of the shoe, disc, or conical type with thermal capacity
suitable for class and service specified in this section. Shoe, disc, and conical
brakes shall be spring-set and electrically-released by a continuously rated
direct acting magnet. Brakes shall be self-aligning and provide for easy
adjustment for torque setting and lining wear. Brake lining material shall be
asbestos free. Brake wheels shall be cast iron conforming to ASTM A 159 or
shall be the manufacturer's standard high-strength ductile cast-iron, provided
that the material exhibits wear characteristics in the form of powdered wear
particles and is resistant to heat-checking. Disc brakes shall be totally enclosed
and have multiple discs with stationary releasing magnets. Brake torque shall
be easily adjustable over a 2:1 torque range.

a. Hoist Holding Breakers: Each hoist shall be equipped with at least 14
holding brakes. Holding brake shall be disc, shoe, or conical design,
applied to one of the following: motor shaft or gear reducer shaft or
rope drum. Braking system shall be designed to have zero hook lowering
motion when a raise motion is initiated. Primary brake shall be a spring-
set, electrically-released, disc, shoe, or conical type brake. Brake shall
have a minimum torque rating of 150 percent of motor torque. Brake
shall be capable of holding the rated load with zero hook drift. Primary
brake shall be automatically set when controls are released or when
power is interrupted. Provisions shall be made to facilitate easy brake
adjustment. Hoists shall be furnished with mechanical-control braking or
a power-control braking system. Typical power means include dynamic
lowering, eddy-current braking, counter-torque, regenerative braking,
variable frequency, and adjustable or variable voltage.
b. Hoist Control Brake: Each hoist shall be equipped with an integral
mechanical load brake of the "Weston" type or multiple-disc type.
Multiple disc-type brake shall be provided with external adjustment for
wear
c. Trolley Brake: Trolley braking system shall be provided with spring-
applied and electrically-released shoe, disc or conical brakes. Electrical
portion of the braking system shall be designed such that the shoes will
be spring-applied and electrically-released. Braking system shall be
automatically set when controls are released or power is interrupted.
Provisions shall be made to facilitate easy brake adjustment. Brakes shall
have a torque rating of at least 50 percent of trolley drive motor rated
torque.
d. Bridge Brakes: Bridge braking system shall be provided with a spring-
applied and electrically-released single shoe, disc or conical brake for
each bridge drive motor. Electrical portion of braking system shall be
designed so that the shoes will be spring-applied and electrically-
released. Braking system shall be automatically set when controls are
released or power is interrupted. Provisions shall be made to facilitate
easy brake adjustment. Brakes shall have a torque rating of at least 50
percent of bridge drive motor rated torque.
8. Wheels: Wheels shall be manufactured of rolled or forged steel. Wheel treads

and flanges shall be rim toughened to between 320 and 370 Brinell hardness
number. Bridge and trolley wheels shall be double-flanged. Trolley wheels sha
1 have straight treads. Bridge wheels shall have straight treads. Wheels shall
be equipped with self-aligning double-row spherical roller-bearings of capacity
as recommended by bearing manufacturer for design load of trolley or bridge.
9. Bearings: Bearings shall be antifriction type, except bearings, which are
subject only to small rocker motion. Equalizer sheaves shall be equipped with
sintered oil – impregnated type bushings in accordance with ASTM B 438/B
438M, ASTM B 439 or ASTM B 439.
10. Anti-Drip Provisions: Cranes shall be designed to preclude leakage of
lubricants onto the lifted loads or the floor. Equipment and components, which
cannot be made leak-proof, shall be fitted with suitable drip pans. Drip pans
shall be manufactured of steel and designed to permit removal of collected
lubricant.

11. Lubrication System: Splash-type oil lubrication system shall be provided for
hoist, trolley and bridge gear cases; an oil pump shall be used on vertical-
mounted gear cases exceeding two reductions. Oil pumps shall be the
reversible type capable of maintaining the same oil flow direction and volume
while being driven in either direction. Electric motor-driven pumps may be
used when input shaft speed is too low at any operating condition to ensure
adequate oil flow. In such applications, pump shall be energized whenever
drive mechanism brakes are released.
12. Electrically Driven Oil Pump Alarm: If an electric-driven lubricating pump is
used, an audible alarm and red indicating light shall be provided and shall be
energized in the event of pump malfunction.
2.4 ELECTRICAL COMPONENTS
A. General Requirements: Motors shall be designed specifically for crane and hoist
duty. Drain holes shall be provided at low points near each end. Inspection and
service covers shall be provided with gaskets. Hardware shall be corrosion-resistant.
Motors shall conform to the requirements of NFPA 70, NEMA MG 1 and UL 1004.
Motor heaters shall be energized when mainline contactor is de-energized, and
water heaters shall be de-energized when mainline contactor is de-energized. Motors
15 lÑ 20 HP and larger shall be provided with a suitable heater to prevent
condensation during long periods of inactivity. One thermal sensitive device
embedded in hoist motor windings shall be provided. Device and associated circuitry
shall serve as an alarm activating an amber signal or pilot light visible to control
stations when motor temperatures become excessive. Set point shall be set below
the Class B insulation temperature limit. Thermal-sensitive device and associated
circuits shall be self-restoring (automatic reset). Two-speed, two-winding motors
with a solid-state control will not be allowed for creep-speed use.
B. Main Hoist Motor.
C. Motor Enclosures
D. Hoist Motor Insulation and Time Rating: Hoist motors shall be provided with
insulation which has a Class H rating based on an l25-degree C motor temperature
rise above 40 degrees C ambient, with frame size selection based on continuous
ratings.
E. Bridge and Trolley Motor Insulation and Time Rating: Bridge and trolley drive mtors
shall be provided with an insulation which has a Class H rating based on 125 degrees
C motor temperature rise above 40 degree C ambient with frame size selection based
on continuous rating.
F. Electric Brakes
1. Brakes: Electric-hydraulic trolley brakes shall be do shunt magnet type

equipped with hydraulic actuators manually-operated with a foot-operated
master control unit in the operator's cab, and electrically released with the
operation of the mainline contactor POWER-OFF pushbutton or power failure.
Remote control bleeders operable by pushbutton and foot pedal shall be

provided except for power-assisted brake systems. Remote control bleeders
shall be complete with pushbutton clearly labeled and located in operator's
cab where the operator can easily depress the pushbutton and pump the
brake simultaneously. In lieu of the combination electric-hydraulic brakes,
separate hydraulic and electric brakes may be provided. Hydraulic brake
system shall be designed to ensure equal pressure at each brake cylinder.
2. Hoist Brake Time Delay: One of the hoist holding brakes shall be provided with
a time-delay setting from 1 to 3 seconds. The time-delay shall be initiated
upon releasing the control pushbutton or returning the master switch to OFF.
Operation of mainline POWER-OFF pushbutton or power failure shall result in
each hoist brake’s setting without any time-delay.
3. Automatic Stop System: Electrically-controlled brakes shall be fail-safe spring
set when power is interrupted. Brakes shall be released with a mainline
contractor POWER-Off pushbutton or a master switch for the associated drive.
Brakes shall automatically stop when there is a power failure. Electric shall be
designed to be mechanically released. Enclosures for electrical – controlled
brake components shall be NEMA ICS 6 type. Direct current shunt magnetic
shoe brakes shall be provided with an electric
A. Control System: A separate controller shall be provided for each motor, a duplex
type for 2-motor bridge drives and a quadraplex type for 4-motor bridge drives on ac
central cranes. When 2-motor bridge drives are furnished and dc magnetic control is
required, dc series-connected motors shall be provided. When 4-motor bridge drives
are furnished and dc magnetic control is required, dc series-parallel connected
motors shall be provided. Overload protection shall be in conformance with
requirements of NEMA ICS 2 and NFPA 70. When contractors are used for starting,
stopping and reversing, contractors shall be mechanically and electrically interlocked.
1. Control Panels: Control Panels shall be fabricated of solid sheet steel designed
and constructed to conform to requirements of NEMA ICS 6 type at or above 0
degrees C shall be provided in each static crane control panel. Control panel
heaters shall be energized when mainline contractor is de-energized, and shall
be de-energized when mainline contactor is energized to prevent anti-
condensation. Control panel doors shall be hinged, equipped with gaskets and
fitted with key-lock handle design, complete with a single key to open all locks.
2. Main Hoist Control
a. Hoist motor control system shall provide two speeds in each direction
with of an electrically-operated, full-magnetic, across-the-line reversing
type starter. Electrical and mechanical interlocks shall be used to
prevent the operation of high speeds and low speeds.
b. Hoist control system shall provide reversing, constant potential dc, five-
speed, dynamic lowering, variable-resistance, do magnetic control of do
series wound hoist drive motors. Full-load lowering speed shall not
exceed the following percentages of rated full-load hoisting speeds: 30
percent on first point; 205 percent on fifth speed point. First point
hoisting shall provide not more than 30 percent of rated-motor speed at
no-load motor torque, and zero speed (plus 5 percent, minus 0 percent
of rated speed) at not less than G0 percent of rated-motor torque.
Emergency dynamic speed at no-load motor torque. Emergency dynamic

braking circuits shall be established when the motion control switch is in
the OFF position and when power supply is disrupted.
3. Bridge and Trolley Control
a. Bridge and trolley main control systems shall provide two speeds in each
direction with an electrically-operated, full- magnetic, across-the-line
reversing type starter. Centrifugal switches shall be used in control
circuit to prevent the plugging of trolley or bridge drive motors; each
switch shall be arranged to set the associated drive's brake while
attempts are made to plug. The ridge and trolley main control system
shall be provided with reduced voltage starting for all speed points.
b. Bridge and trolley main control systems shall be dc magnetic control
type, five-speed, reversing, plugging type.
4. General: Pendant control station enclosure shall be NEMA Type 12 Physical

size of pendant shall be held to a minimum. A separate cable of corrosion-
resistant chain consisting of minimum 6.4 mm 1/4 inch wire shall be provided.
Pendant station shall be attached to an auxiliary girder and shall hang
vertically with bottom of pendant at 1 m 40 inches above floor. Weight of
pendant shall not be supported by control cable.
5. Operating Pushbuttons: Operating pushbuttons shall be heavy-duty, dust-and-
oil-tight type with distinctly-felt operating positions which meet requirements
of NEMA ICS 2. Pendant control buttons shall be momentary pushbuttons.
Pushbuttons (except the POWER-OFF button) shall be the recessed type to
avoid accidental operation. Diameter of buttons shall be a size, which will
make operation possible with a thumb while holding the pendant with same
hand. Nameplates shall be provided adjacent to each pushbutton. Barriers
shall be provided on pendant between various pushbutton functions; except
on elements mounted in junction box. In a multi-speed application, dual-
position pushbuttons shall have a definite click-decent position for each speed.
Pushbuttons shall be designed and manufactured not to hang up in control
case. Pendant shall include a separate set of pushbuttons for each motion and
for POWER-ON POWER-OFF. Pushbuttons shall be as follows:
a. POWER-OFF
b. POWER-ON.
c. Hoist-up.
d. Hoist-down.
e. Trolley-left.
f. Trolley-right.
6. Light Indicators: Pilot lights shall meet heavy-duty requirements of NEMA ICS
2. One amber pilot light to indicate excessive hoist motor temperature shall be
provided on pendant station. A blue pilot light shall be provided to indicate
that the main contactor is energized, and a white pilot light to indicate that
power is available on the load side of crane disconnect switch. A bright red
mushroom head shall be provided with the POWER-OFF pushbutton. A 2-
position selector switch shall be provided to select between normal and micro-
drive. A single green pilot light shall be provided to indicate all micro-drive

clutches are engaged.
7. Pendant Drive Control: A 3-position momentary contact spring-return to OFF
toggle switch shall be provided to control the motorized trolley for pendant.
8. Transfer of Control Stations: Pendant shall be provided with a green pilot light
to indicate that control has been transferred to pendant station from cab with
key lock-out.
9. Circuit Breakers: Circuit breakers shall meet the requirements of UL 489.
10. Overloads: Alternating current circuit overload relays shall be of the ambient
compensated, automatic reset, inverse time type located in all phases
individual motor circuits. Overload relays shall be arranged to de-energize the
associated motor on an overload condition. An automatically reset inverse
time-trip running overload relay shall be provided for each do motor circuit. An
automatically reset instantaneous trip overload relay shall be provided in each
do motor circuit or for a pair of series-connected motors. Overload relays shall
be arranged to de-energize the associated motor on an overload condition.
C. Limit–Switches: Geared limit-switches shall be heavy-duty quick-break double-pole

double-throw type conforming to NE MA ICS 2. The geared limit-switch
interruption of a motion in one direction shall not prevent the opposite motion.
Geared limit-switches shall reset automatically. Limit-switch housings shall be NEMA
Type 4. Limit-switches shall Interrupt power to the primary and micro-drive control
systems.
1. Hoist Upper Limit-Switches: Two limit-switches shall be provided for each hoist.
A rotating-type adjustable geared-control circuit interrupt limit-switch shall
provide hoist-up limiting. A secondary hoist-upper-limit shall be provided with a
weight-operated power circuit limit-switch to prevent the hoist from raising
beyond the safe limit. The secondary limit-switch shall operate to interrupt
power to all hoist motor conductors, set the hoist holding brakes and directly
open all “raise” power circuits
2. Bridge and Trolley Travel Limit-Switches: Runway (track-type) limit-switches
shall be provided for crane bridge and trolley motions to stop the bridge and
trolley motions, respectively. Limit-switch actuators shall be installed on
building and trolley frame to actuate the limit-switches and stop the crane
bridge or trolley prior to contacting the trolley frame bumpers. Trip
mechanism for trolley motion shall be located on crane runway to trip the
switch before the bumper contacts the stop. Trip mechanism for bridge motion
shall be located on crane runway to trip switch before bumper contacts the
stop. When the switch is tripped, the switch shall permit opposite travel in the
direction of stop and then automatically reset.
A. Wiring: Wiring shall comply with Article 610 of NFPA 70. Wires shall be numbered or
tagged at connection points. Splices shall be made in boxes or panels on terminals
boards or standoff insulators. Motor loop, branch circuit and brake conductor
selection shall be based on NFPA 70 for 90 degree C conductor rating on indoor
cranes, and for 75 degree C conductor rating on outdoor cranes. Conductors in the
vicinity of resistors and conductors connected to resistors shall be Type 5RML.
1. Crane Runway Conductors: Collectors shall be heavy-duty sliding shoe type

compatible with the electrification system. Two tandem designed collector

heads shall be provided for each conductor rail to provide redundancy. Crane
runway conductor system shall be the festooned type consisting of a support
rail, cables, junction boxes, cable cars and accessories. Hardware shall be
corrosion-resistant or protected against corrosion.
2. Bridge Span Conductors: Bridge span conductor system shall be the festooned
type consisting of a support rail, electrical cables, junction boxes, cable cars
and accessories. Cable loops shall not drop below the hook high position.
Outdoor crane bridge festoon system hardware shall be corrosion resistant.
3. Pendant Festoon System: Pendant festoon system shall consist of a support
rail, cables, junction boxes, cable cars and accessories. Cable loops shall not
drop below the hook high position. Pendant control car shall be provided with
NEMA Type 12 junction box. Pendant festoon shall be towed by trolley.
Outdoor crane pendant festoon system hardware shall be corrosion resistant.
PART 3 - EXECUTION
3.1 ERECTION
A. The entire crane erection shall be performed in accordance with manufacturer's

instructions under the full-time supervision of the manufacturer's representative.
Contractor shall provide a written certificate from crane manufacturer indicating the
crane is erected in accordance with manufacturer's recommendations before testing
the completed installation.
1. Shop Assembly: Major crane components shall be shop assembled as

completely as possible. Disassembled parts shall be match marked and
electrical connections tagged after complete no-load shop testing. Parts and
equipment at site shall be protected from weather, damage, abuse and loss of
identification. Erection procedures shall ensure that the crane is erected
without initial stresses, forced or improvised fits, misalignments, nicks of high-
strength structural steel components, stress-raising welds and rough burrs.
Damaged painted surfaces shall be cleaned and repainted after crane is
erected. All necessary grease and oil of approved quality and grade for the
initial servicing and field test shall be provided by the Contractor.
2. Mechanical Alignment: Motors, couplings, brakes, gear boxes and drive
components shall be aligned when reinstalled in accordance with manufacturer's
instructions.
3. Electrical Alignment: Control system shall be aligned in accordance with
manufacturer's instructions. A copy of the final alignment data shall be stored
in control panel door and shall include but not be limited to timer settings,
resistor tap settings, potentiometer settings, test-point voltages, supply
voltages, motor voltages, motor currents and test conditions such as ambient
temperature, motor load, date performed and personn performing the
alignment.
4. Welding: Welders, welding operations and welding procedures shall be
qualified or prequalified in accordance with AW 114.1/D14.lM. Welding shall
be performed indoors and the surface of parts to be welded shall be free from
rust, scale, paint, grease or other foreign matter. Minimum preheat and
interpass temperatures shall conform to the requirements of AWS

D14.1/D14.lM. Welding shall be performed in accordance with written
procedures which specify the Contractor's standard dimensional tolerances for
deviation from camber and sweep. Such tolerances shall not exceed those
specified in accordance with AWS D14.1/D14.1M. Allowable stress ranges shall
be in accordance with CMAA 70. Welding of girders and beams shall conform
with AWS D14.1/D14.1M.
5. Field Painting: Painting required for surfaces not otherwise specified, and
finish painting of items only primed at the facility, shall be as specified in
Section 09 90 00 PAINTS AND COATINGS. Bridge crane including bridge, trolley,
hoist and all attached items shall be painted in accordance with the
manufacturer's standard practice. The complete crane shall be of one color.
Bridge rail, supports and bracing shall be painted in accordance with Section 09
90 00 PAINTS AND COATINGS. Items such as surfaces in contact with the rail
wheels, wheel tread, hooks, wire rope, surfaces on the electrical collector bars
in contact with the collector shoes and nameplates shall not be painted.
3.2 ACCEPTANCE TESTING
A. General: Contractor shall provide all personnel necessary to conduct the required
testing which shall include but not be limited to crane operators, riggers, rigging gear
and test weights. Testing shall be performed in the presence of Contracting Officer or
his designated representative. Contractor shall notify Contracting Officer 7 days prior
to testing operations. Contractor shall operate all equipment and make all necessary
corrections and adjustments prior to the testing operations witnessed by Contracting
Officer. A representative of the Contractor responsible for procuring and installing
hoist equipment shall be present to direct the field testing. Test loads shall be
compact and permit a minimum of 50 percent of vertical lift. Test loads shall be
minus 0 percent to plus 5 percent of the required weight and shall be verified prior to
testing. Operational testing shall not be performed until after building interior has
been painted. Three copies of all test reports shall be furnished to Contracting
officer.
1. Test Sequence: Crane shall be tested in accordance with applicable paragraphs

of this procedure in the sequence provided.
a. Inspect for evidence of bending, warping, permanent deformation,

cracking or malfunction of structural components.
b. Inspect for evidence of slippage in wire rope sockets and fittings.
c. Check for overheating in brake operation; check for proper stopping. All
safety devices including emergency stop switches and POWER-OFF
pushbuttons shall be tested and inspected separately to verify proper
operation of the brakes. When provided, safety accessories including
warning horn, lighting, gauges, warning lights and accuracy of wind
indicating device and alarm shall be inspected.
d. Check for abnormal noise or vibration and overheating in machinery
drive components.
e. Check wire rope sheaves and drum spooling for proper reeving and
operation, freedom of movement, abnormal noise or vibration.
f. Check electrical drive components for proper operation, freedom from

chatter, noise, overheating, and lockout/tagout devices for energy
isolation.
g. Inspect gears for abnormal wear patterns, damage, or inadequate
lubrication.
h. Verify that locations of crane capacity plates are visible from pendant
opeator’s position.
2. No-Load Testing
3. Load Test
a. Hoist Static Load Test: Holding brakes and hoisting components shall be
tested by raising the test load approximately 300 mm 1 foot and
manually releasing one of the holding brakes. Load shall be held for 10
minutes. First holding brake shall be reapplied and second holding brake
released. Load shall be held for 10 minutes. Any lowering that may occur
indicates a malfunction of brakes or lowering components.
b. Dynamic Load Test: Test load shall be raised and lowered through the
full range operating in each speed. Machinery shall be completely
stopped at least once in each direction to ensure proper brake
operation.
c. Hoist Mechanical Load Brake: With test load raised approximately 1.5 m
5 feet and with the hoist controller in the neutral position, holding brake
shall be released. Mechanical load brake shall be capable of holding the
test load. With holding brake in released position, test load shall be
lowered first point and the controller shall be returned to OFF position
as the test load lowers. Mechanical load brake shall prevent the test
load from accelerating.
d. Hoist Loss of Power Test: After raising test load to approximately 2.5 m 8
feet, slowly lowering the test load, the main power source and control
pushbutton shall be released verifying that the test load will not lower
and that both brakes will set. Test shall be repeated using micro-drive
controls.
e. Trolley Dynamic Load Test: While operating the trolley the full distance
of bridge rails in each direction with test load on the hook (one cycle),
proper functioning of all primary drive and speed control points and
proper brake action shall be tested.
f. Bridge Dynamic Load Test: With test load on hook, bridge shall be
operated for the full length of runway in both directions with trolley at
each extreme end of bridge. Proper functioning of all primary drive
speed control points and brake action shall be verified. Binding of the
bridge end trucks shall indicate malfunction.
A. Trolley and Bridge Loss of Power Test: A test load of 100 to 105 percent of rated load
shall be raised clear of any obstructions on operating floor. Starting at a safe distance
from walls or other obstructions, a slow speed shall be selected using the trolley and
bridge primary drive. While maintaining a safe distance to obstructions, the main
power source shall be disconnected and brakes shall be verified to have set and that
the equipment stops within the distance recommended by manufacturer.

B. Overload Tests: After the operational tests, bridge crane system and all functions of
bridge crane shall be tested at 125 percent of rated load.
C. Acceleration and Deceleration Tests: The acceleration and deceleration of bridge

and trolley shall be tested with approximately 10 percent of rated load at lowest
possible location of hook. Bridge and trolley shall be operated to run up to high
speed and then stopped without jarring or swinging the load.
D. Grounding Test: Hoist shall be tested to determine that the hoist, including hook and
pendant, are grounded to building during all phases of hoist operation. The
grounding of bridge and trolley shall be tested with approximately 10 percent of
rated load on hook. Grounding shall be tested between hoist hook and the
structure's grounding system.
E. Adjustments and Repairs: Adjustments and repairs shall be performed by Contractor

under the direction of the Contracting Officer at no additional cost to the
Government, until satisfactory conditions are maintained, and contract compliance is
affected. After adjustments are made to assure correct functioning of the
components, pertinent testing shall be repeated.
3.3 SCHEMATIC DIAGRAMS
A. Schematic diagrams for equipment shall be stored where indicated on drawings.
3.4 MANUFACTURER’S FIELD SERVICE REPRESENTATIVE
A. Contractor shall furnish a qualified experienced manufacturer's field service

representative to supervise the crane installation, assist in the performance of the on
site testing, and instruct personnel in the operational and maintenance features of
the equipment.
3.5 FIELD TRAINING
A. Contractor shall conduct a training course for e operating staff. Training period shall
consist of a total of hours at normal working time and shall start after the system is
functionally completed but prior to final acceptance. Course instructions shall cover
pertinent points involved in operating, starting, stopping, and servicing the
equipment, including all major elements of the Operation and Maintenance Manuals.
Course instructions shall demonstrate all routine maintenance operations such as
lubrication, general inspection; Contracting Officer shall be given at least 2 weeks
advance notice of field training.
3.6 SPARE PARTS
A. One set of manufacturer’s recommended spare parts shall be furnished and

delivered to the site. The spare parts shall be suitably packaged for long-term
protection and storage. The packaging shall be legibly labeled to identify the spare
parts. A list of the furnished spare parts shall be included in the Maintenance manual.

3.7 ACCEPTANCE
A. Final acceptance of crane system will not be given until Contractor has successfully
completed all testing operations, corrected all material and equipment defects,
made all proper operation adjustments, and removed paint or over spray on wire
rope, hook and electrical collector bars.
3.8 EQUIPMENT SCHEDULE
CRANE SCHEDULE
Crane Type Overhead Traveling
Capacity (Ton) 2
Span (M). 10
Crane Location (Building) Inside Pump Room
Quantity Required 1
END OF SECTION 412215.10


Vol. III (B)

Uploaded by

Copyright:

Available Formats

Vol. III (B)

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Vol. III (B)

Uploaded by

Copyright:

Available Formats

TECHNICAL SPECIFICATION COVER SHEET REVISED SHEETS

THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS BUT

REV. DATE PREPARED REVIEWED APPROVED PAGES REMARKS

A Oct. 2021 M.M. C.AMAM C.MYSM 3 ISSUED FOR DETAILED DSIGN

0 Jan. 2022 M.M. C.AMAM C.MYSM 3 ISSUED FOR TENDER

1 Feb. 2022 M.M. C.AMAM C.MYSM 3 ISSUED FOR CONSTRUCTION

ECG Form No. E409 Rev. 5/03 Sheet 0 of 3

METHOD OF MEASUREMENT, BILL OF QUANTITY,

000010 Table of Contents

DIVISION 1: GENERAL REQUIREMENTS

012700 Method of Measurement

033000 Cast In Place Concrete

042000 Unit Masonry

051200 Structural Steel

Division 07 Thermal and Moisture Protection

071340 Polyethylene Sheet

Table of Contents Section 000010

081113 Hollow Metal Doors and Frames

092400 Cement Plaster

102800 Toilet and Bath Accessories

Division 13 Special Construction

131500 Reinforced Concrete Water Structures

Division 21 Fire Suppression

212200 Clean-Agent Fire Extinguishing Systems

220523 General-Duty Valves for Plumbing Piping

Division 23 Heating Ventilating and Air Conditioning

230500 Common Work Results for Hvac

Table of Contents Section 000010

TECHNICAL SPECIFICATIONS – PART B

260513 Medium-Voltage Cables

Division 28 Electronic Safety and Security

283100 Fire-Alarm System

312000 Earth Moving

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

REV. DATE PREPARED REVIEWED APPROVED PAGES REMARKS

0 Jan. 2022 M.M. C.MMAL C.EBEE 16 ISSUED FOR TENDER

1 Feb. 2022 M.M. C.MMAL C.EBEE 16 ISSUED FOR CONSTRUCTION

ECG Form No. E409 Rev. 5/03 Sheet 0 of 16

MEDIUM VOLTAGE CABLES

Medium Voltage Cables Section 260513

1.1 RELATED DOCUMENTS

A Drawings and General Provisions of the Contract including General Conditions,

B The Contractor manufactures shall be responsible to deliver approved products, for

D Data and Samples: Equipment, performance and Manufacturer’s catalog data,

F Instructions: Manufacturer's Instructions shall be provided showing the

1. Medium Voltage Power Cable Systems

G Statements: Listing of products installed shall be provided showing qualifications of

Medium Voltage Cables Section 260513

1. Dielectric Absorption Tests

I Certificates: Certificates of Compliance shall be provided for the following showing

1.4 QUALITY ASSURANCE

a. Except as modified or supplemented herein, all equipment and

2. In addition to meet the requirements of this specification all cables provided

a. IEC 60228 Nominal cross-sectional areas and compositions of

Medium Voltage Cables Section 260513