ilo itb no 58/2017 annex 2 technical specifications lot a

CHAGHOUR HAMMANA – CAZA OF BAABDA. LOT A: CONSTRUCTION OF A 500 M3 GROUND RESERVOIR PAGE 1 OF 49

ILO ITB No 58/2017 Annex 2

Technical

Specifications LOT A LOT B LOT C

EIIP Lebanon received Technical Drawings and Specifications for the Construction of the Ground Reservoir, Construction & Equipping of Treatment & Control Station and Construction Gravity Line from the Ministry of Energy and Water. The design was prepared by World Engineering & Technology, Beirut & Mount Lebanon Water Establishment, and financially supported by UNICEF.


LOT A

Chaghour Hammana‐ Caza of Baabda: Construction of a 500m3 Ground

Reservoir



Contents LOT A Section i general specifications ...................................................................................................................................... 6

1. Definitions ........................................................................................................................................................ 6

2. Location ............................................................................................................................................................ 7

3. General requirements ..................................................................................................................................... 7

4. Sign boards and visibility panels ...................................................................................................................... 7

5. Method statements and time table schedule ................................................................................................. 7

6. Safeguards of existing pipes & relevant structures......................................................................................... 7

7. Record drawings .............................................................................................................................................. 7

8. Project management ....................................................................................................................................... 8

9. Required standards ......................................................................................................................................... 8

10. Silence of specifications ............................................................................................................................... 8

11. Correspondence and records .......................................................................................................................... 9

12. Units ............................................................................................................................................................. 9

13. Intent of the contract .................................................................................................................................. 9

14. Terms in the contract ................................................................................................................................... 9

15. Quality control ............................................................................................................................................. 9

16. Reporting ..................................................................................................................................................... 9

17. Refusal of delivered materials ................................................................................................................... 10

18. Quality of supplied materials and of workmanship .................................................................................. 10

19. Approval on materials ............................................................................................................................... 21

20. Work on private lands ............................................................................................................................... 21

21. Damages to utility properties .................................................................................................................... 21

22. Access road to site ..................................................................................................................................... 21

23. Site limits .................................................................................................................................................... 21

24. Work initiation – submittal of shop drawings ........................................................................................... 21

25. Levels, dimensions, benchmarks and level datum ................................................................................... 22

26. Miscellaneous works on site ..................................................................................................................... 22

27. Insurance ................................................................................................................................................... 22

28. Site demobilization .................................................................................................................................... 23

section ii particular specifications ................................................................................................................................ 24

lot a: construction of a 500 m3 ground reservoir ......................................................................................................... 24

1. Introduction .................................................................................................................................................... 24

1.1. Conditions on site ................................................................................................................................... 24

2. General requirements & guidelines ................................................................................................................ 24

2.1. Site mobilization ..................................................................................................................................... 24

2.2. Mobilization of equipment ..................................................................................................................... 24

2.3. Operation & maintenance manuals ....................................................................................................... 24

3. Submittals ....................................................................................................................................................... 25

3.1. Materials, product data, equipment specifications & catalogues .......................................................... 25

3.2. Shop drawings ........................................................................................................................................ 25

3.3. Manufacturer certifications ................................................................................................................... 26


3.4. Manufacturer recommendations ........................................................................................................... 26

3.5. Installation & testing .............................................................................................................................. 26

3.6. As‐built drawings .................................................................................................................................... 27

4. Material storage & handling ........................................................................................................................... 27

4.1. Transportation & handling ..................................................................................................................... 27

4.2. Storage & handling ................................................................................................................................. 27

4.3. Materials to be supplied by contractor .................................................................................................. 27

5. Excavations for concrete reservoir construction ............................................................................................. 28

5.1. Geo‐technical investigations & reporting ............................................................................................... 28

5.2. Excavations ............................................................................................................................................. 28

6. Concrete .......................................................................................................................................................... 29

6.1. Composition ........................................................................................................................................... 29

6.2. Cement ................................................................................................................................................... 30

6.3. Aggregate – sand .................................................................................................................................... 30

6.4. Broken rock and gravel ........................................................................................................................... 30

6.5. Storing of cement ................................................................................................................................... 31

6.6. Sampling of concrete .............................................................................................................................. 31

6.7. Stockpiling of aggregates ....................................................................................................................... 31

6.8. Ready mix concrete ................................................................................................................................ 32

6.9. Admixtures ............................................................................................................................................. 32

6.10. Water ..................................................................................................................................................... 32

6.11. Steel for concrete reinforcement ........................................................................................................... 32

6.12. Falsework & formwork ........................................................................................................................... 33

6.13. Tolerance ................................................................................................................................................ 35

7. Concreting ....................................................................................................................................................... 36

7.1. Requirements ......................................................................................................................................... 36

7.2. Transporting ........................................................................................................................................... 36

7.3. Placing & compaction ............................................................................................................................. 36

7.4. Concreting in deep lifts .......................................................................................................................... 36

7.5. Hot weather concreting (above 20ºc) .................................................................................................... 37

7.6. Wet weather concreting ........................................................................................................................ 37

7.7. Holes, cavities & fixings .......................................................................................................................... 37

7.8. Protection ............................................................................................................................................... 38

7.9. Membrane applied by spray ................................................................................................................... 38

7.10. Polythene sheeting ................................................................................................................................. 38

8. Water retaining structures .............................................................................................................................. 39

8.1. Construction joints in water retaining structures .................................................................................. 39

8.2. Water tightness of structures ................................................................................................................. 39

8.3. Waterproof coatings .............................................................................................................................. 39

8.4. Hydrophilic rubber sealer ....................................................................................................................... 39

9. Joints ............................................................................................................................................................... 40

9.1. Construction joints ................................................................................................................................. 40

9.2. Slabs supported on the ground .............................................................................................................. 40


9.3. Suspended beams & slabs ...................................................................................................................... 40

9.4. Walls ....................................................................................................................................................... 40

9.5. ‘wash‐off method’ of construction joints ............................................................................................... 40

9.6. Joints ...................................................................................................................................................... 40

9.7. Water stop.............................................................................................................................................. 41

9.8. Joint filler ................................................................................................................................................ 42

9.9. Joint sealants .......................................................................................................................................... 42

9.10. Slip membrane ....................................................................................................................................... 42

9.11. Dowel bars .............................................................................................................................................. 43

10. Finishing ...................................................................................................................................................... 43

10.1. General ................................................................................................................................................... 43

10.2. Surface finishing ..................................................................................................................................... 43

10.3. Making good ........................................................................................................................................... 43

11. Defects ............................................................................................................................................................ 44

11.1. Removal and replacement of unsatisfactory concrete .......................................................................... 44

11.2. Loading tests .......................................................................................................................................... 44

12. Water proofing & thermal insulation ......................................................................................................... 45

13. Thermal insulation ...................................................................................................................................... 46

14. Valves & accessories ................................................................................................................................... 46

14.1. Cast iron steel gate valves (pn 16 pressure valves) ................................................................................ 46

14.2. Standard materials for high pressure gate valves (where applicable) .................................................... 46

14.3. High pressure cast iron steel spring loaded check valve ........................................................................ 47

14.4. Pipe works .............................................................................................................................................. 47

14.5. Saddles, tees, flanges & other accessories installation .......................................................................... 47

15. Plastering (where applicable) ..................................................................................................................... 47

16. Block works ................................................................................................................................................. 48

17. Painting (where applicable) ........................................................................................................................ 48

18. Metal doors and louvers ............................................................................................................................. 49

18.1. Metalwork .............................................................................................................................................. 49

18.2. Surface finishing ..................................................................................................................................... 49

18.3. Protection of metals against corrosion .................................................................................................. 49


Section I General Specifications

1. DEFINITIONS

• Architect and Engineer: also referred to as Design Architect or Engineer means the individual or organization who furnished the design, which includes but not limited to the construction drawings and technical specifications

• The “project implementer” means Employment Intensive Infrastructure Progamme in Lebanon (EIIP).

• The “EIIP Project Engineer”, means the person whose services have been engaged by EIIP Project to technically monitor and administer the subcontract as provided therein, as will be notified in writing to the contractor or stated in the Contract Data of the contract.

• The “contractor” means the person or corporate body whose bid to carry out the work has been accepted by the project implementer who in this case is EIIP Project.


2. LOCATION

The project is located in the village of Hammana – Caza of Baabda.

Hammana village gets its water from a local spring (Al Chaghour spring) located at 1400 meters above sea level. An old ductile iron pipeline conveys water to the village’s reservoir.

During winter season Chaghour’s water become highly turbid and the village is completely deprived from water.

3. GENERAL REQUIREMENTS

Prior to any works, the contractor must obtain written EIIP Project Engineer.

Approval must include proposed time table schedule submitted by Contractor, and approved by EIIP Project .

Contractor responsibilities include:

• Site investigation and location of existing infrastructural installations,

• Site investigation of reservoir location and reservoir access road to allow for the transportation of material needed for reservoir construction.

4. SIGN BOARDS AND VISIBILITY PANELS

Contractor must provide visibility signs (sign boards) approved by EIIP Project. 5. METHOD STATEMENTS AND TIME TABLE SCHEDULE

The Contractor shall provide in a reasonably timely manner a method statement to the EIIP Project engineer for any part of works upon request from the EIIP Project engineer.

The Contractor shall also provide a detailed time table schedule on MS project or Primavera software, indicating all the phases of the project, starting and ending dates and specific key times for any particular job and major milestones to be achieved all along implementation period.

All schedules shall be in the English language and any system of dimensions (English or metric) shown shall be consistent with that used in the subcontract.

An update of the schedule shall be provided, schedule of deliverables, showing the actual progress achieved on each activity and the effect of the progress achieved on the timing of the remaining work, including any changes to the sequence of the activities.

The contractor shall submit to the EIIP Project engineer for approval an update schedule.

The EIIP Project engineer approval of the schedule shall not alter the contractor’s obligation to perform within the period of performance. The contractor may revise the schedule and submit it to the EIIP Project engineer again at any time. A revised schedule shall show the effect of change orders, where applicable.

6. SAFEGUARDS OF EXISTING PIPES & RELEVANT STRUCTURES

It shall be the Contractor’s responsibility to safeguard by means of temporary and permanent support or otherwise all existing installations that will be encountered during the construction of pipeline networks and reservoir.

7. RECORD DRAWINGS

Where the Contractor executes work under the contract, including locations where the Contractor undertakes construction, repair or rehabilitations work. The Contractor shall record the location and nature of all existing installations and their associated services.

Where instructed by the EIIP Project Engineer for the purpose of producing record drawings, the Contractor shall undertake such surveys and investigations to determine the location of existing services. Such surveys and investigations shall be additional to those surveys and investigations undertaken by the Contractor for the purpose of determining the location of services prior to excavation.


The Contractor shall where necessary utilize appropriate equipment and where instructed by the EIIP Project engineer excavate trial pits to confirm the location and determine the size and nature of the buried services.

For sites where the Contractor undertakes permanent works the record drawings shall be submitted to the EIIP Project Engineer for approval, as part of the as built drawings. In the case of repairs and rehabilitation the record drawings shall be submitted for approval within a period of 15 days following execution of the work.

8. PROJECT MANAGEMENT

The Contractor shall provide within his site organization a project management section to recommend and be directly responsible to the Contractor’s Project Manager. The duties of the section shall include the following:

Planning and program preparation particularly in relation to the requirements of the Employer and the public authorities, and the requirements to maintain water supply service where careful detailed arrangements have to be made and adhered to.

Planning the execution of the works in a manner which minimizes disruption to the water supply system and will permit the efficient and effective commissioning of the water supply system and their respective components.

Ensuring that adequate potable water supplies are maintained to all consumers, and that no contamination to those pipes might result from his ongoing works.

Continuous surveillance of progress and anticipation of factors likely to affect the timely performance of the contract.

Making proposal for modification to forward planning and to the program at an early stage in the light of factors resulting from (d) above.

Continuous appraisal of the Contractor’s methods and routines particularly as to their effectiveness relating to speed of execution and to their effect on the community and property.

Forward planning for resource requirements taking due account of possible shortages and delays in the arrival on site of materials, equipment, plant and personal and their mobilization for effective usage.

Acquisition and process of up-to-date information for progress with the EIIP Project Engineer. The preparation of monthly progress reports including an update of the detailed program and cash flow forecast which shall include progress pictures as directed by the EIIP Project Engineer.

9. REQUIRED STANDARDS

Works covering the construction of reservoir must conform to the technical specifications described later on in the tender documents.

Any reference to codes, specifications or standard means the latest edition or revision of above referenced codes or standard.

Any work shall be manufactured (constructed), tested and installed in conformance to international standards, or regulations applicable to such work.

The approval of “EIIP Project engineer” is a must prior to any work.

Any alternative proposal on required standards covering specifications, drawings and bill of quantities, must be approved by “EIIP Project engineer”.

Proposed standards and codes governing this contract cover pipeline networks and related accessories, reservoir construction and valve chambers as well as all works required to complete the project.

10. SILENCE OF SPECIFICATIONS


The apparent silence of the specifications as to any detail, shall be considered as meaning “that only the best general practice” is to be used.

In such case “EIIP Project engineer ” will make the necessary and relevant interpretations covering such works.

11. CORRESPONDENCE AND RECORDS

All correspondence between Contractor and “EIIP Project engineer ” shall be made in English. All records, sheets, drawings and documents shall be in English language.

12. UNITS

The international system of metric units shall be used throughout this contract.

13. INTENT OF THE CONTRACT

The contract determines and specifies all the work conditions for the construction and completion of the desired work.

Intent of contract is also the description of the work procedures in every detail enlisting all items related to:

The responsibilities and duties of the Contractor to furnish all the supplies, such as: labors material, equipment, transportation in accordance with the plans, specifications and terms of the contract documents.

Submittal of shop drawings, (plans & sections) will be approved or returned for modifications within 8 days of submittal.

14. TERMS IN THE CONTRACT

Expressions Like:

• Contractor refers to the entity responsible for implementing the works.

• “As shown”, “as indicate”, “as detailed” as terms of the same connotation, imply that the work should be done according to the drawings and the related specifications.

• “As approved”, “as directed”, “as required”, “as accepted” should mean and understood that the approval, direction, requirement, permission, authorization, review or acceptance of the “EIIP Project engineer “ is intended

• “Provide”, that be understood to mean “complete in place”, “that is”, “furnish and install”.

• “Equal” or “equivalent” means that material or equipment will be acceptable when composed of parts or equal quality, or equal workmanship and finish, designed and constructed to perform or accomplish the desired result as efficiently as the named brand, pattern, grade, class or model.

15. QUALITY CONTROL

Contractor is responsible for his own quality control and shall provide competent personal for supervising his works, taking and preparing samples and for carrying out all necessary required tasks including asphalt cutting pipes welding, concrete construction & casting, trench backfilling, installation of valves road reinstatement and carrying out all necessary tests during work implementation.

16. REPORTING

Contractor in coordination with “EIIP Project engineer ” will prepare and submit a detailed measurement of works that are completed within the month frame.

All materials that must be brought on site must be supplied in suitable containers and in appropriate batch sizes for the work to be undertaken.


Information to be provided:

• Storage instructions.

• The manufacturer’s name.

• Shelf life and dates of manufacture.

• Material identification.

• Batch reference number.

• Net weight.

• Mixing instructions.

• Any warnings or precautions concerning the contents and their safe use;

Add to this that Contractor shall supply with each consignment of proprietary material delivered to the site, certificate furnished by the manufacturer including:

• The manufacturer’s name and address;

• Material identification;

• Batch reference numbers, size of each batch and the number of containers in the consignment;

• Date of manufacture;

17. REFUSAL OF DELIVERED MATERIALS

In case delivered articles or materials are found unsound or of poor quality, such items will not be used and must be removed from site, and replaced by materials pre-inspected and approved by “EIIP Project engineer ”.

18. QUALITY OF SUPPLIED MATERIALS AND OF WORKMANSHIP

The materials and work man ship shall be the best of their respective kinds to the approval of the “EIIP Project engineer ”.

The words “to the approval of “EIIP Project engineer ” shall be deemed to be included in the description of all materials and workmanship for the due execution of works.


19. APPROVAL ON MATERIALS

All proposed and supplied sources of materials, construction requirements and proposed standards should be deemed to the “EIIP Project Engineer ’s” approval, the “EIIP Project Engineer’s” has to approve and agree upon any standard or method of manufacture or specification whether to maintain or change these items.

In other words, nothing related to the constructions or works, or the choice of standard materials in terms of quality (and liability or validity) should be carried out or obtained without the ultimate approval of the “EIIP Project Engineer”.

Samples of materials shall be submitted to the “EIIP Project Engineer” for approval, materials supplied must confirm to the quality of the samples that have been approved by the “EIIP Project Engineer”.

20. WORK ON PRIVATE LANDS

There will be no need to obtain clearance from private owners unless specified otherwise.

In any case and unless clearance is given by the Water Establishment and the concerned municipality, the contractor shall not disrupt any private or public access way without providing alternative arrangements, in such case property access affected by the works must be maintained, trench crossings must be provided via special road plates.

21. DAMAGES TO UTILITY PROPERTIES

Any damage occurring in the course or progress of work that is adjacent to telegraph, telephone and power agencies or companies or even adjacent to neighboring property, shall be rearranged on Contractor’s expenses in cooperation with the owners of any underground or overhead utility lines.

The damage resulting in terms of considerable expense or inconvenience shall be managed before the continuation of work.

22. ACCESS ROAD TO SITE

Beside main access road any other work requesting access to specific location on site must be implemented and achieved by Contractor himself.

The employer does not guarantee availability of any temporary or existing road inside site premises, and will not entertain any claim in respect of the non-suitability or availability of any such road for continuous use during the contract period.

At the end of works, all temporary roads must be closed, and Contractor must restore landscape to its original form or as indicated by “EIIP Project Engineer ”.

23. SITE LIMITS

Once boundaries and site limits have been established; (during handing over of site to Contractor) existing boundaries (fences, wire mesh, walls, sidewalks….) will not be modified unless approved by “EIIP Project Engineer”.

24. WORK INITIATION – SUBMITTAL OF SHOP DRAWINGS

Upon receiving clearance to start works, Contractor will submit to the “EIIP Project Engineer’s” approval, detailed drawings and data sheets required to start works.

Coordination will be made between “EIIP Project Engineer” and Contractor, so as to agree on basic information supplementary to that shown on submitted drawings like base lines, borders, center lines in order to locate exact level of pipes and their relative slopes.

Supplementary information will be submitted on draft drawings, sketches or in writing.


The Contractor shall submit to the “EIIP Project Engineer” shop drawings that shall satisfactorily establish actual details of manufactured or fabricated items and of works to be executed.

Shop drawings shall clarify and amplify the design drawings and other design requirements and shall, incorporate minor changes in design or construction as may be necessary to suit the requirements of the work.

By submitting shop drawings, the Contractor thereby admits that he has determined and verified all dimensions in relations to existing works, as well as with regards to future works on site.

Accuracy of information submitted by Contractor is under his strict responsibility and any discrepancies, errors or omissions in supplied drawings must be corrected and then re-approved by “EIIP Project Engineer”.

The Contractor shall submit final as-built record drawings to the “EIIP Project Engineer” for his review by the specified date.

After review and approval by the “EIIP Project Engineer” of the final as-built drawings, the Contractor shall within 7 days thereof, produce a final set of “as-built drawings” and submit to the “EIIP Project Engineer”, one computerized disk copy and 2 printed copies.

In case there are no changes with proposed design drawings, the contractor must obtain the approval of “EIIP Project Engineer” prior to commence works.

25. LEVELS, DIMENSIONS, BENCHMARKS AND LEVEL DATUM

All construction drawings must be referred to the institute of national height datum. The contractor must obtain the location of permanent bench marks.

In the event that benchmarks do not exist, site datum must be approved by “EIIP Project Engineer”.

Upon commencement of construction work, steel datum pegs shall be erected in locations approved by “EIIP Project Engineer”.

All levels used in the construction shall be referred to these steel pegs.

Accuracy of established datum shall be regularly checked during the construction process. Benchmarks in the area that appear on the drawings shall be established by Contractor.

The Contractor shall provide one sign board mounted on suitable steel frame, in positions and heights indicated by “EIIP Project Engineer ”.

Wherever necessary, safety barriers must be installed to protect pedestrians and people working on site as well as visitors.

26. MISCELLANEOUS WORKS ON SITE

While working on site, Contractor must keep the site as clean as possible by removing wastes, debris and other materials to approved dumping locations.

At the end of works, Contractor shall clean the site to restore it to its initial condition, to the exception of works he has completed.

On all occasions works shall be properly flagged.

Site must be lighted at sunset and whenever visibility is found poor.

27. INSURANCE

Contractor must insure his staff and materials against incident and theft, and must also insure his site against any incident that might occur to pedestrians and vehicles and against any third party claim with regard to his work on site.

Insurance must cover the whole period of works on site.


28. SITE DEMOBILIZATION

Upon completion of works and after getting the approval of “EIIP Project Engineer ”, Contractor will start dismantling of stores, work shops, offices and will proceed to the removal of all equipment from site.

Contractor must clean the site and remove all remaining debris, materials in excess, temporary structures.


Section II Particular Specifications

LOT A: Construction of a 500 m3 Ground Reservoir 1. INTRODUCTION

EIIP Project assistance will be in the construction of a 500m3 ground reservoir and 1 new valve chamber on the same land parcel of the existing old reservoir and valve chambers that must be demolished prior to the construction of the new structures.

1.1. Conditions on site

Before carrying out works, the site shall be inspected by the Contractor in conjunction with the “EIIP Project engineer ” to establish its general condition which shall be agreed and recorded in writing, and where in the opinion of the EIIP Project engineer it is deemed necessary, by means of photography.

Details records shall include the location of all boundary and survey beacons, the conditions of buildings, surfaces, terracing (if any), ditches, watercourses, roads, tracks, fences and other information relating to the site and elsewhere which may be affected by the works. 2. GENERAL REQUIREMENTS & GUIDELINES

2.1. Site Mobilization

Mobilization of site covers all preliminary works necessary to start works on the ground.

Contractor is requested to submit a Construction Planning Program (C.P.P) with a time table schedule sheet, C.P.P must describe every task and its correlation with any other job.

Submitted time table must also cover ordering and delivering of materials and consumables.

Contractor’s time table schedule sheet will be used as the basis for progress reports during construction phase (weekly & monthly).

2.2. Mobilization of Equipment

All equipment and machinery needed to implement works must be brought on site prior to the startup of works.

Contractor must provide equipment in good conditions recently maintained and tested.

All consumables needed for machinery and equipment operation must also be brought on site and properly stored in a safe way and to the approval of the “EIIP Project engineer ”.

Fine tuning of various machinery’s engines must be implemented prior to work on site to prevent pollution during operation (Obnoxious gas).

2.3. Operation & Maintenance Manuals

The “EIIP Project engineer ” will control and supervise, and eventually approve any set of instructions, after the Contractor has submitted draft copies of the operation and maintenance manuals. On the other hand,


the Contractor shall abide and conform to any amendments on additions necessary and indispensable dictated by the “EIIP Project Engineer“ in the production of the final manuals. Each installation requires a provision of a separate set of instructions.

The Contractor shall confine his work to verify that all the instructions are being followed step by step till the completion of each section or part of the works respectively.

Any modifications of the original or initial manuals shall be incorporated in the final version.

Operation & maintenance should be supplied in a written form in both English and Arab languages. All parts and equipment listings are to be described and listed in English.

The draft operation and maintenance manuals must be on site during tests and this to verify that operations comply with instructions.

Any modifications found necessary will be incorporated in the final operation and maintenance version.

3. SUBMITTALS

The Contractor shall order materials to suit the construction program and shall plan his necessary submittals to the “EIIP Project engineer” in accordance with the required specifications in a timely manner to suit the ordering, delivery and construction timing requirements. The Contractor shall submit as a minimum the following documents for review and approval by the “EIIP Project engineer ”.

3.1. Materials, Product Data, Equipment Specifications & Catalogues

All specifications, diagrams, samples, drawings and such other data shall be provided by the Contractor, in a format to be agreed upon with the “EIIP Project engineer ”, which may be required to demonstrate compliance with the specification.

This shall include but not limited to the following information:

• Originals of catalogues and Supervising data sheets for manufactured items; each item and option to be provided shall be clearly marked and each item not be provided shall be deleted.

• Literature to show that products provided meet the requirements for material, construction, operation, and testing.

• Information on the following items as a minimum: pipes; pipe jointing systems, manhole covers and all other hydraulic accessories.

• Manufacturer’s installation instructions for all items.

• Certified reports for all tests and inspections designated herein, showing full compliance with referenced standards.

• Maintenance requirements and procedures.

• Period of guarantee for products. 3.2. Shop drawings

The Contractor shall prepare shop drawings based on project design plans and section including but not limited to the following information:

• Drawings (plans & sections) for the proposed ground reservoir and valve chamber.

• Updating topographical stakes and reservoir limits in order to ensure the reservoir is at an adequate distance from the road and neighboring plots


• Information on all equipment and material to be supplied including brand, class, grade, pressure rating, dimension, location and identification number of each item, pipes hydraulic accessories and pipe fitting to be furnished and installed.

• Procedures for installations.

• All other miscellaneous details required to complete the whole installation process The review and approval of shop drawings by the “EIIP Project engineer” shall not relieve the Contractor from any of his responsibilities under the contract for successful completion of the work.

3.3. Manufacturer Certifications

In case decided by the client, Contractor must submit a certification mark scheme issued by an independent third party testing organization to the satisfaction of “EIIP Project engineer ” stating that production has been carried out under a standard system for supervision, control and testing, applied during manufacture, in accordance with ISO or an equal procedure.

In any case, Contractor will have to submit a certificate of origin and production date of material that must not exceed 18 months.

3.4. Manufacturer Recommendations

The Contractor shall submit installation recommendations issued by the manufacturer for construction, installation, and commissioning of all piping equipment and related accessories.

Recommendations shall include testing methods, storage requirements and maintenance and operational data.

The Contractor shall have a copy of the manufacturer’s instructions available on site at all times while works are in progress and shall strictly follow these instructions unless otherwise authorized to deviate by the “EIIP Project engineer”.

3.5. Installation & Testing

The Contractor shall submit his proposed work method statement prior to commencing work.

The statement shall detail proposed sequence of work, hold points, testing frequency and document control.


3.6. As‐built Drawings

The Contractor shall maintain one set of contract drawings for the sole purpose of recording accurate changes made as the work progresses (“As-Built” conditions of the water project).

All changes previously agreed upon with the “EIIP Project engineer” and all completed work shall be recorded on these drawings.

The Contractor shall prepare as-built drawings clearly showing all shapes and dimensions of all works as executed. All pumps, pipes valves locations shall be identified and recorded. The Contractor shall submit as-built drawings for all installations. 4. MATERIAL STORAGE & HANDLING

4.1. Transportation & Handling

All materials shall be delivered in the manufacturers' original protective packaging and shall be inspected by “EIIP Project engineer” upon delivery on site.

Any products, which are damaged and are not in accordance with specifications shall be immediately removed from the site and replaced on Contractor’s expenses.

The Contractor must inspect the shipments to assure that products comply with requirements, and that delivered quantities are correct and undamaged.

All products shall be handled and stored in accordance with manufacturer’s printed recommendations.

The manufacturer must package products for shipment in a manner suitable for safe transport by commercial carrier. When delivered, a receiving inspection shall be performed, and any shipping damage must be reported to the manufacturer, contractor being obliged to replace damaged materials immediately.

It is the responsibility of the Contractor to safety transport pump sets, control panels and all hydraulic accessories to site and proceed for proper stockpiling.

4.2. Storage & Handling

The Contractor shall store and protect products in accordance with manufacturers' instructions, with seals and labels intact and legible.

The Contractor shall cover products subject to deterioration with impervious sheet covering and provide ventilation to avoid condensation.

The Contractor shall arrange storage of products to permit access for inspection and shall periodically inspect products to ensure that the products are undamaged and are maintained under specified conditions.

4.3. Materials to be supplied by Contractor

All material that must be provided by the Contractor for the construction of the reservoir, shall include but are not limited to:

• Cement

• Aggregates (sand and gravel)

• Steel

• Scaffolding

• Concrete add-mixture products


• Pipes for valve chambers

• Valves

• Fittings The material provided by the Contractor shall include all material for temporary works, planking and strutting, excavations, shuttering and formwork, staging and scaffolding, compliant filling materials, such as primer, coal tar enamel etc., all concrete of each required class including reinforcing steel and mesh.

All materials supplied locally by the Contractor shall be of the best quality in their class and of the respective kinds as described in the contract and in accordance with the “EIIP Project engineer’s” instructions and to the satisfaction of the “EIIP Project engineer ”. They shall be inspected from time to time at the site during the progress of the work.

Any materials arriving on site found unsuitable shall be rejected. The Contractor shall replace the rejected material at his own expense. 5. EXCAVATIONS FOR CONCRETE RESERVOIR CONSTRUCTION

5.1. Geo‐Technical Investigations & Reporting

The contractor will undertake a detailed geo-technical investigation to determine the exact nature of sub- service formations. In order to do so, the contractor needs to:

• Provide a special coring drill capable of reaching a depth of 15 meters below ground level.

• Undertake a minimum of 3 different coring samples with a minimum depth of 10 meters per core A comprehensive geo-technical report should then be submitted, detailing the results of the phases of the investigation as described above. The site soil should be clearly identified and described in accordance with the ASTM standards, and should include the following:

• Subsurface interpretation profile with suggested design parameters for each of the strata encountered (bulk density, shear strength parameters, and permeability)

• Recommendation for Foundation design (Foundation type, allowable bearing capacity, and modulus of subgrade reaction)

• Discussion of possible settlements and lateral earth pressure

• Clear recommendations and provisions for excavation support

• Discussion of possible dewatering schemes and requirements for the raft foundation of the reservoir given the rough information on permeability obtained from the investigation program

• Submittal of 4 factual report copies that include borehole logs, photographs, laboratory test results and all data required

5.2. Excavations

Prior to the excavation process, contractor must demolish existing reservoir and remove all debris to authorized dumping places.

Demolishing of reservoir must be implemented after taking all preventive measures to protect the workers on site, machineries and neighboring structures; moreover contractor must preserve the site and restore the site to its initial condition prior to the beginning of works.

Contractor to proceed for excavations at indicated locations for ground reservoir.


Excavations shall be to the depth indicated by EIIP Project engineer based on geo-technical investigation findings.

All excavations shall be deemed to consist of “Common Excavations” regardless of the nature of encountered soils.

The contractor must verify the natural ground level where reservoir shall be erected; he shall take all levels and proceed for the topographical stacking of final reservoir location.

In case dewatering is needed to reach final depth contractor shall take all necessary arrangements to divert water or pumping it outside the excavated pit and this, during the whole period prior to the construction of the concrete structure.

The sides of excavations shall be supported wherever needed or instructed by EIIP Project engineer .

Contractor must take all necessary precautions to protect his employees and EIIP Project staff and any other person that might be present on site, especially in order to avoid slipping, falling or any other incident that might occur.

For this, contractor must also install a protective fence beside opened trenches and shall provide warning lights for night view.

All additional excavated volumes must be disposed of in legally designated dumping sites.

6. CONCRETE

Concrete will be used for ground reservoir construction as well as valve chamber and retaining walls. Concrete must have a minimum compressive strength of 300 kg/cm2 at 28 days.

6.1. Composition

Concrete shall be composed of cement, sand, broken rock or gravel, and water all well mixed and brought to the proper consistency. In case of adverse weather conditions (freezing temperature), powdered admixture shall be added to decrease concrete curing period.

The exact proportions, in which these materials are to be used for different parts of the work, shall be as determined from time to time during the progress of the work and as analysis and tests are made of samples of the aggregates and the resulting concrete.

The meter cube of concrete shall be composed as follows:

• 350 to 400 Kg of Portland cement,

• 800 Liters of gravels as per required specification with maximum gravel size of 20 mm,

• 400 Liters of sand free from organic materials (marine sand is strictly forbidden). These proportions may be modified to suit the work or the nature of the materials used or to comply with the water cement ratio limitation hereinafter specified.

The individual mixes will be based upon securing concrete having suitable workability, density, impermeability, and required strength, without the use of an excessive amount of cement.

Such means and equipment as are required shall be provided to accurately determine and control the relative amounts of the various materials, including water and each individual size of aggregate entering the concrete.


All batches of concrete shall be proportioned on the basis of integral sacks of cement, unless the cement is weighed, and the amount of each individual size of aggregate entering each batch of concrete shall be determined by direct weighing.

The amount of water shall be determined by direct weighing or volumetric measurement.

The amount of water used shall be changed as required to secure concrete of proper consistency and to adjust for any variation in moisture content of the aggregate as it enters the mixer, provided that a water cement ratio of 0.60, by weight, shall not at any time exceeded.

Contractor is responsible for the design of concrete and shall take the approval of “EIIP Project engineer “ for the mix proportions.

The proportion of cement, aggregates and water shall be determined in accordance with (2, 3, and 4) BS 5328.

Cylinders of concrete must be put on site (minimum 3 for each cast), and crushing tests will be made at day 7 & day 28.

The quantity of water entering any batch of concrete shall be just sufficient, with a normal mixing period, to produce concrete of the required consistency.

Excessive over mixing, requiring additions of water to preserve the required concrete consistency will not be permitted.

Uniformity in concrete consistency from batch to batch will be required. Slump tests will be made in accordance with the Tentative Method of Test for Consistency of Portland- Cement Concrete (A.S.T.M. Designation: D138-32T) of the American Society for Testing Materials.

6.2. Cement

Cement for concrete shall comply with the Standard Specifications for Portland cement, and shall be C-S 42,5 according to the Lebanese norm, also the heat of hydration of cement measured by the method of “ Bouteille isolante” defined by “ Centre d’Etudes et de Recherches de l’industrie des liants hydraulique” shall not exceed 70 calories / gram of cement at t= 7 days

Cement delivered in bulk shall not be used.

The quality of the Portland cement shall be equivalent to AASHTO M85, type I, II, III or V. Cement will be delivered in bags of 50 kg each.

6.3. Aggregate – Sand

Sand for concrete and grout may be obtained from natural deposits or may be made by crushing suitable rock.

The sand particles shall be hard, dense, durable, uncoated, nonorganic rock fragments that will pass a 6mm square or a 8mm round opening.

It must be free from injurious amounts of dust, lumps, soft or flaky particles, shale, alkali, organic matter, loam, mica, or other deleterious substances.

The sand as it is used in the concrete must be so graded that concrete of the required workability, density, and strength can be made without the use of an excess of water or cement.

The sand for concrete shall have a fineness modulus of not less than 2.75 nor more than 3.25, unless approval is given to use sand not meeting this requirement.

6.4. Broken Rock and Gravel


The broken rock or gravel for concrete must be hard, dense, durable, uncoated rock fragments free from injurious amounts of soft friable, thin, elongated, or laminated pieces, alkali, organic, or other deleterious matter.

It shall be so graded that concrete of the required workability, density, and strength can be made without the use of an excess of sand, water, or cement.

The suitability of the broken rock or gravel will be determined with the aid of tests made in accordance with the standard practices.

Any crushing, blending, screening, washing, or other operation on the broken rock or gravel required to meet these specifications shall be done by the Contractor, and the cost thereof shall be included in the unit prices bid in the schedule for the items of work in which the broken rock or gravel is used.

The broken rock or gravel shall all pass through a screen having 7 cm square or 8 cm round openings and shall be retained on a screen having 0.7 cm square or 0.8 cm round openings.

It shall also be separated into three intermediate sizes by screens having 2 cm square or 2.25 cm round openings and 4 cm square or 4.5 cm round openings.

Screens having openings of other sizes or shapes may be used, provided that equivalent results, as determined by test, are obtained.

The relative amounts of each size of broken rock or gravel to be used in each mix of concrete and in all parts of the work will be based on securing concrete having the required workability, density, impermeability, strength, and economy, without the use of an excess of sand, water, or cement, and using, insofar as practicable, the entire yield of suitable material from the natural deposits from which the broken rock or gravel is obtained.

For concrete used in structural parts of chambers the maximum size of particles shall not exceed 2 cm. For other uses of concrete the maximum size can go up to 3 cm.

6.5. Storing of Cement

Cement bags will be stock piled on site and must be protected from any damage occurring by climatic conditions.

Cement must be transported to the mixer in its original sacks. Each batch shall contain the full amount of cement for the batch. In case cement is placed in contact with the aggregates it must be mixed within 60 minutes or it will be rejected.

6.6. Sampling of Concrete

Preparation of concrete will be under contactor’s responsibility.

Approval of “EIIP Project engineer ” on mix proportions must be obtained at least one week prior to the beginning of concrete work.

Mixing proportions of cement, aggregates and water must be done in accordance with BS 5328. Concrete must have a minimum compressive strength of 300 kg/cm2 at 28 days.

For each cast a minimum of two cylinders must be taken and stored in adequate places as specified by “EIIP Project engineer”.

Cylinders on site will be stored in a locked place and key will be put at the disposal of “EIIP Project engineer”.

6.7. Stockpiling of Aggregates


Batching site must have an adequate size to allow the stockpiling of materials.

Approved materials must be in sufficient quantities so work can be implemented without interruption.

All aggregates will be stored (stockpiled) before use in order to prevent segregation of material and to provide uniform conditions for proportioning mixing control, thus obtaining a uniform concrete.

In any case stockpiling of aggregates must be approved by “EIIP Project engineer” and every precaution must be taken to prevent segregation like not making layers above 1.5 m and in case additional layer is brought to site it is forbidden to cone down new layer above old one.

Also aggregates must be protected against contamination from water diverted from site or from water pumped during dewatering of ponds.

If instructed by “EIIP Project engineer”, aggregate stockpiles will be sprinkled with water 12 hours before use and this in order to maintain moisture content in the aggregates equivalent to the water absorption value of the aggregates as determined by AASHTO T84 & 85.

6.8. Ready Mix Concrete

Ready mix concrete can be used and must have the same properties listed above. Unless otherwise stated the relevant clauses of BS 1926 shall apply.

Ready mixed concrete shall only be used after approval of the EIIP Project engineer .

The contractor shall not be relieved of his obligation to provide concrete to the standard laid down in this Specification by virtue of any approval given for the use of concrete supplied by others, and the EIIP Project Engineer reserves the right to withdraw his approval at any time consequent on any deterioration in the quality of the concrete, or unsatisfactory delivery or any other reason he considered detrimental to the Works,

Ready mixed concrete manufactured off the site shall be transported in a revolving drum and shall be continuously agitated until it is used in the work unless otherwise approved. The time interval between adding water to the drum and placing shall not exceed 90 minutes.

6.9. Admixtures

Before approval for the use of a proprietary admixture is given the Contractor will be required to satisfy the EIIP Project Engineer as to its suitability for the work and its compatibility with the cement it is intended to complement and for the intended use of structure. Admixtures that contain chlorine shall not be used for potable water retaining structures.

6.10. Water

Water for use in concrete and in concreting operations shall be of potable quality:

Where required by the EIIP Project engineer it shall be tested in accordance with BS 3148 and if necessary shall be treated to assure compliance therewith.

Water for washing and curing shall be such that it will impair neither the strength of the finished concrete nor its appearance.

6.11. Steel for Concrete Reinforcement

All steel bars used for concrete reinforcement shall conform to the requirements of AASHTO M31 grade 60.

6.11.1. Reinforcement of Steel Bars

All reinforcement bars shall be free detrimental dirt, mill scale, rust, paint, grease, oil or other foreign


substance, fins or tears. The Contractor will not be required to remove slight rusting which discolors the metal, but he shall remove all loose mill scale and scales rust.

Brushing to clean blue metal will not be required.

Supports, metal supports, approved by the “EIIP Project engineer”, shall be provided and used to retain the reinforcement at proper distances from the forms. Supports under horizontal bars slabs shall be spaced at not more than eighty (80) diameters of the bar.

All reinforcement shall be so rigidly supported and fastened that displacement will not occur during construction. Reinforcing steel shall be inspected in place and must be approved by the “EIIP Project engineer” before any concrete is deposited.

Reinforcing steel shall be stored above the ground on plate forms, skids, or other supports. It shall be stored in such a manner and adequately marked to facilitate inspection and checking. When placed in the work, the reinforcing steel shall be free from dirt, detrimental scale, paint, oil or other foreign substance.

All cutting and bending of reinforcement bars shall be done by competent workmen and with equipment approved by the “EIIP Project engineer”.

All reinforcement bars shall be cut and bent in an onsite fabrication shop.

Bent bar reinforcement shall be cold bent to the shapes shown on the plan, and unless otherwise provided on the plans or by written authorization of the “EIIP Project engineer”, bends shall conform to the following requirements: D= 6d for five (5) millimeter through twenty two (22) millimeter bar sizes.

D= 8d for twenty four (24) millimeter through twenty eight (28) millimeter bar sizes. D= 10d for thirty (30) millimeter and over bar sizes.

Where:

D= minimum pin diameter around which a bar may be bent d= bar diameter.

All reinforcing steel shall be accurately placed and, during the placing of concrete, firmly held by approved supports in the position shown on the plans.

Reinforcing bars shall be securely fastened together; reinforcement placed in any member shall be inspected and approved before any concrete is placed.

Laying or driving bars into the concrete after placement will not be permitted.

All horizontal reinforcement shall be supported on metal supports or spacers as approved by the “EIIP Project engineer”.

The use of small stones or wood blocks for supporting reinforcement will not be permitted.

The reinforcement shall be held securely in place at the proper position and spacing as indicated on the plans by the use of wire ties at bar intersections and tying to the supports and spacers.

The adequacy of the supports and ties to secure the reinforcement properly shall be subject to the approval of the “EIIP Project engineer”.

6.12. Falsework & Formwork

Construction of concrete structure requires proper implementation of various jobs needed to complete works.

Work consist in furnishing and placing Portland cement concrete for structures in accordance with the


specifications and conformity with the lines, grades and dimensions of drawings and plans. 6.12.1. Falsework

Where needed and whenever asked, Contractor must submit detailed plans for falsework.

Falsework design must provide rigidity to with stand and support loads without excessive settlement or deformation.

Falsework columns shall be mounted on wood or metal bases when it cannot be supported on rock, shale or thick deposits of other compact material in their natural bed.

In no case, and unless it is on foundation footing, falsework will not be supported on any part of the structure.

Spacing of false work columns in the general framing must be approved by “EIIP Project engineer ”.

Falsework and centering shall be designed and constructed to support the total anticipated loads with a deflection not to exceed two one thousandths (0.002) of the falsework span.

The Contractor shall submit calculations to support this requirement for all spans over 3 meters and other spans if requested by the “EIIP Project engineer”.

The Contractor shall provide means for accurately measuring settlement in false work during placement of concrete and shall provide a competent staff (Forman of skilled labor) to observe to observe and correct the settlement.

Timber used in falsework must be composed of sand wood in good condition and free from defects that might weaken its strength.

Note: In designing forms, concrete will be regarded as a liquid having a weight of 2,400 kg per m3, and

not less than 1,400 kg per m3 shall be assured for horizontal pressure. 6.12.2. Formwork

Forms must be rigid to withstand pressure of concrete or any other incidental loads that occurs during construction including vibrations.

It must be mortar tight and free from opening, it shall be designed to permit easy removal without injury to the concrete.

Form lining material shall not bulge, wrap or blister, nor shall it stain the concrete. Form lining shall be used in the largest practicable panels to minimize joints.

The joints in the lining shall be tight and smoothly cut.

Forms shall be maintained after erection to eliminate warping and shrinkage. They shall be checked for dimensions and condition immediately prior to the placement of concrete.

Metal forms may be used and are subject to the same requirements and approvals specified for wood forms.

The inside of all forms shall be oiled with light, clear, paraffin base oil that will not discolor or otherwise injure the surface of the concrete.

The oiling shall be done where possible after the completion of the forms and prior to placement or reinforcement.

The width and thickness of the lumber, the size and spacing of studs and Wales shall be determined with due regard to the nature of the work and shall be sufficient to ensure rigidity of the forms and to prevent


distortion due to the pressure of the concrete.

All curved surfaces shall be formed with approved plywood or steel.

When the Contractor instructed by the “EIIP Project engineer” shall submit formwork drawings and calculations to the “EIIP Project engineer” in advance of the concreting.

Formwork shall be of such accuracy, strength and rigidity as to carry the weight and pressure from the concrete to be placed on or against it.

Formwork shall be sufficiently tight without plugging to prevent loss of grout during the vibration of the concrete.

Faces of formwork shall be clean, free from projecting nails adhering grout and other imperfections or defects. Formwork shall be treated with approved mold oil before positioning.

Formwork shall be such as to allow for its removal without damaging the concrete and in the case of suspend floors for the removal of the beam sides and slab sophist without disturbing the beam bottom boards and their props.

Before concreting, the areas which are intended to receive the concrete shall be cleaned by jetting with compressed air and all water extraneous material removed.

Where timber is used for formwork it shall be properly cured free from warp straight, clean and free from loose snots.

6.13. Tolerance

Unless otherwise indicated on the drawings, the tolerances of the finished concrete with respect to the dimensions shown on the drawings shall not exceed the limits set out in the following table. Formwork shall be constructed to ensure completed work within the following tolerance limits:

Departure from established alignment: 0.5 cm

Departure from established grade: 0.5 cm

Variations from plumb or specified batter in lines and surfaces of columns, piers and walls:

0.5 cm in 3 meters, if exposed

0.5 cm in 3 meters, if backfill


Variations from level or indicated grade in slabs, beams etc...:


Variation in cross-sectional dimension of columns, piers, slabs, walls, beams: -0.5 cm + 0.5 cm Variation in slab thickness: -0.5 cm + 0.5 cm

Footing: plan dimensions: -0.5 cm + 0.5 cm

Eccentricity: 2 percent of footing width, not exceeding 5 cm Reduction in thickness: 2 percent of specified thickness

Immediately after the removal of the forms, all fins caused by form joints and other projections shall be removed and all pockets cleaned and filled with a cement mortar composed of one part by volume of Portland cement and two parts sand. Sufficient white Portland cement shall be mixed with the cement in the mortar, so that when dry, the color will match the surrounding concrete.

CHAGHOUR HAMMANA – CAZA OF BAABDA. LOT A: CONSTRUCTION OF A 500 M3 GROUND RESERVOIR PAGE 50 OF49

7. CONCRETING

7.1. Requirements

The finished concrete shall be dense, durable, and impervious to the access of water, free from cracks and honeycombing, and resistant to wear and mild chemical attack.

7.2. Transporting

Concrete shall be transported to the place of final deposit by approved means:

Barrows, spades and other equipment used in the process of transporting concrete shall be thoroughly cleaned before each day’s work or after a long interruption and they shall be free from hardened concrete.

Concrete shall be transported as soon as possible after mixing, by methods which will prevent the segregation, loss or contamination of the ingredients.

Bridging for traffic over reinforcement shall be provided so that the reinforcement is not distorted, damaged or displaced.

Where approval is obtained for concrete to be conveyed by chutes, they shall have a slope (not exceeding 1 vertical to 2 horizontal) such as to ensure a continuous flow of concrete. Additional water shall not be introduced to assist the flow. If deposition is to be intermittent the chute shall be arranged to discharge into a storage hopper. In no case will a clear fall of more than 1 m be permitted at the discharge end of the chute.

Where approval is obtained for pumping the concrete, the pump manufacturer’s recommendations as approved by the EIIP Project Engineer shall be followed. The pumps used shall be of adequate capacity and power to ensure delivery of a continuous supply.

Wherever transport of concrete is interrupted for any period of over half an hour the chutes, pumps, and any other means of distribution shall be thoroughly flushed out and cleaned. These shall also be flushed out immediately prior to resumption of concreting and shall be kept free from hardened concrete. All WASH water used shall be discharged outside the formwork and clear of any freshly placed concrete.

7.3. Placing & Compaction

No concrete shall be placed until the Contractor has obtained approval from the EIIP Project Engineer. When the Contractor intends to place concrete he shall inform the EIIP Project Engineer in sufficient time to enable his inspection. The Contractor shall provide all facilities for such inspection.

Concrete shall be placed within 30 minutes to mixing, to uniform level, in layers not exceeding 500mm deep in such manner as to avoid segregation. Each layer shall be compacted by means of approved vibrators to form a dense material free from honeycombing and other blemishes.

If internal vibrators are used, they shall be withdrawn immediately water or a thin film of mortar begins to appear on the surface of the concrete. Withdrawal shall be carried out slowly to avoid the formation of voids.

If external vibrators are used, the formwork shall be designed for external vibration and shall be strong enough to withstand the forces of vibration.

Temporary or permanent stoppages of work shall be made only against stop ends.

Unless otherwise specified, before placing new concrete against concrete which has already hardened, the face of the older concrete shall be prepared by the removal of any laitance and loose aggregate, and shall be cleaned by a jet of compressed air.

7.4. Concreting in Deep Lifts


Where concrete is to be placed in lifts greater than 2.5 m high it shall be placed by suitable tremie pipes. 7.5. Hot Weather Concreting (above 20ºC)

Concreting shall not be permitted if its temperature at placing is in excess of 38 ºC. In order to maintain the temperature of the concrete below this value the following precautions shall be taken wholly or in part as instructed by the EIIP Project engineer :

• All aggregate stockpiles, water lines and tanks as well as the mixer shall be protected from the direct rays of the sun;

• Coarse aggregate shall be cooled by constant watering where possible;

• Mixing water shall be cooled by the addition of ice to the storage tanks where necessary

• Rapid-hardening cement shall not be used;

• Where the above precautions are inadequate concreting shall be carried out during the cooler parts of the day or during the night as may be directed by the EIIP Project Engineer.

When the air temperature is above 20ºC loss of mixing water by evaporation shall be considered in arriving at the amount of water to be added to the mix. To maintain the water/cement ratio within permissible limits an approved water-reducing agent shall be included in the mix.

The maximum water/cement ratios may be increased with the EIIP Project Engineer’s permission by 0.05 (or 2.5 liters/50 kg of cement) during mixing but on no account shall water be added to concrete once it has left the mixer.

In order to reduce premature during of the concrete during transporting and placing, all chutes, formwork and reinforcement shall be added by watering when possible, or shall otherwise be protected from the direct rays of the sun. Any water so used shall be removed by jetting with compressed air before placing the concrete.

As soon as possible after concreting the formwork shall stripped and the surface of the concrete shall be treated.

Where drying winds are encountered, wind shields shall be positioned as necessary to protect exposed surfaces of the curing concrete.

7.6. Wet Weather Concreting

Concreting during periods of constant rain shall not be permitted unless aggregate stockpiles, mixers and transporting equipment, and the areas to be concreted are adequately covered.

During showery weather, the Contractor shall ensure that work can be concluded at short notice by the provision of stop ends. On no account shall work be terminated before each section, between one stop end and another, is complete. Adequate covering shall be provided to protect newly placed concrete from the rain.

7.7. Holes, Cavities & Fixings

Holes, shall be accurately marked and boxed-out for before concreting operations commence, no holes, shall be formed after the concrete has set.

Where bars, if placed to specified spacing would foul holes of size less than 250mm x 250mm the full length of the bar shall be moved to one side unless otherwise indicated on the Drawings for holes exceeding 250mm x 250mm the bars shall be cut on site and lapped with additional equivalent bars.

Wherever possible, the Contractor shall build in all pipework, ironwork, and steelwork which passes


through walls and floors. The pipework, ironwork, and steelwork shall first be thoroughly cleaned and freed from any deleterious matter. Every care shall be taken to ensure that it is thoroughly encased in concrete.

Bolts, hooks and other fixings shall be embedded in concrete, or holes shall be drilled and fitted with threaded expanding anchors to receive the bolts. The Contractor shall ensure that bolts, hooks, and fixings are accurately, positioned. Holding down bolts for machinery shall be set to template.

Where brick or stonework is to form a facing to the concrete or where the end of a brick or stone wall butts against a concrete face, galvanized metal ties of approved manufacture to BS 1243 shall be incorporated.

7.8. Protection

Newly placed concrete shall be protected by approved means from rain, drying winds, sun. No traffic or constructional loads shall be permitted on newly placed concrete until it has hardened sufficiently to take such traffic or load. Curing methods shall ensure that cracking, distortion and efflorescence are minimized. Concrete shall be cured using methods approved by the EIIP Project Engineer. The method of curing shall prevent loss of moisture from the concrete. Immediately after compaction and 7 days thereafter concrete shall be protected against harmful effects of weather, including rain, rapid temperature changes and from drying out.

The curing time shall be the number of days in table 3.7 unless the average temperature of the concrete during the required number of days falls below 10ºC in which case the period of curing shall be extended until the maturity of the concrete reaches the value given in the table.

Curing shall be carried out using either of the following basic methods, or any other method agreed with the EIIP Project engineer. Methods involving the use of dampened Hessian coverings shall not be used. The method adopted for any particular situation shall be agreed with the EIIP Project engineer.

7.9. Membrane Applied by Spray

Liquid membrane compounds shall be applied to moist concrete surfaces as follows:

• Unformed Surfaces: The compound shall be applied immediately after the free water has left the surface.

• Formed Surfaces: The compound shall be applied immediately after removing the forms. If there is appreciable drying, the surface shall be mist sprayed with water to produce a uniformly damp appearance before the compound is applied.

The method and rate of application shall be in accordance with the compound manufacturer’s instructions as approved by the EIIP Project engineer.

If rains falls on the newly coated surface before the film has dried sufficiently to resist damage, or if the film is damaged in any other manner, a new coat of compound shall be applied to the affected area. The membrane shall be applied to the affected area. The membrane shall be maintained effective for the specified curing time.

Compound applied to construction joint surfaces, or to other surfaces to which concrete are to be bonded, shall be removed prior to placing the fresh concrete.

7.10. Polythene Sheeting

The concrete surfaces shall be covered with white polythene sheeting as follows:-


Unformed Surfaces:

The sheeting shall be laid over the surface as soon as possible without marking the surface, and not until initial stiffening has taken place.

Formed Surfaces:

The surfaces shall be covered immediately after the removal of the forms.

The sheeting may be in contact with the concrete or made into portable shelters on light weight frames. In both cases, the sheeting shall be jointed and sealed against to concrete surfaces to prevent wind blowing between the sheeting and the concrete. 8. WATER RETAINING STRUCTURES

The design, detailing, materials and workmanship shall comply with the requirements of BS 8007.

The cement mortar used in filling recesses in the concrete formed by bobbins in connection with formwork shall contain an approved expanding admixture.

8.1. Construction Joints in Water Retaining Structures

Water stops not less than 150mm wide shall be built into all construction joints in external walls and construction. Construction joints shall only be formed at positions approved by the EIIP Project engineer .

8.2. Water tightness of Structures

The Contractor shall be responsible for the water tightness of structures and any remedial measures necessary. Where detailed on the Drawings the surface of concrete shall be coated with a waterproof coating.

In the event that a structure designed and specified to be water retaining fails to satisfy the water tightness tests specified in Section 1.0 the Contractor shall undertake such remedial works as are necessary and are approved by the EIIP Project Engineer.

8.3. Waterproof Coatings

Waterproof coatings shall be applied to the internal water retain face of reservoirs or where instructed by the EIIP Project Engineer.

The coating shall comprise a waterproofing system which creates a vapor permeable sub-surface barrier to prevent water leakage and the ingress of contaminants into the cracks and concrete matrix.

The waterproofing system shall comprise non-toxic, clear and odorless solution that penetrates into the concrete surface to form a non-water soluble gel which forms chemically resistant compound in cracks, pores capillaries.

Expansion joints shall be formed in the waterproofing system by the use of compatible sealants as recommended by the manufacturer.

The system shall be cured for a period of not less than 7 days. 8.4. Hydrophilic Rubber Sealer

Hydrophilic rubber sealer shall be co-extruded from chloroprene and hydrophilic rubbers into a cellular strip approximately 25mm x 7mm thick which expands as it absorbs water. The strip shall incorporate an expansion delay coating to prevent activation during setting of the surrounding concrete.

Hydrophilic rubber sealer shall be applied to the perimeter of all pipes to be built into concrete structures, to existing concrete walls and slabs at or below water levels which have been demolished and require extension, and to other locations as indicated on the Drawings.


The strip sealer shall be bonded to the pipe diameter or on to the face of demolished structures on to which new concrete is to be placed so as to be at least 100mm from the wall surface. Where dowel bars are incorporated in bonding new concrete to old the sealer shall be placed above the dowel bars on the ‘’wet’’ side of the structure. Bonding shall be accomplished using proprietary neoprene or epoxy adhesives to ensure the sealer is not disturbed during placement of the concrete.

The application shall be in accordance with the manufacturer’s recommendations. 9. JOINTS

9.1. Construction Joints

The position of construction joints, when not shown on the Drawings or otherwise required by this Specification, shall be decided on site having regard to the plant and labor made available by the Contractor for the manufacture, placing and compaction of the concrete as well as its curing, the climatic conditions prevailing at the time of concreting, the nature and size of the formwork and the conditions of operation of the work. The contractor shall submit his proposal to the EIIP Project engineer for his approval before commencing the work.

Where possible Construction joint shall be prepared by the ‘’WASH-off’’ method as specified below.

When expanded metal lathing is used for the formation of construction joints a rebate will not be required to be formed. The expanded metal lathing shall be left in the work and shall not extend closer to the finished surface of the concrete than 25mm. it shall be securely fixed to the reinforcement.

9.2. Slabs Supported on the Ground

To ensure control in the placing of concrete the contractor shall provide control boards to form panels not larger than 15m2 in area. These shall be lifted as the concreting proceeds except where they are of expanded metal in which case they may be left in position as part of the permanent works, provided that they shall not extend closer to the finished surface of the concrete than 25mm. The joint so formed shall then be treated as a construction joint. Where Ready-mixed concrete is permitted the control boards shall be positioned so as to enclose a volume of concrete equal to that delivered by each truck.

Construction joints and control joints shall be formed normal to the surface of the concrete. 9.3. Suspended Beams & Slabs

T-beams shall be formed to their full depth integrally with the adjacent slab and without horizontal joints. 9.4. Walls

Horizontal construction joints in walls shall be formed along straight lines, powers shall be made to the full height of the formwork.

Unless otherwise shown on the Drawings or permitted by the EIIP Project Engineer concerning of circular tanks shall be varied out continuously for the full circumference without vertical joints.

In rectangular tanks, vertical joints shall not be positioned closer to any corner than one meter. Unreinforced concrete manholes shall be constructed without vertical joints.

9.5. ‘Wash‐off Method’ of Construction Joints

As soon as possible after concreting, and while the surface is still green the surface of the concrete forming the joint shall be freed of loose aggregate and sprayed with a fine spray of water to prevent the formation of laitance. All excess water shall be removed by a jet of compressed air and the surface left clean to receive further concrete.

9.6. Joints


Contraction and expansion joints and shall be as shown on the Drawings.

A period of at least five days shall elapse between the concreting of the section on each side of the joint.

Where the Drawings indicate a contraction gas shall be formed in any panel (the gap shall not exceed one meter), concerning on either side of the gap shall be carried out so as to form partial contraction joints at each side of the gap. Prior to the concreting of the gap section, the joint surfaces shall be cleaned but otherwise left untreated. The concreting of the gap section shall not be carried out until a period of at least five days has elapsed after completion of the adjacent sections.

Alternate panel construction (other than contraction gap construction outlined above) will be permitted only in water retaining structures or as otherwise approved by the EIIP Project Engineer where the panels are separated by expansion or contraction joints.

9.7. Water Stop

Water stop shall be manufactured of rubber or PVC (polyvinylchloride) as shown on the Drawings, and shall be of the type and size shown on the Drawing. Site joints shall be made in accordance with the manufacturer’s instructions as approved by the EIIP Project engineer . All intersections and junctions shall be obtained prefabricated from the approved manufacturer. For water retaining structures the Contractor shall submit water stop fabrication drawings on the EIIP Project engineer prior to fabrication.

Plasticized PVC water stops shall comply with the relevant provisions of Wls No. 4-31-02.

Rubber water stops shall have the following properties when tested in accordance with the relevant Part of BS 903:

Table 1: Properties of Rubber Water Stops

Part of BS 903 Property Requirements

A1 Density 1100 Kg/m3 (±5%)

A26 Hardness 60-70 IRHD

A2 Tensile strength No less than 17.5 N/mm2

A2 Elongation at break point No less than 450%

A16 Water absorption (48 hours Not exceeding 5%

immersion)

Rubber water stops shall be suitable for storage, handling, installation and service within a temperature range of 0°C to +40°C

CHAGHOUR HAMMANA – CAZA OF BAABDA. LOT A: CONSTRUCTION OF A 500 M3 GROUND RESERVOIR PAGE 42 of 49

All water stop and jointing materials which are not required for immediate use shall be stored at all times in a cool damp place.

Water stop shall be located and maintained accurately in position. Details of the proposed method of fixing shall be submitted to the EIIP Project engineer for approval. On no account shall water stop be secured by nails or by any other means involving puncture of or damage to the water stop material unless purpose made nailing flanges are incorporated in the design of the eater stop.

9.8. Joint Filler

Joint filler for joints in structures to retain aqueous liquids shall be self-expanding cork, natural bonded cork, resin bonded cork, or other material as detailed on the Drawings or itemized in the Bill of Quantities. Joint filler shall be cut and trimmed accurately to suit the joint profile and shall be maintained accurately in position by means of an approved adhesive. Self-expanding cork filler shall consist of cork granules bound together with an insoluble synthetic resin. Cork filler shall have a maximum water absorption of 0.3% by volume when tested in accordance with ASTM D3595. The load required to compress the filler to 50% of its original thickness shall not exceed 1.5 N/mm2 for self-expanding cork (moist), 0.6 N/mm for resin bonded cork and 0.90 N/mm2 for natural bonded cork. Recovery after compression test shall exceed 90%.

Joint filler in non-water retaining concrete structures shall be non-extruded bitumen impregnated fiberboard.

9.9. Joint Sealants

Joint sealing compounds shall be impermeable ductile materials of a type suitable for the conditions of exposure in which they are to be placed, and capable of providing a durable, flexible and water tight seal by adhesion to the concrete throughout the range of joint movement.

Hot poured joint sealants shall comply with BS 2499, Ordinary Type A1 sealant.

Cold poured polymer-based joint sealants shall comply with BS 5212; part 1, Normal Type N sealant.

Two part polysulfide-based sealants shall comply with the relevant provisions of BS 4254. Pouring Grade shall be applied to horizontal upward-facing joints and Gun Grade to joints of any other aspect or inclination. Other two-part polymer-based sealants of Gun or Trowel Grade shall comply with the physical and test requirements of BS 4254.

Silicone based building sealants shall comply with the relevant provisions of BS 5889.

Primers for use with joint sealants shall be compatible with, and obtained from the same manufacturers as, the adjacent sealant. Primers shall have no harmful effects on concrete.

Sealants and primers which will be in contact with water to be used for potable supply shall not impart to water taste, color, or any effect known to be harmful to health, and shall be resistant to bacterial growth.

Sealants and primers which will be in contact with sewage or sewage sludge shall be resistant to biodegradation.

9.10. Slip Membrane

The slip membrane shall be not less than 1.5mm thick and shall be a plastic performed strip with low coefficient or friction specially manufactured for use as a separating membrane in sliding joints between concrete surfaces. Each joint shall comprise two layers of the membrane unless otherwise shown on the drawings.

The concrete surface to which the slip membrane is to be fixed shall be finished with a steel float to provide


a smooth true surface free from dust and loose particles. 9.11. Dowel Bars

Dowel bars for expansion joints in concrete shall consist of mild steel complying with the provisions of BS 4449, Grade 250.

Dowel bars shall be straight, free from burrs or other irregularities and shall have their sliding ends sawn. The sliding half of each dowel bar shall be painted with a thin coat of bond breaking compound, and the end of this half shall be provided with a close fitting plastic or waterproof cardboard cap at least 100 mm long, the end 20 mm of which shall be fitted with a disc of joint filler or a pad of cotton waste. Bond Breaking Compound for Dowel Bars

Bond breaking compound for dowel bars shall consist of a bitumen paint containing 66% of 200 pen bitumen, blended hot with 14% light creosote oil with the addition, when cold, of 20% solvent naphtha. It shall in no way retard or otherwise affect the setting of concrete. 10. FINISHING

10.1. General

All exposed faces of concrete unless otherwise specified shall be hard, smooth and free from honeycombing, air and water holes and other blemishes.

All projecting imperfections shall be rubbed down with carborundum stone or by other approved means and grit and dust therefrom shall be thoroughly washed off with clean water.

10.2. Surface Finishing

i. Wood float finishing shall be formed by smooth floating the accurately leveled and screeded surface. Care shall be taken to ensure that the concrete is worked no more than is necessary to produce a uniform surface free from screed marks.

ii. Mechanical and Manual Steel trowel finishing shall be formed while the concrete is still wet by means of a steel trowel applied to an accurately leveled and screeded surface.

iii. Screeded finishing shall be formed by leveling and screeding the concrete to produce a uniform, plain or ridged surface as specified.

iv. Bush-hammered or pattern-worked finishing.

v. When exposed aggregate is to be the surface texture, the Contractor shall ensure that a uniform distribution of the coarse aggregate takes place at the face. The formwork shall be removed as soon as possible from the face to be treated; the surface shall be thoroughly wetted and wire brushed, and-hammered or pattern-worked as and when instructed. Surface retarders shall be used only when permitted by the EIIP Project Engineer.

vi. Bush-hammering or pattern-working shall not be relied upon to obscure any defects in the concrete face which arise from formwork imperfections.

10.3. Making Good

Honeycombed or damaged surfaces of concrete, which in the opinion of the EIIP Project Engineer, are not such as to warrant the cutting out and replacement of the concrete, shall be made good as soon as possible after removal of the formwork as follows:-

Portland cement and sand mixture shall be worked into the pores over the whole surface with a fine carborundum float in such a manner that no more material is left on the concrete face than is necessary completely to fill the pores so that a uniformly smooth and dense surface of uniform color is finally


presented. 11. DEFECTS

11.1. Removal and replacement of Unsatisfactory Concrete

The Contractor shall on the EIIP Project engineer’s instructions to do so cut out and replace any concrete in any part of the structure if in the EIIP Project engineer’s opinion:

i. the concrete does not conform to the Specification, or

ii. deleterious materials or materials which are likely to produce harmful effects have been included in the concrete, or

iii. the honeycombed or damaged surfaces are too extensive, or

iv. the finished concrete sizes are not in accordance with the Drawings witching allowable tolerances, or

v. the setting-out is incorrect, or

vi. the steel cover has not been maintained, or

vii. the protection, including curing, of the concrete during the construction was inadequate, resulting in damage, or

viii. the work of making good or other remedial measures the EIIP Project engineer may indicate are not carried out to his satisfaction, or

ix. undue deformation of or damage to the works has taken place due to inadequate formwork, or to premature traffic or to excessive loading, or

x. Any combination of the above points has taken place resulting in unsatisfactory work. 11.2. Loading Tests

The EIIP Project engineer may permit that a loading test be made on the works or any part thereof for one or more of the following reasons:-

i. failure of ‘’Site Cubes’’ to attain the strength requirements;

ii. premature removal of formwork;

iii. overloading of structure during construction;

iv. improper compaction and/or curing of concrete;

v. any other circumstances attributable to alleged negligence on the part of the Contractor, which, in the opinion of the EIIP Project engineer, may result in a structure being of less than the required strength;

vi. Loading test shall be carried out in accordance with the requirements of BS 8110.

If the results of the test are not satisfactory, the EIIP Project engineer will direct that the part of the work concerned be taken don or removed and reconstructed to comply with the Specification, or that such other remedial measures as he may think fit be taken to make the work acceptable.

The EIIP Project engineer may instruct the Contractor to take out cylindrical core specimens from the structures concerned and have them tested. The cutting equipment and the method of doing the work shall be to the EIIP Project engineer’s approval. The specimens shall be dealt with in accordance with BS 1881. Prior to testing, the specimens shall be available for examination by the EIIP Project engineer.


12. WATER PROOFING & THERMAL INSULATION

The provisions of this division shall apply to the following:

Reservoir

Roof covers

Buried concrete surfaces

The provisions here below shall apply to the materials, products and execution procedures concerning the waterproofing of the reservoir roof covers.

Waterproofing approved membranes (for both reservoir covers and roof building terraces) will be one layer of 4mm minimum thickness (minimum 4.7 kg/m2 with protection) with Elastomeric (styrene- butadiene styrene = SBS) (for altitude above 300m) or Plastometric (Atactic Polypropylene = APP) (for altitude below 300m).

The assembly of manufactured sheets will be by torch welding.

These membranes will generally be self-protected from the factory (mineral self-protection). The general characteristics of the membranes are as follows: (non limited list)

Elongation at break (for reinforced membrane: 50%).

In case of special architectural designed roof (dome) the waterproofing coat could be constituted by a liquid elastomeric bitumen which characteristics must be proposed by the Contractor for the approval of the EIIP Project engineer. Anyhow a U.V. radiations resistance shall be required in any case.

The particular characteristics of the SBS and APP membranes are resumed here below (non limited list)

a) SBS elastomeric membranes are classified according to the type of reinforcement.

-Rolls reinforced with polyester (PY = 180 to 350 g/m2)

b) APP Polymeric membranes are modified bitumen base sheet with APP polymers.

-4mm thick reinforced with polyester min weight 180 g/m2 nonwoven polyester (PY)

The Contractor must in his offer enumerate all the characteristics of the membranes, including but not limited to:

their dimensions (rolls) (1 m x 10m)

their thickness or their weight (minimum thickness 4mm, minimum weight 4.7 kg/m2)

the type of bitumen

the kind and weight of reinforcement (g/m2)

the surface protection

their mechanical characteristics

The overlapping size (overlapping waterproofing membrane shall be not less than 10 cm).

etc.

SBS and APP membranes shall be applied by the Contractor on site according to the technical sheets specifications of each product and to the manufacturer’s prescriptions.

All reservoir roof covers and roof building terraces are deemed to be not accessible unless to repairs


necessity.

Horizontal and vertical exposed membrane will be mineral self-protected. 13. THERMAL INSULATION

A normal insulation with extruded polystyrene thermal insulation is approved.

The insulation panels must be protected against weather.

The Contractor shall propose to the EIIP Project Engineer’s approval all insulation material and specific original documentation from the manufacturer, mainly (non limited list):

The thermal conductivity ( 0.029 w/m o C) The laying procedure

All limitations of use, according to associated waterproofing, destination of reservoir cover or roof terraces.

The thickness of the insulation panels with the way this thickness was determined according to the total thermal resistance of the reservoir cover or roof terrace. (thickness : 50mm)

Separation and protection sheet layer (nonwoven polyester) thermally bounded nonwoven polypropylene: Mass: 100 – 105 g/m2.

The protection needed (graded gravels, screed, circulation slabs (500 x 500 x 50 mm) 14. VALVES & ACCESSORIES

All valves related to valve chamber shall comply with international standards mainly (ISO, DIN & API). 14.1. Cast Iron Steel Gate Valves (PN 16 pressure valves)

The valves shall be made of cast iron steel, and sustain a nominal pressure of 16 bars (PN16).

The valves and components must pass the hydrostatic pressure test at the manufacture and sustain the maximum allowable pressure to NFE-29-311, ISO 5208 & API 602 for different PN selects, and in case required by the client it must be approved and certified by known quality control office i.e. Bureau VERITAS or other.

The cast steel gate valves and components shall comply with:

API 300 for wall thickness.

ASME B16.5 for flange design

BS 1873 for general design. 14.2. Standard Materials for High Pressure Gate Valves (where applicable)

Length for each valve is to suit valve depth. Spindles are to have cast iron cap and coupling, BS 1452 grade 12 or BS 310 respectively, on both sides of the extension spindle (the cap for the operating spindle and coupling for connecting to valve). The set screws of caps and couplings are to be mild steel M12.

Lifting keys: Are to be made of mild steel.


14.3. High Pressure Cast Iron Steel Spring Loaded Check Valve

Checks valves shall be made of cast steel, and sustain a nominal pressure of 24 bars (PN24).

The valves and components must pass the hydrostatic pressure test at the manufacture and sustain the maximum allowable pressure to NFE-29-311, ISO 5208 & API 602.

Specifications being as follow:

Body and cover: To be implemented as per precision machined castings.

Body and cover joint: Accurately machined, fully-enclosed gasket. Disc: Robust one-piece construction to withstand the severe shock of check valve service.

Hard-faced with 13Cr, CoCr alloy, SS 316

Disc assembly: Non-rotating disc must be fastened securely to disc hanger with a lock nut and cotter pin.

Disc hanger must be supported on a sturdy disc carrier hinge pin of excellent bearing qualities.

All parts must be accessible from top for easy servicing.

Flanges: as per ASME Class 600–1500: 1⁄4” raised face. 14.4. Pipe Works

No pipes shall be delivered to site before inspection has been made on pipes by EIIP Project Engineer in Contractor’s warehouse.

Certificate of origin and quality control certificate (if required) for proposed pipes must be checked and approved by EIIP Project Engineer prior to delivery of material onsite.

Pipes for main header will be from seamless steel material and shall be according to API 5L grade B. All headers shall be treated with epoxy paint suitable for potable water.

Main header will have an internal diameter of 150 mm. 14.5. Saddles, Tees, Flanges & Other Accessories Installation

Bends, joints, flanges, tees… shall be installed in accordance with the manufacturer’s recommended procedures.

Flanges faces shall be centered and aligned to each other before assembling and tightening bolts. In no case shall the flange bolts be used to draw the flanges into alignment.

Bolts threads shall be lubricated, and flats washers shall be fitted under the flanges nuts.

Bolts shall be evenly tightened according to the tightening pattern and torque step recommendations of the Manufacturer at least 1 hour after initial assemble, flange connections shall be re-tightened following the tightening pattern and torque step recommendations of the Manufacturer. The final tightening torque shall be 135 Nm or less as recommended by the manufacturer. 15. PLASTERING (WHERE APPLICABLE)

Masonry plastering shall be prepared on site with approved cement and sand materials.

Cement marker for plastering shall composed of cement and sand mixed in the proportions of 50 Kg cement to 0.14 m3 sand.


Plastering shall be at least 15 mm and no more than 20 mm thick and carried out in a minimum of two coats.

The first coat being a render coat which shall be left scratched to receive the finishing coat.

The finishing coat shall be worked to a true and even surface and polished to a smooth surface using a steel trowel.

Plastered surfaces shall be perfectly level and shall be to thickness as specified. The edges shall be straight. Before applying plastering, the surfaces that are to be coated shall be thoroughly cleaned. 16. BLOCK WORKS

Block works shall be 20 cm thick; they must be new and free from any defects.

Block works must be hollow type of top quality and manufactured in an approved factory, and made of vibrated and compressed concrete and thoroughly watered.

The mix proportion for block works shall be as follow:

Mix proportion:

1 bag of cement 50 kg.

120 l of stone chippings

90 l of sand

Characteristics of the finished material:

Minimum 1700 kg/m3. They must be 40 days old minimum, and must have a crushing strength at 28 days equal to 40

Kg/cm2 (measured on the whole block surface). Sand for mortar:

The sand shall be natural sand from clay and shall comply with the best intimation standards provisions.

The cement for mortar shall be Portland cement complying with B. S.12.

The proportion for mortar shall be 1:3

One part of cement and three parts of sand or approved fine aggregate.

The mixing of cement mortar shall not be made on the bare ground, and must be used within the hour after mixing.

All blocks shall be thoroughly wetted before use, and a perfectly rectilinear wooden ruler and a plumb line shall be permanently kept on site to allow for the EIIP Project engineer to verify the verticality of constructed masonry wall.

17. PAINTING (WHERE APPLICABLE)

All painting (internal and external surfaces) shall be applied in conformity with the manufacturer’s recommendations.

Paints shall be washable, of a perfect solidity and shall allow a flawless application.


Surfaces that must be painted shall first be cleaned, and sand papered before the application of the first coat of sealer.

A second sanding shall be followed by the application of a primer coat.

Finally two (2) paint coats shall be applied in conformity with the colors and samples approved by the EIIP Project Engineer.

For exterior surfaces a plastic paint ready to use under the form of a unctuous thixotropic paste will be used; it shall be composed of vinyl- maleate resins or water, the painting must adhere perfectly and be totally waterproof and offering a perfect resistance to chemical agents, heat and fire.

Before any commencement of application of the paint, contractor must make sure that all surfaces are clean, without grease and dustless.

The contractor shall apply a primer coat (undercoat) acting as a surface regulator and then will apply two coats using an alxeol roll.

Application must be in thick layer and must be starting from down toward upper zones. The product must be applied in important quantities but not spread. 18. METAL DOORS AND LOUVERS

The contractor shall supply and install steel doors for reservoir valve chamber. The contractor shall also supply and install windows with louvers protection.

Steel for doors, windows and other metal work shall be new, first grade quality mild steel without mill defects, cracks, grooms or rough surfaces and shall comply with all requirements specified on the attached drawings.

18.1. Metalwork

Hinges and locks shall be secured by means of metal-screws for any eventual unmaking.

Other accessories may be welded. Unless otherwise specified, bolts, casement bolts, locks, etc., shall mortised, hinges shall be solid and of quantity corresponding to door leaves size and weight. They shall have the exact required sizes and allow an easy setting and replacement.

Metal fittings are integral parts of each door or hatch even when not explicitly stated in the work description.

The contractor shall take on site all dimensions deemed necessary for metalwork and remain wholly responsible for their good adaptation to the concrete and masonry works in the building.

Joints shall be notched and angles mitered. Electric welding shall be as continuous as possible along the joint after filing the metal elements.


Surface finishing of works shall be in strict accordance with the General Technical specification and shall include the protection of materials and the surface treatment.

Exposed surfaces shall have no unevenness, burrs, or metal run-out. Salient angles and projecting parts shall be rounded off. Welds shall be carefully ground. Screws shall be inserted and then painted. Accessible bolts shall be covered. Element showing appearance or assembly defects shall be rejected. It is expressly forbidden to cover and hide these defects.

18.3. Protection of Metals against Corrosion

No metal part shall be accepted on site unless previously protected against corrosion.


Elements shall be in-factory protected according to relevant applicable standards. Unprotected iron parts shall be painted after removal of calamine, rust, and oil, with a rust proof zinc chromate paint, 60 microns thick, compatible with the top coat specified in the relevant section (or eventually with two coats of red lead).

Immediately after installation, any painted surface showing imperfections due to impacts or handling shall be wire brushed and repainted

Chaghour Spring sand & carbon filters / Hammana – Mount Lebanon Page | 1

LOT B Chaghour Hammana ‐ Caza of Baabda

Construction & Equipping of Treatment & Control Station


TECHNICAL SPECIFICATIONS

Section I: General Specifications

Section II: Particular Specifications for treatment plant &

reinforced concrete clarifier & Storage Tank

Section III: Particular Specifications for Water Treatment

Equipment

March 2017


Contents LOT B

Section I ....................................................................................................................................................... 7

General Specifications ................................................................................................................................ 7

1. Definitions ....................................................................................................................................... 8

2. Location ........................................................................................................................................... 8

3. General requirements .................................................................................................................... 9

4. Sign boards and visibility panels..................................................................................................... 9

5. Method Statements and time table schedule ............................................................................... 9

6. Safeguards of existing pipes & relevant structures ..................................................................... 10

7. Record drawings ........................................................................................................................... 10

8. Project Management .................................................................................................................... 10

9. Required standards....................................................................................................................... 11

10. Silence of specifications ........................................................................................................... 12

11. Correspondence and records................................................................................................... 12

12. Units .......................................................................................................................................... 12

13. Intent of the contract ............................................................................................................... 12

14. Terms in the contract ............................................................................................................... 13

15. Quality control .......................................................................................................................... 13

16. Reporting................................................................................................................................... 13

17. Refusal of delivered materials .................................................................................................. 14

18. Quality of supplied materials and of workmanship ................................................................ 14

19. Approval on materials .............................................................................................................. 14

20. Work on private lands .............................................................................................................. 15

21. Damages to utility properties .................................................................................................. 15

22. Access road to site .................................................................................................................... 15

23. Site limits ................................................................................................................................... 16

24. Work Initiation – Submittal of shop drawings ......................................................................... 16

25. Levels, dimensions, benchmarks and level datum .................................................................. 17

26. Miscellaneous works on site .................................................................................................... 17

27. Insurance ................................................................................................................................... 17

28. Site demobilization ................................................................................................................... 18

Lot B‐Construction & Equipping of Treatment & Control Station .......................................................... 19

TECHNICAL SPECIFICATIONS DOCUMENTS ............................................................................................. 19

Section II .................................................................................................................................................... 19


Civil Works for Treatment Plant Building & Reinforced Concrete Clarifier & Storage Tank .................. 19

1. Introduction .................................................................................................................................. 20

1.1. Conditions on site ................................................................................................................. 20

2. General requirements & guidelines ............................................................................................. 20

2.1. Site Mobilization ................................................................................................................... 20

2.2. Mobilization of Equipment .................................................................................................. 21

2.3. Operation & Maintenance Manuals .................................................................................... 21

3. Submittals ..................................................................................................................................... 21

3.1. Materials, Product Data, Equipment Specifications & Catalogues .................................... 22

3.2. Shop drawings ...................................................................................................................... 22

3.3. Manufacturer Certifications................................................................................................. 23

3.4. Manufacturer Recommendations ....................................................................................... 23

3.5. Installation & Testing ............................................................................................................ 23

3.6. As‐built Drawings .................................................................................................................. 23

4. Material Storage & Handling ........................................................................................................ 24

4.1. Transportation & Handling................................................................................................... 24

4.2. Storage & Handling ............................................................................................................... 24

4.3. Materials to be supplied by Contractor ............................................................................... 24

5. Excavations for concrete reservoir construction ........................................................................ 25

5.1. Geo‐Technical Investigations & Reporting .......................................................................... 25

5.2. Excavations ........................................................................................................................... 26

6. Concrete ........................................................................................................................................ 27

6.1. Composition .......................................................................................................................... 27

6.2. Cement .................................................................................................................................. 28

6.3. Aggregate – Sand .................................................................................................................. 29

6.4. Broken Rock and Gravel ....................................................................................................... 29

6.5. Storing of Cement ................................................................................................................. 30

6.6. Sampling of Concrete ........................................................................................................... 30

6.7. Stockpiling of Aggregates ..................................................................................................... 31

6.8. Ready Mix Concrete ............................................................................................................. 31

6.9. Admixtures ............................................................................................................................ 32

6.10. Water ................................................................................................................................ 32

6.11. Steel for Concrete Reinforcement ................................................................................... 32

6.12. Falsework & Formwork .................................................................................................... 34

6.13. Tolerance .......................................................................................................................... 36


7. CONCRETING ................................................................................................................................. 37

7.1. Requirements ....................................................................................................................... 37

7.2. Transporting ......................................................................................................................... 37

7.3. Placing & Compaction .......................................................................................................... 38

7.4. Concreting in Deep Lifts ....................................................................................................... 38

7.5. Hot Weather Concreting (above 20ºC) ............................................................................... 38

7.6. Wet Weather Concreting ..................................................................................................... 39

7.7. Holes, Cavities & Fixings ....................................................................................................... 40

7.8. Protection ............................................................................................................................. 40

7.9. Membrane Applied by Spray ............................................................................................... 41

7.10. Polythene Sheeting .......................................................................................................... 41

8. Water Retaining Structures .......................................................................................................... 42

8.1. Construction Joints in Water Retaining Structures ............................................................. 42

8.2. Water tightness of Structures .............................................................................................. 42

8.3. Waterproof Coatings ............................................................................................................ 42

8.4. Hydrophilic Rubber Sealer ................................................................................................... 43

9. Joints.............................................................................................................................................. 44

9.1. Construction Joints ............................................................................................................... 44

9.2. Slabs Supported on the Ground .......................................................................................... 44

9.3. Suspended Beams & Slabs ................................................................................................... 44

9.4. Walls ...................................................................................................................................... 44

9.5. ‘Wash‐off Method’ of Construction Joints .......................................................................... 45

9.6. Joints ..................................................................................................................................... 45

9.7. Water Stop ............................................................................................................................ 45

9.8. Joint Filler .............................................................................................................................. 46

9.9. Joint Sealants ........................................................................................................................ 47

9.10. Slip Membrane ................................................................................................................. 47

9.11. Dowel Bars ........................................................................................................................ 48

10. Finishing .................................................................................................................................... 48

10.1. General .............................................................................................................................. 48

10.2. Surface Finishing ............................................................................................................... 48

10.3. Making Good .................................................................................................................... 49

11. Defects ...................................................................................................................................... 49

11.1. Removal and replacement of Unsatisfactory Concrete .................................................. 49

11.2. Loading Tests .................................................................................................................... 50


12. Water Proofing & Thermal Insulation ...................................................................................... 50

13. Thermal insulation .................................................................................................................... 52

14. Valves & Accessories ................................................................................................................ 52

14.1. Cast Iron Steel Gate Valves (PN 16 pressure valves) ...................................................... 53

14.2. Standard Materials for High Pressure Gate Valves (where applicable) ......................... 53

14.3. High Pressure Cast Iron Steel Spring Loaded Check Valve ............................................. 53

14.4. Pipe Works ........................................................................................................................ 54

14.5. Saddles, Tees, Flanges & Other Accessories Installation ................................................ 54

15. Plastering (where applicable)................................................................................................... 55

16. Block Works .............................................................................................................................. 55

17. Painting ..................................................................................................................................... 56

18. Tiling .......................................................................................................................................... 57

19. Metal doors and louvers .......................................................................................................... 58

19.1. Metalwork ......................................................................................................................... 58

19.2. Surface Finishing ............................................................................................................... 58

19.3. Protection of Metals against Corrosion........................................................................... 58

20. Aluminum Work ........................................................................................................................ 59

20.1. Execution of Works .......................................................................................................... 60

20.2. Workmanship ................................................................................................................... 60

20.2.1. Fixing ................................................................................................................................. 60

20.2.2. Tightness of joints............................................................................................................. 61

20.2.3. Installation ........................................................................................................................ 61

20.2.4. Contact between different materials and alloys ............................................................. 61

20.3. Tolerance on setting out .................................................................................................. 61

20.3.1. Tolerance on installation .................................................................................................. 61

20.3.2. Sealing ............................................................................................................................... 62

20.3.3. Protection ......................................................................................................................... 62

Lot B‐Construction & Equipping of Treatment & Control Station .......................................................... 63

TECHNICAL SPECIFICATIONS DOCUMENTS ............................................................................................. 63

Section III ................................................................................................................................................... 63

Treatment Plant Equipment ..................................................................................................................... 63

1. General Data ................................................................................................................................. 64

2. Chemical Dosing ........................................................................................................................... 64

2.1. Pre‐chlorination ........................................................................................................................ 64

2.2. Post‐chlorination ...................................................................................................................... 65


2.3. Aluminum Sulfate ..................................................................................................................... 65

3. Horizontal Booster Pump ............................................................................................................. 65

4. Pressurized Sand Filter: ................................................................................................................ 68

5. Carbon Filter: ................................................................................................................................ 69

6. Piping System ................................................................................................................................ 70

7. Piping System ................................................................................................................................ 70

8. Water Sampling ............................................................................................................................ 71

9. Testing, Operation & Maintenance ............................................................................................. 72


Chaghour Hammana‐ Caza of Baabda Lot B‐Construction & Equipping of Treatment & Control Station

TECHNICAL SPECIFICATIONS DOCUMENTS

Section I

General Specifications


1. Definitions

• Architect and Engineer: also referred to as Design Architect or Engineer means the individual or organization who furnished the design, which includes but not limited to the construction drawings and technical specifications.

• The “project implementer” means Employment Intensive Infrastructure Program in Lebanon (EIIP) .

• The “EIIP Project Engineer ”, means the person whose services have been engaged by Employment Intensive Infrastructure Program in Lebanon (EIIP) to technically monitor and administer the subcontract as provided therein, as will be notified in writing to the contractor or stated in the Contract Data of the subcontract.

• The “contractor” means the person or corporate body whose bid to carry out the work has been accepted by the project implementer who in this case is Employment Intensive Infrastructure Program in Lebanon (EIIP).

2. Location

The project is located in the village of Hammana – Caza of Baabda.

Hammana village gets its water from a local spring (Al Chaghour spring) located at 1400 meters above sea level. An old ductile iron pipeline conveys water to the village’s reservoir.

During winter season Chaghour’s water become highly turbid and the village is completely deprived from water.


The current tender, LOT B, is related to the construction of a water treatment room and an intermediate clarifier & storage reservoir to store raw water prior to filtration, in addition to the water treatment units sand & carbon filters with related chemical dosing feeders.

3. General requirements

Prior to any works, the contractor must obtain written approval from EIIP Project Engineer.

Approval must include proposed time table schedule submitted by Contractor, and approved by EIIP Project .


• Site investigation and location of existing infrastructural installations,

• Site investigation of reservoir location and reservoir access road to allow for the transportation of material needed for reservoir construction.

4. Sign boards and visibility panels

Contractor must provide visibility signs (sign boards) approved by EIIP Project.

5. Method Statements and time table schedule

The Contractor shall provide in a reasonably timely manner a method statement to the EIIP Project Engineer for any part of works upon request from the EIIP Project Engineer.




The contractor shall submit to the EIIP Project Engineer representative for approval an update schedule.

The EIIP Project Engineer approval of the schedule shall not alter the contractor’s obligation to perform within the period of performance. The contractor may revise the schedule and submit it to the EIIP Project Engineer again at any time. A revised schedule shall show the effect of change orders, where applicable.

6. Safeguards of existing pipes & relevant structures

It shall be the Contractor’s responsibility to safeguard by means of temporary and permanent support or otherwise all existing installations that will be encountered during the construction of pipeline networks and reservoir.

7. Record drawings

Where the Contractor executes work under the contract, including locations where the Contractor undertakes construction, repair or rehabilitations work. The Contractor shall record the location and nature of all existing installations and their associated services.



The Contractor shall where necessary utilize appropriate equipment and where instructed by the EIIP Project Engineer excavate trial pits to confirm the location and determine the size and nature of the buried services.


8. Project Management


Planning and program preparation particularly in relation to the requirements of the Employer and the public authorities, and the requirements to maintain water supply service where careful detailed arrangements have to be made and adhered to.

Planning the execution of the works in a manner which minimizes disruption to the water supply system and will permit the efficient and effective commissioning of the water supply system and their respective components.

Ensuring that adequate potable water supplies are maintained to all consumers, and that no contamination to those pipes might result from his ongoing works.

Continuous surveillance of progress and anticipation of factors likely to affect the timely performance of the contract.

Making proposal for modification to forward planning and to the program at an early stage in the light of factors resulting from (d) above.

Continuous appraisal of the Contractor’s methods and routines particularly as to their effectiveness relating to speed of execution and to their effect on the community and property.

Forward planning for resource requirements taking due account of possible shortages and delays in the arrival on site of materials, equipment, plant and personal and their mobilization for effective usage.

Acquisition and process of up‐to‐date information for progress with the EIIP Project Engineer. The preparation of monthly progress reports including an update of the detailed program and cash flow forecast which shall include progress pictures as directed by the EIIP Project Engineer.

9. Required standards

Works covering the construction of reservoir must conform to the technical specifications described later on in the tender documents.




The approval of “EIIP Project Engineer” is a must prior to any work.

Any alternative proposal on required standards covering specifications, drawings and bill of quantities, must be approved by “EIIP Project Engineer”.

Proposed standards and codes governing this contract cover pipeline networks and related accessories, reservoir construction and valve chambers as well as all works required to complete the project.

10. Silence of specifications


In such case “EIIP Project Engineer” will make the necessary and relevant interpretations covering such works.

11. Correspondence and records

All correspondence between Contractor and “EIIP Project Engineer” shall be made in English. All records, sheets, drawings and documents shall be in English language.

12. Units


13. Intent of the contract




Submittal of shop drawings, (plans & sections) will be approved or returned for modifications within 8 days of submittal.

14. Terms in the contract

Expressions Like:

• Contractor refers to the entity responsible for implementing the works.

• “As shown”, “as indicate”, “as detailed” as terms of the same connotation, imply that the work should be done according to the drawings and the related specifications.

• “As approved”, “as directed”, “as required”, “as accepted” should mean and understood that the approval, direction, requirement, permission, authorization, review or acceptance of the “EIIP Project Engineer” is intended

• “Provide”, that be understood to mean “complete in place”, “that is”, “furnish and install”.

• “Equal” or “equivalent” means that material or equipment will be acceptable when


composed of parts or equal quality, or equal workmanship and finish, designed and constructed to perform or accomplish the desired result as efficiently as the named brand, pattern, grade, class or model.

15. Quality control


16. Reporting

Contractor in coordination with “EIIP Project Engineer” will prepare and submit a detailed measurement of works that are completed within the month frame.

Measurements are according to B.O.Q items and any addition in works greater than what is mentioned within the B.O.Q must be within an approved work order variation (V.O).



• Storage instructions.

• The manufacturer’s name.

• Shelf life and dates of manufacture.

• Material identification.

• Batch reference number.

• Net weight.

• Mixing instructions.

• Any warnings or precautions concerning the contents and their safe use;

Add to this that Contractor shall supply with each consignment of proprietary material delivered to the site, certificate furnished by the manufacturer including:

• The manufacturer’s name and address;

• Material identification;

• Batch reference numbers, size of each batch and the number of containers in the consignment;

• Date of manufacture;

17. Refusal of delivered materials

In case delivered articles or materials are found unsound or of poor quality, such items will not be used and must be removed from site, and replaced by materials pre‐inspected and approved by “EIIP Project Engineer”.

18. Quality of supplied materials and of workmanship


The materials and work man ship shall be the best of their respective kinds to the approval of the “EIIP Project Engineer”.

The words “to the approval of EIIP Project Engineer” shall be deemed to be included in the description of all materials and workmanship for the due execution of works.

19. Approval on materials

All proposed and supplied sources of materials, construction requirements and proposed standards should be deemed to the “EIIP Project Engineer’s” approval, the “EIIP Project Engineer’s” has to approve and agree upon any standard or method of manufacture or specification whether to maintain or change these items.



20. Work on private lands

There will be no need to obtain clearance from private owners unless specified otherwise.

In any case and unless clearance is given by the Water Establishment and the concerned municipality, the contractor shall not disrupt any private or public access way without providing alternative arrangements, in such case property access affected by the works must be maintained, trench crossings must be provided via special road plates.

21. Damages to utility properties



22. Access road to site


The employer does not guarantee availability of any temporary or existing road inside site premises, and will not entertain any claim in respect of the non‐suitability or availability of any such road for continuous use during the contract period.

At the end of works, all temporary roads must be closed, and Contractor must restore landscape to its original form or as indicated by “EIIP Project Engineer”.


23. Site limits


24. Work Initiation – Submittal of shop drawings

Upon receiving clearance to start works, Contractor will submit to the “EIIP Project Engineer’s” approval, detailed drawings and data sheets required to start works.

Coordination will be made between “EIIP Project Engineer” and Contractor, so as to agree on basic information supplementary to that shown on submitted drawings like base lines, borders, center lines in order to locate exact level of pipes and their relative slopes.





Accuracy of information submitted by Contractor is under his strict responsibility and any discrepancies, errors or omissions in supplied drawings must be corrected and then re‐ approved by “EIIP Project Engineer”.

The Contractor shall submit final as‐built record drawings to the “EIIP Project Engineer” for his review by the specified date.

After review and approval by the “EIIP Project Engineer” of the final as‐built drawings, the Contractor shall within 7 days thereof, produce a final set of “as‐built drawings” and submit to the “EIIP Project Engineer”, one computerized disk copy and 2 printed copies.

In case there are no changes with proposed design drawings, the contractor must obtain the approval of “EIIP Project Engineer” prior to commence works.

25. Levels, dimensions, benchmarks and level datum

All construction drawings must be referred to the institute of national height datum. The contractor must obtain the location of permanent bench marks.




Accuracy of established datum shall be regularly checked during the construction process. Benchmarks in the area that appear on the drawings shall be established by Contractor.


The Contractor shall provide one sign board mounted on suitable steel frame, in positions and heights indicated by “EIIP Project Engineer”.

Wherever necessary, safety barriers must be installed to protect pedestrians and people working on site as well as visitors.

26. Miscellaneous works on site

While working on site, Contractor must keep the site as clean as possible by removing wastes, debris and other materials to approved dumping locations.


On all occasions works shall be properly flagged.


27. Insurance



28. Site demobilization

Upon completion of works and after getting the approval of “EIIP Project Engineer”, Contractor will start dismantling of stores, work shops, offices and will proceed to the removal of all equipment from site.





Section II

Civil Works for Treatment Plant Building & Reinforced Concrete Clarifier &

Storage Tank


1. Introduction

The EIIP project is assisting the Hammana municipality in the construction of a water treatment room and an intermediate clarifier & storage reservoir to store raw water prior to filtration, in addition to the water treatment units sand & carbon filters with related chemical dosing feeders.

Work in this Lot covers the construction of a 15 m x 7 m water treatment station and reinforced concrete clarifier and storage reservoir in addition to the supply and installation of treatment units i.e pressurized sand & carbon filters, chlorine & Aluminum Sulfates dosing pumps as well as booster units to operate the filters.

1.1. Conditions on site

Before carrying out works, the site shall be inspected by the Contractor in conjunction with the “EIIP Project Engineer” to establish its general condition which shall be agreed and recorded in writing, and where in the opinion of the EIIP Project Engineer it is deemed necessary, by means of photography.

Details records shall include the location of all boundary and survey beacons, the conditions of buildings, surfaces, terracing (if any), ditches, watercourses, roads, tracks, fences and other information relating to the site and elsewhere which may be affected by the works.

2. General requirements & guidelines

2.1. Site Mobilization

Mobilization of site covers all preliminary works necessary to start works on the ground. Contractor is requested to submit a Construction Planning Program (C.P.P) with a time table schedule sheet, C.P.P must describe every task and its correlation with any other job.

Submitted time table must also cover ordering and delivering of materials and consumables. Contractor’s time table schedule sheet will be used as the basis for progress reports during construction phase (weekly & monthly).

2.2. Mobilization of Equipment

All equipment and machinery needed to implement works must be brought on site prior to the startup of works.


All consumables needed for machinery and equipment operation must also be brought on site and properly stored in a safe way and to the approval of the “EIIP Project Engineer”.

Fine tuning of various machinery’s engines must be implemented prior to work on site to prevent pollution during operation (Obnoxious gas).

2.3. Operation & Maintenance Manuals

The “EIIP Project Engineer” will control and supervise, and eventually approve any set of instructions, after the Contractor has submitted draft copies of the operation and maintenance manuals. On the other hand, the Contractor shall abide and conform to any amendments on additions necessary and indispensable dictated by the “EIIP Project Engineer” in the production of the final manuals. Each installation requires a provision of a separate set of instructions.




Operation & maintenance should be supplied in a written form in both English and Arab languages. All parts and equipment listings are to be described and listed in English.

The draft operation and maintenance manuals must be on site during tests and this to verify that operations comply with instructions.


3. Submittals

The Contractor shall order materials to suit the construction program and shall plan his necessary submittals to the “EIIP Project Engineer” in accordance with the required specifications in a timely manner to suit the ordering, delivery and construction timing requirements. The Contractor shall submit as a minimum the following documents for review and approval by the “EIIP Project Engineer”.

3.1. Materials, Product Data, Equipment Specifications & Catalogues

All specifications, diagrams, samples, drawings and such other data shall be provided by the Contractor, in a format to be agreed upon with the “EIIP Project Engineer”, which may be required to demonstrate compliance with the specification.


• Originals of catalogues and Supervising data sheets for manufactured items; each item and option to be provided shall be clearly marked and each item not be provided shall be deleted.

• Literature to show that products provided meet the requirements for material, construction, operation, and testing.

• Information on the following items as a minimum: pipes; pipe jointing systems, manhole covers and all other hydraulic accessories.

• Manufacturer’s installation instructions for all items.

• Certified reports for all tests and inspections designated herein, showing full compliance with referenced standards.

• Maintenance requirements and procedures.

• Period of guarantee for products.

3.2. Shop drawings


• Drawings (plans & sections) for the proposed ground reservoir and valve chamber.

• Updating topographical stakes and reservoir limits in order to ensure the reservoir is at an adequate distance from the road and neighboring plots

• Information on all equipment and material to be supplied including brand, class, grade, pressure rating, dimension, location and identification number of each item, pipes hydraulic accessories and pipe fitting to be furnished and installed.


• Procedures for installations.

• All other miscellaneous details required to complete the whole installation process

The review and approval of shop drawings by the “EIIP Project Engineer” shall not relieve the Contractor from any of his responsibilities under the contract for successful completion of the work.

3.3. Manufacturer Certifications

In case decided by the client, Contractor must submit a certification mark scheme issued by an independent third party testing organization to the satisfaction of “EIIP Project Engineer” stating that production has been carried out under a standard system for supervision, control and testing, applied during manufacture, in accordance with ISO or an equal procedure.


3.4. Manufacturer Recommendations

The Contractor shall submit installation recommendations issued by the manufacturer for construction, installation, and commissioning of all piping equipment and related accessories.

Recommendations shall include testing methods, storage requirements and maintenance and operational data.

The Contractor shall have a copy of the manufacturer’s instructions available on site at all times while works are in progress and shall strictly follow these instructions unless otherwise authorized to deviate by the “EIIP Project Engineer”.

3.5. Installation & Testing



3.6. As‐built Drawings

The Contractor shall maintain one set of contract drawings for the sole purpose of recording accurate changes made as the work progresses (“As‐Built” conditions of the water project).

All changes previously agreed upon with the “EIIP Project Engineer” and all completed work shall be recorded on these drawings.

The Contractor shall prepare as‐built drawings clearly showing all shapes and dimensions of all works as executed. All pumps, pipes valves locations shall be identified and recorded. The Contractor shall submit as‐built drawings for all installations.

4. Material Storage & Handling

4.1. Transportation & Handling

All materials shall be delivered in the manufacturers' original protective packaging and shall be inspected by “EIIP Project Engineer ” upon delivery on site.


The Contractor must inspect the shipments to assure that products comply with requirements, and that delivered quantities are correct and undamaged.

All products shall be handled and stored in accordance with manufacturer’s printed recommendations.


The manufacturer must package products for shipment in a manner suitable for safe transport by commercial carrier. When delivered, a receiving inspection shall be performed, and any shipping damage must be reported to the manufacturer, contractor being obliged to replace damaged materials immediately

It is the responsibility of the Contractor to safety transport pump sets, control panels and all hydraulic accessories to site and proceed for proper stockpiling.

4.2. Storage & Handling




4.3. Materials to be supplied by Contractor

All material that must be provided by the Contractor for the construction of the reservoir, shall include but are not limited to:

• Cement

• Aggregates (sand and gravel)

• Steel

• Scaffolding

• Concrete add‐mixture products

• Pipes for valve chambers

• Valves

• Fittings

The material provided by the Contractor shall include all material for temporary works, planking and strutting, excavations, shuttering and formwork, staging and scaffolding, compliant filling materials, such as primer, coal tar enamel etc., all concrete of each required class including reinforcing steel and mesh.

All materials supplied locally by the Contractor shall be of the best quality in their class and of the respective kinds as described in the contract and in accordance with the “EIIP Project Engineer’s” instructions and to the satisfaction of the “EIIP Project Engineer”. They shall be inspected from time to time at the site during the progress of the work.

Any materials arriving on site found unsuitable shall be rejected. The Contractor shall replace the rejected material at his own expense.

5. Excavations for concrete reservoir construction

5.1. Geo‐Technical Investigations & Reporting

The contractor will undertake a detailed geo‐technical investigation to determine the exact nature of sub‐service formations. In order to do so, the contractor needs to:

• Provide a special coring drill capable of reaching a depth of 15 meters below ground


level.

• Undertake a minimum of 3 different coring samples with a minimum depth of 10 meters per core

A comprehensive geo‐technical report should then be submitted, detailing the results of the phases of the investigation as described above. The site soil should be clearly identified and described in accordance with the ASTM standards, and should include the following:

• Subsurface interpretation profile with suggested design parameters for each of the strata encountered (bulk density, shear strength parameters, and permeability)

• Recommendation for Foundation design (Foundation type, allowable bearing capacity, and modulus of subgrade reaction)

• Discussion of possible settlements and lateral earth pressure

• Clear recommendations and provisions for excavation support

• Discussion of possible dewatering schemes and requirements for the raft foundation of the reservoir given the rough information on permeability obtained from the investigation program

• Submittal of 4 factual report copies that include borehole logs, photographs, laboratory test results and all data required

5.2. Excavations

Prior to the excavation process, contractor must demolish existing reservoir and remove all debris to authorized dumping places.

Demolishing of reservoir must be implemented after taking all preventive measures to protect the workers on site, machineries and neighboring structures; moreover contractor must preserve the site and restore the site to its initial condition prior to the beginning of works.

Contractor to proceed for excavations at indicated locations for ground reservoir.

Excavations shall be to the depth indicated by EIIP Project Engineer based on geo‐technical investigation findings.

All excavations shall be deemed to consist of “Common Excavations” regardless of the nature of encountered soils.

The contractor must verify the natural ground level where reservoir shall be erected; he shall take all levels and proceed for the topographical stacking of final reservoir location.

In case dewatering is needed to reach final depth contractor shall take all necessary arrangements to divert water or pumping it outside the excavated pit and this, during the whole period prior to the construction of the concrete structure.

The sides of excavations shall be supported wherever needed or instructed by EIIP Project Engineer.

Contractor must take all necessary precautions to protect his employees and BMLWE staff and any other person that might be present on site, especially in order to avoid slipping, falling or any other incident that might occur.

For this, contractor must also install a protective fence beside opened trenches and shall provide warning lights for night view.

All additional excavated volumes must be disposed of in legally designated dumping sites.


6. Concrete

Concrete will be used for construction as well as valve chamber and retaining walls. Concrete must have a minimum compressive strength of 300 kg/cm2 at 28 days.

6.1. Composition

Concrete shall be composed of cement, sand, broken rock or gravel, and water all well mixed and brought to the proper consistency. In case of adverse weather conditions (freezing temperature), powdered admixture shall be added to decrease concrete curing period.

The exact proportions, in which these materials are to be used for different parts of the work, shall be as determined from time to time during the progress of the work and as analysis and tests are made of samples of the aggregates and the resulting concrete.

The meter cube of concrete shall be composed as follows:

• 350 to 400 Kg of Portland cement,

• 800 Liters of gravels as per required specification with maximum gravel size of 20 mm,

• 400 Liters of sand free from organic materials (marine sand is strictly forbidden).

These proportions may be modified to suit the work or the nature of the materials used or to comply with the water cement ratio limitation hereinafter specified.





The amount of water used shall be changed as required to secure concrete of proper consistency and to adjust for any variation in moisture content of the aggregate as it enters the mixer, provided that a water cement ratio of 0.60, by weight, shall not at any time exceeded.

Contractor is responsible for the design of concrete and shall take the approval of “EIIP Project Engineer” for the mix proportions.

The proportion of cement, aggregates and water shall be determined in accordance with (2, 3, and 4) BS 5328.




Uniformity in concrete consistency from batch to batch will be required.


Slump tests will be made in accordance with the Tentative Method of Test for Consistency of Portland‐Cement Concrete (A.S.T.M. Designation: D138‐32T) of the American Society for Testing Materials.

6.2. Cement

Cement for concrete shall comply with the Standard Specifications for Portland cement, and shall be C‐S 42,5 according to the Lebanese norm, also the heat of hydration of cement measured by the method of “ Bouteille isolante” defined by “ Centre d’Etudes et de Recherches de l’industrie des liants hydraulique” shall not exceed 70 calories / gram of cement at t= 7 days


The quality of the Portland cement shall be equivalent to AASHTO M85, type I, II, III or V. Cement will be delivered in bags of 50 kg each.

6.3. Aggregate – Sand






6.4. Broken Rock and Gravel



The suitability of the broken rock or gravel will be determined with the aid of tests made in accordance with the standard practices.

Any crushing, blending, screening, washing, or other operation on the broken rock or gravel required to meet these specifications shall be done by the Contractor, and the cost thereof shall be included in the unit prices bid in the schedule for the items of work in which the broken rock or gravel is used.





The relative amounts of each size of broken rock or gravel to be used in each mix of concrete and in all parts of the work will be based on securing concrete having the required workability, density, impermeability, strength, and economy, without the use of an excess of sand, water, or cement, and using, insofar as practicable, the entire yield of suitable material from the natural deposits from which the broken rock or gravel is obtained.


6.5. Storing of Cement


Cement must be transported to the mixer in its original sacks. Each batch shall contain the full amount of cement for the batch. In case cement is placed in contact with the aggregates it must be mixed within 60 minutes or it will be rejected.

6.6. Sampling of Concrete


Approval of “EIIP Project Engineer” on mix proportions must be obtained at least one week prior to the beginning of concrete work.

Mixing proportions of cement, aggregates and water must be done in accordance with BS 5328.

Concrete must have a minimum compressive strength of 300 kg/cm2 at 28 days.

For each cast a minimum of two cylinders must be taken and stored in adequate places as specified by “EIIP Project Engineer”.

Cylinders on site will be stored in a locked place and key will be put at the disposal of “EIIP Project Engineer”.

6.7. Stockpiling of Aggregates




In any case stockpiling of aggregates must be approved by “EIIP Project Engineer” and every precaution must be taken to prevent segregation like not making layers above 1.5 m and in case additional layer is brought to site it is forbidden to cone down new layer above old one.

Also aggregates must be protected against contamination from water diverted from site or from water pumped during dewatering of ponds.

If instructed by “EIIP Project Engineer”, aggregate stockpiles will be sprinkled with water 12 hours before use and this in order to maintain moisture content in the aggregates equivalent


to the water absorption value of the aggregates as determined by AASHTO T84 & 85.

6.8. Ready Mix Concrete

Ready mix concrete can be used and must have the same properties listed above. Unless otherwise stated the relevant clauses of BS 1926 shall apply.

Ready mixed concrete shall only be used after approval of the EIIP Project Engineer .

The contractor shall not be relieved of his obligation to provide concrete to the standard laid down in this Specification by virtue of any approval given for the use of concrete supplied by others, and the EIIP Project Engineer reserves the right to withdraw his approval at any time consequent on any deterioration in the quality of the concrete, or unsatisfactory delivery or any other reason he considered detrimental to the Works,

Ready mixed concrete manufactured off the site shall be transported in a revolving drum and shall be continuously agitated until it is used in the work unless otherwise approved. The time interval between adding water to the drum and placing shall not exceed 90 minutes.

6.9. Admixtures

Before approval for the use of a proprietary admixture is given the Contractor will be required to satisfy the EIIP Project Engineer as to its suitability for the work and its compatibility with the cement it is intended to complement and for the intended use of structure. Admixtures that contain chlorine shall not be used for potable water retaining structures.

6.10. Water

Water for use in concrete and in concreting operations shall be of potable quality:

Where required by the EIIP Project Engineer it shall be tested in accordance with BS 3148 and if necessary shall be treated to assure compliance therewith.

Water for washing and curing shall be such that it will impair neither the strength of the finished concrete nor its appearance.

6.11. Steel for Concrete Reinforcement


6.11.1. Reinforcement of Steel Bars

All reinforcement bars shall be free detrimental dirt, mill scale, rust, paint, grease, oil or other foreign substance, fins or tears. The Contractor will not be required to remove slight rusting which discolors the metal, but he shall remove all loose mill scale and scales rust.


Supports, metal supports, approved by the “EIIP Project Engineer”, shall be provided and used to retain the reinforcement at proper distances from the forms. Supports under horizontal bars slabs shall be spaced at not more than eighty (80) diameters of the bar.

All reinforcement shall be so rigidly supported and fastened that displacement will not occur during construction. Reinforcing steel shall be inspected in place and must be approved by the “EIIP Project Engineer” before any concrete is deposited.

Reinforcing steel shall be stored above the ground on plate forms, skids, or other supports. It shall be stored in such a manner and adequately marked to facilitate inspection and checking. When placed in the work, the reinforcing steel shall be free from dirt, detrimental scale, paint, oil or other foreign substance.


All cutting and bending of reinforcement bars shall be done by competent workmen and with equipment approved by the “EIIP Project Engineer”.


Bent bar reinforcement shall be cold bent to the shapes shown on the plan, and unless otherwise provided on the plans or by written authorization of the “EIIP Project Engineer”, bends shall conform to the following requirements:

D= 6d for five (5) millimeter through twenty two (22) millimeter bar sizes.

D= 8d for twenty four (24) millimeter through twenty eight (28) millimeter bar sizes. D= 10d for thirty (30) millimeter and over bar sizes.

Where:

D= minimum pin diameter around which a bar may be bent d= bar diameter.

All reinforcing steel shall be accurately placed and, during the placing of concrete, firmly held by approved supports in the position shown on the plans.

Reinforcing bars shall be securely fastened together; reinforcement placed in any member shall be inspected and approved before any concrete is placed.


All horizontal reinforcement shall be supported on metal supports or spacers as approved by the “EIIP Project Engineer”.



The adequacy of the supports and ties to secure the reinforcement properly shall be subject to the approval of the “EIIP Project Engineer”.

6.12. Falsework & Formwork


Work consist in furnishing and placing Portland cement concrete for structures in accordance with the specifications and conformity with the lines, grades and dimensions of drawings and plans.

6.12.1. Falsework





Spacing of false work columns in the general framing must be approved by “EIIP Project Engineer”.



The Contractor shall submit calculations to support this requirement for all spans over 3 meters and other spans if requested by the “EIIP Project Engineer”.



Note: In designing forms, concrete will be regarded as a liquid having a weight of 2,400 kg per m3, and not less than 1,400 kg per m3 shall be assured for horizontal pressure.

6.12.2. Formwork









The width and thickness of the lumber, the size and spacing of studs and Wales shall be determined with due regard to the nature of the work and shall be sufficient to ensure rigidity of the forms and to prevent distortion due to the pressure of the concrete.


When the Contractor instructed by the “EIIP Project Engineer” shall submit formwork drawings and calculations to the “EIIP Project Engineer” in advance of the concreting.








6.13. Tolerance

Unless otherwise indicated on the drawings, the tolerances of the finished concrete with respect to the dimensions shown on the drawings shall not exceed the limits set out in the following table. Formwork shall be constructed to ensure completed work within the following tolerance limits:

Departure from established alignment: 0.5 cm Departure from established grade: 0.5 cm

Variations from plumb or specified batter in lines and surfaces of columns, piers and walls:

• 0.5 cm in 3 meters, if exposed

• 0.5 cm in 3 meters, if backfill

• 0.5 cm in 3 meters, if exposed

Variations from level or indicated grade in slabs, beams etc...:

• 0.5 cm in 3 meters, if backfill

Variation in cross‐sectional dimension of columns, piers, slabs, walls, beams: ‐0.5 cm + 0.5 cm Variation in slab thickness: ‐0.5 cm + 0.5 cm

Footing: plan dimensions: ‐0.5 cm + 0.5 cm

Eccentricity: 2 percent of footing width, not exceeding 5 cm

Reduction in thickness: 2 percent of specified thickness


7. CONCRETING

7.1. Requirements

The finished concrete shall be dense, durable, and impervious to the access of water, free from cracks and honeycombing, and resistant to wear and mild chemical attack.

7.2. Transporting

Concrete shall be transported to the place of final deposit by approved means:

Barrows, spades and other equipment used in the process of transporting concrete shall be


thoroughly cleaned before each day’s work or after a long interruption and they shall be free from hardened concrete.

Concrete shall be transported as soon as possible after mixing, by methods which will prevent the segregation, loss or contamination of the ingredients.

Bridging for traffic over reinforcement shall be provided so that the reinforcement is not distorted, damaged or displaced.

Where approval is obtained for concrete to be conveyed by chutes, they shall have a slope (not exceeding 1 vertical to 2 horizontal) such as to ensure a continuous flow of concrete. Additional water shall not be introduced to assist the flow. If deposition is to be intermittent the chute shall be arranged to discharge into a storage hopper. In no case will a clear fall of more than 1 m be permitted at the discharge end of the chute.

Where approval is obtained for pumping the concrete, the pump manufacturer’s recommendations as approved by the EIIP Project Engineer shall be followed. The pumps used shall be of adequate capacity and power to ensure delivery of a continuous supply.

Wherever transport of concrete is interrupted for any period of over half an hour the chutes, pumps, and any other means of distribution shall be thoroughly flushed out and cleaned. These shall also be flushed out immediately prior to resumption of concreting and shall be kept free from hardened concrete. All WASH water used shall be discharged outside the formwork and clear of any freshly placed concrete.

7.3. Placing & Compaction

No concrete shall be placed until the Contractor has obtained approval from the EIIP Project Engineer. When the Contractor intends to place concrete he shall inform the EIIP Project Engineer in sufficient time to enable his inspection. The Contractor shall provide all facilities for such inspection.

Concrete shall be placed within 30 minutes to mixing, to uniform level, in layers not exceeding 500mm deep in such manner as to avoid segregation. Each layer shall be compacted by means of approved vibrators to form a dense material free from honeycombing and other blemishes.

If internal vibrators are used, they shall be withdrawn immediately water or a thin film of mortar begins to appear on the surface of the concrete. Withdrawal shall be carried out slowly to avoid the formation of voids.

If external vibrators are used, the formwork shall be designed for external vibration and shall be strong enough to withstand the forces of vibration.

Temporary or permanent stoppages of work shall be made only against stop ends.

Unless otherwise specified, before placing new concrete against concrete which has already hardened, the face of the older concrete shall be prepared by the removal of any laitance and loose aggregate, and shall be cleaned by a jet of compressed air.

7.4. Concreting in Deep Lifts

Where concrete is to be placed in lifts greater than 2.5 m high it shall be placed by suitable tremie pipes.

7.5. Hot Weather Concreting (above 20ºC)

Concreting shall not be permitted if its temperature at placing is in excess of 38 ºC. In order to maintain the temperature of the concrete below this value the following precautions shall be taken wholly or in part as instructed by the EIIP Project Engineer:


• All aggregate stockpiles, water lines and tanks as well as the mixer shall be protected from the direct rays of the sun;

• Coarse aggregate shall be cooled by constant watering where possible;

• Mixing water shall be cooled by the addition of ice to the storage tanks where necessary

• Rapid‐hardening cement shall not be used;

• Where the above precautions are inadequate concreting shall be carried out during the cooler parts of the day or during the night as may be directed by the EIIP Project Engineer.

When the air temperature is above 20ºC loss of mixing water by evaporation shall be considered in arriving at the amount of water to be added to the mix. To maintain the water/cement ratio within permissible limits an approved water‐reducing agent shall be included in the mix.

The maximum water/cement ratios may be increased with the EIIP Project Engineer’s permission by 0.05 (or 2.5 liters/50 kg of cement) during mixing but on no account shall water be added to concrete once it has left the mixer.

In order to reduce premature during of the concrete during transporting and placing, all chutes, formwork and reinforcement shall be added by watering when possible, or shall otherwise be protected from the direct rays of the sun. Any water so used shall be removed by jetting with compressed air before placing the concrete.

As soon as possible after concreting the formwork shall stripped and the surface of the concrete shall be treated.

Where drying winds are encountered, wind shields shall be positioned as necessary to protect exposed surfaces of the curing concrete.

7.6. Wet Weather Concreting

Concreting during periods of constant rain shall not be permitted unless aggregate stockpiles, mixers and transporting equipment, and the areas to be concreted are adequately covered.

During showery weather, the Contractor shall ensure that work can be concluded at short notice by the provision of stop ends. On no account shall work be terminated before each section, between one stop end and another, is complete. Adequate covering shall be provided to protect newly placed concrete from the rain.

7.7. Holes, Cavities & Fixings

Holes, shall be accurately marked and boxed‐out for before concreting operations commence, no holes, shall be formed after the concrete has set.

Where bars, if placed to specified spacing would foul holes of size less than 250mm x 250mm the full length of the bar shall be moved to one side unless otherwise indicated on the Drawings for holes exceeding 250mm x 250mm the bars shall be cut on site and lapped with additional equivalent bars.

Wherever possible, the Contractor shall build in all pipework, ironwork, and steelwork which passes through walls and floors. The pipework, ironwork, and steelwork shall first be thoroughly cleaned and freed from any deleterious matter. Every care shall be taken to ensure that it is thoroughly encased in concrete.

Bolts, hooks and other fixings shall be embedded in concrete, or holes shall be drilled and fitted


with threaded expanding anchors to receive the bolts. The Contractor shall ensure that bolts, hooks, and fixings are accurately, positioned. Holding down bolts for machinery shall be set to template.

Where brick or stonework is to form a facing to the concrete or where the end of a brick or stone wall butts against a concrete face, galvanized metal ties of approved manufacture to BS 1243 shall be incorporated.

7.8. Protection

Newly placed concrete shall be protected by approved means from rain, drying winds, sun.

No traffic or constructional loads shall be permitted on newly placed concrete until it has hardened sufficiently to take such traffic or load.

Curing methods shall ensure that cracking, distortion and efflorescence are minimized.

Concrete shall be cured using methods approved by the EIIP Project Engineer. The method of curing shall prevent loss of moisture from the concrete. Immediately after compaction and 7 days thereafter concrete shall be protected against harmful effects of weather, including rain, rapid temperature changes and from drying out.

The curing time shall be the number of days in table 3.7 unless the average temperature of the concrete during the required number of days falls below 10ºC in which case the period of curing shall be extended until the maturity of the concrete reaches the value given in the table.

Curing shall be carried out using either of the following basic methods, or any other method agreed with the EIIP Project Engineer. Methods involving the use of dampened Hessian coverings shall not be used. The method adopted for any particular situation shall be agreed with the EIIP Project Engineer.

7.9. Membrane Applied by Spray

Liquid membrane compounds shall be applied to moist concrete surfaces as follows:

• Unformed Surfaces: The compound shall be applied immediately after the free water has left the surface.

• Formed Surfaces: The compound shall be applied immediately after removing the forms. If there is appreciable drying, the surface shall be mist sprayed with water to produce a uniformly damp appearance before the compound is applied.

The method and rate of application shall be in accordance with the compound manufacturer’s instructions as approved by the EIIP Project Engineer.

If rains falls on the newly coated surface before the film has dried sufficiently to resist damage, or if the film is damaged in any other manner, a new coat of compound shall be applied to the affected area. The membrane shall be applied to the affected area. The membrane shall be maintained effective for the specified curing time.

Compound applied to construction joint surfaces, or to other surfaces to which concrete are to be bonded, shall be removed prior to placing the fresh concrete.

7.10. Polythene Sheeting

The concrete surfaces shall be covered with white polythene sheeting as follows:‐

Unformed Surfaces:

The sheeting shall be laid over the surface as soon as possible without marking the surface, and not until initial stiffening has taken place.


Formed Surfaces:

The surfaces shall be covered immediately after the removal of the forms. The sheeting may be in contact with the concrete or made into portable shelters on light weight frames. In both cases, the sheeting shall be jointed and sealed against to concrete surfaces to prevent wind blowing between the sheeting and the concrete.

8. Water Retaining Structures

The design, detailing, materials and workmanship shall comply with the requirements of BS 8007.

The cement mortar used in filling recesses in the concrete formed by bobbins in connection with formwork shall contain an approved expanding admixture.

8.1. Construction Joints in Water Retaining Structures

Water stops not less than 150mm wide shall be built into all construction joints in external walls and construction. Construction joints shall only be formed at positions approved by the EIIP Project Engineer.

8.2. Water tightness of Structures

The Contractor shall be responsible for the water tightness of structures and any remedial measures necessary. Where detailed on the Drawings the surface of concrete shall be coated with a waterproof coating.

In the event that a structure designed and specified to be water retaining fails to satisfy the water tightness tests specified in Section 1.0 the Contractor shall undertake such remedial works as are necessary and are approved by the EIIP Project Engineer.

8.3. Waterproof Coatings

Waterproof coatings shall be applied to the internal water retain face of reservoirs or where instructed by the EIIP Project Engineer.

The coating shall comprise a waterproofing system which creates a vapor permeable sub‐ surface barrier to prevent water leakage and the ingress of contaminants into the cracks and concrete matrix.

The waterproofing system shall comprise non‐toxic, clear and odorless solution that penetrates into the concrete surface to form a non‐water soluble gel which forms chemically resistant compound in cracks, pores capillaries.

Expansion joints shall be formed in the waterproofing system by the use of compatible sealants as recommended by the manufacturer.

The system shall be cured for a period of not less than 7 days.

8.4. Hydrophilic Rubber Sealer

Hydrophilic rubber sealer shall be co‐extruded from chloroprene and hydrophilic rubbers into a cellular strip approximately 25mm x 7mm thick which expands as it absorbs water. The strip shall incorporate an expansion delay coating to prevent activation during setting of the surrounding concrete.

Hydrophilic rubber sealer shall be applied to the perimeter of all pipes to be built into concrete structures, to existing concrete walls and slabs at or below water levels which have been demolished and require extension, and to other locations as indicated on the Drawings.


The strip sealer shall be bonded to the pipe diameter or on to the face of demolished structures on to which new concrete is to be placed so as to be at least 100mm from the wall surface. Where dowel bars are incorporated in bonding new concrete to old the sealer shall be placed above the dowel bars on the ‘’wet’’ side of the structure. Bonding shall be accomplished using proprietary neoprene or epoxy adhesives to ensure the sealer is not disturbed during placement of the concrete.

The application shall be in accordance with the manufacturer’s recommendations.

9. Joints

9.1. Construction Joints

The position of construction joints, when not shown on the Drawings or otherwise required by this Specification, shall be decided on site having regard to the plant and labor made available by the Contractor for the manufacture, placing and compaction of the concrete as well as its curing, the climatic conditions prevailing at the time of concreting, the nature and size of the formwork and the conditions of operation of the work. The contractor shall submit his proposal to the EIIP Project Engineer for his approval before commencing the work.

Where possible Construction joint shall be prepared by the ‘’WASH‐off’’ method as specified below.

When expanded metal lathing is used for the formation of construction joints a rebate will not be required to be formed. The expanded metal lathing shall be left in the work and shall not extend closer to the finished surface of the concrete than 25mm. it shall be securely fixed to the reinforcement.

9.2. Slabs Supported on the Ground

To ensure control in the placing of concrete the contractor shall provide control boards to form panels not larger than 15m2 in area. These shall be lifted as the concreting proceeds except where they are of expanded metal in which case they may be left in position as part of the permanent works, provided that they shall not extend closer to the finished surface of the concrete than 25mm. The joint so formed shall then be treated as a construction joint. Where Ready‐mixed concrete is permitted the control boards shall be positioned so as to enclose a volume of concrete equal to that delivered by each truck.

Construction joints and control joints shall be formed normal to the surface of the concrete.

9.3. Suspended Beams & Slabs

T‐beams shall be formed to their full depth integrally with the adjacent slab and without horizontal joints.

9.4. Walls

Horizontal construction joints in walls shall be formed along straight lines, powers shall be made to the full height of the formwork.

Unless otherwise shown on the Drawings or permitted by the EIIP Project Engineer concerning of circular tanks shall be varied out continuously for the full circumference without vertical joints.

In rectangular tanks, vertical joints shall not be positioned closer to any corner than one meter. Unreinforced concrete manholes shall be constructed without vertical joints.

9.5. ‘Wash‐off Method’ of Construction Joints

As soon as possible after concreting, and while the surface is still green the surface of the concrete forming the joint shall be freed of loose aggregate and sprayed with a fine spray of


water to prevent the formation of laitance. All excess water shall be removed by a jet of compressed air and the surface left clean to receive further concrete.

9.6. Joints

Contraction and expansion joints and shall be as shown on the Drawings.

A period of at least five days shall elapse between the concreting of the section on each side of the joint.

Where the Drawings indicate a contraction gas shall be formed in any panel (the gap shall not exceed one meter), concerning on either side of the gap shall be carried out so as to form partial contraction joints at each side of the gap. Prior to the concreting of the gap section, the joint surfaces shall be cleaned but otherwise left untreated. The concreting of the gap section shall not be carried out until a period of at least five days has elapsed after completion of the adjacent sections.

Alternate panel construction (other than contraction gap construction outlined above) will be permitted only in water retaining structures or as otherwise approved by the EIIP Project Engineer where the panels are separated by expansion or contraction joints.

9.7. Water Stop

Water stop shall be manufactured of rubber or PVC (polyvinylchloride) as shown on the Drawings, and shall be of the type and size shown on the Drawing. Site joints shall be made in accordance with the manufacturer’s instructions as approved by the EIIP Project Engineer. All intersections and junctions shall be obtained prefabricated from the approved manufacturer. For water retaining structures the Contractor shall submit water stop fabrication drawings on the EIIP Project Engineer prior to fabrication.

Plasticized PVC water stops shall comply with the relevant provisions of Wls No. 4‐31‐02.

Rubber water stops shall have the following properties when tested in accordance with the relevant Part of BS 903:

Table 1: Properties of Rubber Water Stops

Part of BS 903 Property Requirements

A1 Density 1100 Kg/m3 (±5%)

A26 Hardness 60‐70 IRHD

A2 Tensile strength No less than 17.5 N/mm2

A2 Elongation at break point No less than 450%

A16 Water absorption (48 hours Not exceeding 5%

immersion)

Rubber water stops shall be suitable for storage, handling, installation and service within a temperature range of 0°C to +40°C

All water stop and jointing materials which are not required for immediate use shall be stored at all times in a cool damp place.

Water stop shall be located and maintained accurately in position. Details of the proposed method of fixing shall be submitted to the EIIP Project Engineer for approval. On no account shall water stop be secured by nails or by any other means involving


puncture of or damage to the water stop material unless purpose made nailing flanges are incorporated in the design of the eater stop.

9.8. Joint Filler

Joint filler for joints in structures to retain aqueous liquids shall be self‐expanding cork, natural bonded cork, resin bonded cork, or other material as detailed on the Drawings or itemized in the Bill of Quantities. Joint filler shall be cut and trimmed accurately to suit the joint profile and shall be maintained accurately in position by means of an approved adhesive. Self‐expanding cork filler shall consist of cork granules bound together with an insoluble synthetic resin. Cork filler shall have a maximum water absorption of 0.3% by volume when tested in accordance with ASTM D3595. The load required to compress the filler to 50% of its original thickness shall not exceed 1.5 N/mm2 for self‐expanding cork (moist), 0.6 N/mm for resin bonded cork and

0.90 N/mm2 for natural bonded cork. Recovery after compression test shall exceed 90%.

Joint filler in non‐water retaining concrete structures shall be non‐extruded bitumen impregnated fiberboard.

9.9. Joint Sealants

Joint sealing compounds shall be impermeable ductile materials of a type suitable for the conditions of exposure in which they are to be placed, and capable of providing a durable, flexible and water tight seal by adhesion to the concrete throughout the range of joint movement.

Hot poured joint sealants shall comply with BS 2499, Ordinary Type A1 sealant.

Cold poured polymer‐based joint sealants shall comply with BS 5212; part 1, Normal Type N sealant.

Two part polysulfide‐based sealants shall comply with the relevant provisions of BS 4254. Pouring Grade shall be applied to horizontal upward‐facing joints and Gun Grade to joints of any other aspect or inclination. Other two‐part polymer‐based sealants of Gun or Trowel Grade shall comply with the physical and test requirements of BS 4254.

Silicone based building sealants shall comply with the relevant provisions of BS 5889.

Primers for use with joint sealants shall be compatible with, and obtained from the same manufacturers as, the adjacent sealant. Primers shall have no harmful effects on concrete.

Sealants and primers which will be in contact with water to be used for potable supply shall not impart to water taste, color, or any effect known to be harmful to health, and shall be resistant to bacterial growth.

Sealants and primers which will be in contact with sewage or sewage sludge shall be resistant to biodegradation.

9.10. Slip Membrane

The slip membrane shall be not less than 1.5mm thick and shall be a plastic performed strip with low coefficient or friction specially manufactured for use as a separating membrane in sliding joints between concrete surfaces. Each joint shall comprise two layers of the membrane unless otherwise shown on the drawings.

The concrete surface to which the slip membrane is to be fixed shall be finished with a steel float to provide a smooth true surface free from dust and loose particles.

9.11. Dowel Bars


Dowel bars for expansion joints in concrete shall consist of mild steel complying with the provisions of BS 4449, Grade 250.

Dowel bars shall be straight, free from burrs or other irregularities and shall have their sliding ends sawn. The sliding half of each dowel bar shall be painted with a thin coat of bond breaking compound, and the end of this half shall be provided with a close fitting plastic or waterproof cardboard cap at least 100 mm long, the end 20 mm of which shall be fitted with a disc of joint filler or a pad of cotton waste.

Bond Breaking Compound for Dowel Bars

Bond breaking compound for dowel bars shall consist of a bitumen paint containing 66% of 200 pen bitumen, blended hot with 14% light creosote oil with the addition, when cold, of 20% solvent naphtha. It shall in no way retard or otherwise affect the setting of concrete.

10. Finishing

10.1. General

All exposed faces of concrete unless otherwise specified shall be hard, smooth and free from honeycombing, air and water holes and other blemishes.

All projecting imperfections shall be rubbed down with carborundum stone or by other approved means and grit and dust therefrom shall be thoroughly washed off with clean water.


i. Wood float finishing shall be formed by smooth floating the accurately leveled and screeded surface. Care shall be taken to ensure that the concrete is worked no more than is necessary to produce a uniform surface free from screed marks.

ii. Mechanical and Manual Steel trowel finishing shall be formed while the concrete is still wet by means of a steel trowel applied to an accurately leveled and screeded surface.

iii. Screeded finishing shall be formed by leveling and screeding the concrete to produce a uniform, plain or ridged surface as specified.

iv. Bush‐hammered or pattern‐worked finishing.

v. When exposed aggregate is to be the surface texture, the Contractor shall ensure that a uniform distribution of the coarse aggregate takes place at the face. The formwork shall be removed as soon as possible from the face to be treated; the surface shall be thoroughly wetted and wire brushed, and‐hammered or pattern‐worked as and when instructed. Surface retarders shall be used only when permitted by the EIIP Project Engineer.

vi. Bush‐hammering or pattern‐working shall not be relied upon to obscure any defects in the concrete face which arise from formwork imperfections.

10.3. Making Good

Honeycombed or damaged surfaces of concrete, which in the opinion of the EIIP Project Engineer, are not such as to warrant the cutting out and replacement of the concrete, shall be made good as soon as possible after removal of the formwork as follows:‐

Portland cement and sand mixture shall be worked into the pores over the whole surface with a fine carborundum float in such a manner that no more material is left on the concrete face than is necessary completely to fill the pores so that a uniformly smooth and dense surface of uniform color is finally presented.


11. Defects

11.1. Removal and replacement of Unsatisfactory Concrete

The Contractor shall on the EIIP Project Engineer’s instructions to do so cut out and replace any concrete in any part of the structure if in the EIIP Project Engineer’s opinion:

i. the concrete does not conform to the Specification, or

ii. deleterious materials or materials which are likely to produce harmful effects have been included in the concrete, or

iii. the honeycombed or damaged surfaces are too extensive, or

iv. the finished concrete sizes are not in accordance with the Drawings witching allowable tolerances, or

v. the setting‐out is incorrect, or

vi. the steel cover has not been maintained, or

vii. the protection, including curing, of the concrete during the construction was inadequate, resulting in damage, or

viii. the work of making good or other remedial measures the EIIP Project Engineer may indicate are not carried out to his satisfaction, or

ix. undue deformation of or damage to the works has taken place due to inadequate formwork, or to premature traffic or to excessive loading, or

x. Any combination of the above points has taken place resulting in unsatisfactory work.

11.2. Loading Tests

The EIIP Project Engineer may permit that a loading test be made on the works or any part thereof for one or more of the following reasons:‐

i. failure of ‘’Site Cubes’’ to attain the strength requirements;

ii. premature removal of formwork;

iii. overloading of structure during construction;

iv. improper compaction and/or curing of concrete;

v. any other circumstances attributable to alleged negligence on the part of the Contractor, which, in the opinion of the EIIP Project Engineer, may result in a structure being of less than the required strength;

vi. Loading test shall be carried out in accordance with the requirements of BS 8110.

If the results of the test are not satisfactory, the EIIP Project Engineer will direct that the part of the work concerned be taken don or removed and reconstructed to comply with the Specification, or that such other remedial measures as he may think fit be taken to make the work acceptable.

The EIIP Project Engineer may instruct the Contractor to take out cylindrical core specimens from the structures concerned and have them tested. The cutting equipment and the method of doing the work shall be to the EIIP Project Engineer’s approval. The specimens shall be dealt with in accordance with BS 1881. Prior to testing, the specimens shall be available for examination by the EIIP Project Engineer.


12. Water Proofing & Thermal Insulation

The provisions of this division shall apply to the following:

Reservoir

Roof covers

Buried concrete surfaces

The provisions here below shall apply to the materials, products and execution procedures concerning the waterproofing of the reservoir roof covers.

Waterproofing approved membranes (for both reservoir covers and roof building terraces) will be one layer of 4mm minimum thickness (minimum 4.7 kg/m2 with protection) with Elastomeric (styrene‐butadiene styrene = SBS) (for altitude above 300m) or Plastometric (Atactic Polypropylene = APP) (for altitude below 300m).

The assembly of manufactured sheets will be by torch welding.

These membranes will generally be self‐protected from the factory (mineral self‐protection). The general characteristics of the membranes are as follows: (non limited list)

Elongation at break (for reinforced membrane: 50%).

In case of special architectural designed roof (dome) the waterproofing coat could be constituted by a liquid elastomeric bitumen which characteristics must be proposed by the Contractor for the approval of the EIIP Project Engineer. Anyhow a U.V. radiations resistance shall be required in any case.

The particular characteristics of the SBS and APP membranes are resumed here below (non limited list)

a) SBS elastomeric membranes are classified according to the type of reinforcement.

‐Rolls reinforced with polyester (PY = 180 to 350 g/m2)

b) APP Polymeric membranes are modified bitumen base sheet with APP polymers.

‐4mm thick reinforced with polyester min weight 180 g/m2 nonwoven polyester (PY)

The Contractor must in his offer enumerate all the characteristics of the membranes, including but not limited to:

their dimensions (rolls) (1 m x 10m)

their thickness or their weight (minimum thickness 4mm, minimum weight 4.7 kg/m2)

the type of bitumen

the kind and weight of reinforcement (g/m2)

the surface protection

their mechanical characteristics

The overlapping size (overlapping waterproofing membrane shall be not less than 10 cm).

etc.


SBS and APP membranes shall be applied by the Contractor on site according to the technical sheets specifications of each product and to the manufacturer’s prescriptions.

All reservoir roof covers and roof building terraces are deemed to be not accessible unless to repairs necessity.

Horizontal and vertical exposed membrane will be mineral self‐protected.

13. Thermal insulation

A normal insulation with extruded polystyrene thermal insulation is approved.

The insulation panels must be protected against weather.

The Contractor shall propose to the EIIP Project Engineer’s approval all insulation material and specific original documentation from the manufacturer, mainly (non limited list):

The thermal conductivity ( 0.029 w/m o C)

The laying procedure

All limitations of use, according to associated waterproofing, destination of reservoir cover or roof terraces.

The thickness of the insulation panels with the way this thickness was determined according to the total thermal resistance of the reservoir cover or roof terrace. (thickness : 50mm)

Separation and protection sheet layer (nonwoven polyester) thermally bounded nonwoven polypropylene: Mass: 100 – 105 g/m2.

The protection needed (graded gravels, screed, circulation slabs (500 x 500 x 50 mm)

14. Valves & Accessories

All valves related to valve chamber shall comply with international standards mainly (ISO, DIN & API).

14.1. Cast Iron Steel Gate Valves (PN 16 pressure valves)

The valves shall be made of cast iron steel, and sustain a nominal pressure of 16 bars (PN16).

The valves and components must pass the hydrostatic pressure test at the manufacture and sustain the maximum allowable pressure to NFE‐29‐311, ISO 5208 & API 602 for different PN selects, and in case required by the client it must be approved and certified by known quality control office i.e. Bureau VERITAS or other.

The cast steel gate valves and components shall comply with:

API 300 for wall thickness.

ASME B16.5 for flange design

BS 1873 for general design.

14.2. Standard Materials for High Pressure Gate Valves (where applicable)



Lifting keys: Are to be made of mild steel.

14.3. High Pressure Cast Iron Steel Spring Loaded Check Valve

Checks valves shall be made of cast steel, and sustain a nominal pressure of 24 bars (PN24).

The valves and components must pass the hydrostatic pressure test at the manufacture and sustain the maximum allowable pressure to NFE‐29‐311, ISO 5208 & API 602.

Specifications being as follow:

Body and cover: To be implemented as per precision machined castings. Body and cover joint: Accurately machined, fully‐enclosed gasket. Disc: Robust one‐piece construction to withstand the severe shock of check valve service.

Hard‐faced with 13Cr, CoCr alloy, SS 316

Disc assembly: Non‐rotating disc must be fastened securely to disc hanger with a lock nut and cotter pin.

Disc hanger must be supported on a sturdy disc carrier hinge pin of excellent bearing qualities.

All parts must be accessible from top for easy servicing. Flanges: as per ASME Class 600–1500: 1⁄4” raised face.

14.4. Pipe Works


Certificate of origin and quality control certificate (if required) for proposed pipes must be checked and approved by EIIP Project Engineer prior to delivery of material onsite.

Pipes for main header will be from seamless steel material and shall be according to API 5L grade B.

All headers shall be treated with epoxy paint suitable for potable water. Main header will have an internal diameter of 150 mm.

14.5. Saddles, Tees, Flanges & Other Accessories Installation

Bends, joints, flanges, tees… shall be installed in accordance with the manufacturer’s recommended procedures.

Flanges faces shall be centered and aligned to each other before assembling and tightening bolts.

In no case shall the flange bolts be used to draw the flanges into alignment.


Bolts shall be evenly tightened according to the tightening pattern and torque step recommendations of the Manufacturer at least 1 hour after initial assemble, flange connections shall be re‐tightened following the tightening pattern and torque step recommendations of the Manufacturer. The final tightening torque shall be 135 Nm or less as recommended by the manufacturer.

15. Plastering (where applicable)

Masonry plastering shall be prepared on site with approved cement and sand materials.

Cement marker for plastering shall composed of cement and sand mixed in the proportions of 50 Kg cement to 0.14 m3 sand.


Plastering shall be at least 15 mm and no more than 20 mm thick and carried out in a minimum of two coats.

The first coat being a render coat which shall be left scratched to receive the finishing coat.

The finishing coat shall be worked to a true and even surface and polished to a smooth surface using a steel trowel.

Plastered surfaces shall be perfectly level and shall be to thickness as specified. The edges shall be straight.

Before applying plastering, the surfaces that are to be coated shall be thoroughly cleaned.

16. Block Works

Block works shall be 20 cm thick; they must be new and free from any defects.

Block works must be hollow type of top quality and manufactured in an approved factory, and made of vibrated and compressed concrete and thoroughly watered.

The mix proportion for block works shall be as follow:

Mix proportion:

1 bag of cement 50 kg.

120 l of stone chippings

90 l of sand

Characteristics of the finished material:

Minimum 1700 kg/m3.

They must be 40 days old minimum, and must have a crushing strength at 28 days equal to 40 Kg/cm2 (measured on the whole block surface).

Sand for mortar:

The sand shall be natural sand from clay and shall comply with the best intimation standards provisions.

The cement for mortar shall be Portland cement complying with B. S.12.

The proportion for mortar shall be 1:3

One part of cement and three parts of sand or approved fine aggregate.

The mixing of cement mortar shall not be made on the bare ground, and must be used within the hour after mixing.

All blocks shall be thoroughly wetted before use, and a perfectly rectilinear wooden ruler and a plumb line shall be permanently kept on site to allow for the EIIP Project Engineer to verify the verticality of constructed masonry wall.

17. Painting

All painting (internal and external surfaces) shall be applied in conformity with the manufacturer’s recommendations.

Paints shall be washable, of a perfect solidity and shall allow a flawless application.


Surfaces that must be painted shall first be cleaned, and sand papered before the application of the first coat of sealer.

A second sanding shall be followed by the application of a primer coat.

Finally two (2) paint coats shall be applied in conformity with the colors and samples approved by the EIIP Project Engineer.

For exterior surfaces a plastic paint ready to use under the form of a unctuous thixotropic paste will be used; it shall be composed of vinyl‐ maleate resins or water, the painting must adhere perfectly and be totally waterproof and offering a perfect resistance to chemical agents, heat and fire.

Before any commencement of application of the paint, contractor must make sure that all surfaces are clean, without grease and dustless.

The contractor shall apply a primer coat (undercoat) acting as a surface regulator and then will apply two coats using an alxeol roll.

Application must be in thick layer and must be starting from down toward upper zones.

The product must be applied in important quantities but not spread.

18. Tiling

Tiling will be used for floors and walls as instructed by the EIIP Project Engineer .

The contractor must take all necessary measures to ensure complete protection for tiling works and this until the taking over.

Cement mortar for wall tiles and skirting’s shall be composed from one part of Portland cement and three parts of sand (Volumetric dosage)

Cement used must conform to B.S.12 and sand must be clean free from dint, clay particles and other impurities.

For wall tiling contractor must use a white ceramic enameled tiles 20cmx20cm, and skirting 10x20cm.

Ceramic tiles must be of a first grade quality and have to be resistant to acids, bases, grease and hydrocarbons.

They must be tested under a 400kg/cm2 load during manufacture.

For floor tiling, contractor must use concrete tiles not less than 3 cm, or cement mosaic tiles 20x20cm.

Mosaic tiles shall be of local manufacture and shall consist of two layers: A wearing layer of 7 mm minimum thickness

A base layer constituted of a mixture of sand and cement proportioned at 350 Kg of cement (7 bags) for 1 m3 of sand.

The minimum thickness of the tiles shall be 200 mm, and must be highly resistant to abrasion.


19. Metal doors and louvers

The contractor shall supply and install steel doors for reservoir valve chamber. The contractor shall also supply and install windows with louvers protection.

Steel for doors, windows and other metal work shall be new, first grade quality mild steel without mill defects, cracks, grooms or rough surfaces and shall comply with all requirements specified on the attached drawings.

19.1. Metalwork

Hinges and locks shall be secured by means of metal‐screws for any eventual unmaking.

Other accessories may be welded. Unless otherwise specified, bolts, casement bolts, locks, etc., shall mortised, hinges shall be solid and of quantity corresponding to door leaves size and weight. They shall have the exact required sizes and allow an easy setting and replacement.

Metal fittings are integral parts of each door or hatch even when not explicitly stated in the work description.

The contractor shall take on site all dimensions deemed necessary for metalwork and remain wholly responsible for their good adaptation to the concrete and masonry works in the building.

Joints shall be notched and angles mitered. Electric welding shall be as continuous as possible along the joint after filing the metal elements.


Surface finishing of works shall be in strict accordance with the General Technical specification and shall include the protection of materials and the surface treatment.

Exposed surfaces shall have no unevenness, burrs, or metal run‐out. Salient angles and projecting parts shall be rounded off. Welds shall be carefully ground. Screws shall be inserted and then painted. Accessible bolts shall be covered. Element showing appearance or assembly defects shall be rejected. It is expressly forbidden to cover and hide these defects.

19.3. Protection of Metals against Corrosion

No metal part shall be accepted on site unless previously protected against corrosion.

Elements shall be in‐factory protected according to relevant applicable standards. Unprotected iron parts shall be painted after removal of calamine, rust, and oil, with a rust proof zinc chromate paint, 60 microns thick, compatible with the top coat specified in the relevant section (or eventually with two coats of red lead).

Immediately after installation, any painted surface showing imperfections due to impacts or handling shall be wire brushed and repainted

20. Aluminum Work

Contractor must provide aluminum doors and windows for internal and external sections of booster pump set room:

Aluminum shall be new, free of defects. The aluminum shapes used for windows, doors and shutter frames shall be of the extruded “solid” or “hollow” type with the main web having a minimum thickness of 2mm. The supplier shall be submitted for approval.


Aluminum work shall be in strict accordance with the Drawings and Al rules basically intended for external works.

All aluminum parts shall be anodized.

The anodic protection shall meet the requirements of B.S. 1615 or B.S. 3987. The color of anodizing shall be in accordance with samples approved by the EIIP Project Engineer.

Aluminum alloy shall be 50 AGE, anodized over 18 microns, satin silvery color or any color as specified.

The Employer may require all necessary tests to be conducted in an approved laboratory to ensure the conformity of the aluminum with the requirements.

Aluminum shall have the following mechanical characteristics:

• Elastic limit at 0.2% 15 kg/mm2

• Breaking load 20 kg/mm2

• Modulus of elasticity 5.700 kg/mm2

Aluminum works shall include:

• Supply of materials

• Assemblage in workshops

• Protection of components as specified

• Transport including loading/unloading

• Assemblage and installation on site

• Lifting and handling

20.1. Execution of Works

Prior to the commencement of works, samples shall be submitted to the EIIP Project Engineer for approval.

20.2. Workmanship

20.2.1. Fixing

Fixing devices shall be submitted to the EIIP Project Engineer for approval. The use of a stud gun is not allowed.

Fixing devices shall be of stainless metal protected against corrosion either by electric zincking or galvanization.

The aluminum casing shall be screwed, where specified, to the galvanized steel frame or to the frame embedded in the concrete.

The frame shall be coated with an approved special bituminous paint. Other fixing methods shall be subject to the EIIP Project Engineer’s approval.

Installation of aluminum works shall be accurate and to the specified plumb. Sliding parts must slide easily. Once closed, aluminum works shall be perfectly tight.


Aluminum works shall be anchored in the wall.

Where specified, holes and spouts shall be provided for discharging condensation and running water to the outside. Spouts shall be fitted with small screens to prevent direct air inflows or water back‐flow.

Sections shall be dimensioned to resist 150 km/h wind velocity, air and rain infiltrations. The following test shall be required to prove the air and water tightness of the system.

Where necessary, stiles with metal stiffeners shall be used to ensure the rigidity of the works and their serial assembling as shown on Drawings.

Ball bearings shall be shielded from both sides. The sliding ball shall be of Hard Nylon or of stainless steel. Operation of opening elements shall be practical, easy and silent. Panels shall be rigid when opened or closed.

Friction between aluminum parts shall not be allowed. Prior to commencement of the works, aluminum works and connection and fixing details shall be submitted to the EIIP Project Engineer for approval.

They shall be anchored to reinforced concrete or metal beams or jambs with cement mortar.

All components shall be carefully installed and wedged to the plumb, alignment and exact levelling.

Mobile parts shall be greased, balanced and adjusted prior to the taking over.

20.2.2. Tightness of joints

Appropriate sealants shall be used to ensure air and water tightness. They shall be of stable mechanical and chemical characteristics, 10 years guaranteed, easily replaced and consistent with the relevant standards. The unit rates of aluminum works include the cost of sealants.

20.2.3. Installation

The Contractor shall take all necessary precautions when installing and wedging the various elements in order to ensure their plumb, alignment, levelling and evenness within the specified tolerances.

20.2.4. Contact between different materials and alloys

All precautions shall be taken to avoid electrolytic corrosion.

20.3. Tolerance on setting out

Maximal variation between the real position of each axis of metalwork and each axis of an opening in a wall shall not exceed 1 cm.

20.3.1. Tolerance on installation

Rectitude and plumb errors in door frames, stiles, and posts shall not entail a deviation exceeding 2 mm, provided that stiles and posts be parallel to 2 mm in all points and planes.

Rectitude and levelling errors in crosspieces shall not exceed 2mm.

The Contractor shall provide for all necessary adjustment elements within the required tolerances.

20.3.2. Sealing

Air and water tightness between the structure and the aluminum works shall be ensured by


stable and 10 year guaranteed sealants. They shall be easily replaced. The unit rates of aluminum works shall include the cost of all sealants.

The Contractor shall provide for all necessary adjustment elements within the required tolerances.

20.3.3. Protection

Parts in contact with masonry shall be coated before their installation with bituminous paint or the like.

Accessories made of any material other than light alloy shall be plated with zinc or cadmium.

The casing and frame elements shall be protected with a polyethylene sheath during installation. The latter shall be removed from the exposed parts at the time of taking over.

Components shall be cautiously placed and secured.

Cleats and wedges shall only be used when firmly secured to avoid displacement or loss during transport.

During handling, great care shall be taken to avoid any damage to the parts or to the paint.

When unloaded, aluminum works shall be placed on scaffoldings or cleats to prevent direct contact with soil and water.

The Contractor shall take necessary measures to avoid damages to reinforced concrete works, and bear the expenses of eventual repairs due to impacts or brutal handling.

In the event of an installation on muddy ground, the Contractor shall take necessary measures to avoid direct contact of the frame with the ground.

Temporary wind bracings shall be installed during installation. Aluminum works shall be clean and in perfect condition prior to taking over.




Section III

Treatment Plant Equipment


1. General Data:

Al Shaghour Spring is Located in Hammana Village ‐Mount Lebanon within the caza of Baabda

The spring requires treatment plant installation, the proposed treatment plant will perform the following tasks:

The spring requires a treatment plant installation to provide safe water supply for the inhabitants and to reduce the high turbidity of water during winter time where the level exceeds 240 NTU

The proposed new treatment plant will perform the following tasks:

• Chemical dosing including chlorine pre‐chlorination & Al2SO4 for quick sedimentation by coagulation

Settling tank with mud evacuation outlet

Pressurized sand filtration ( 3 fine graded layers minimum thickness 33 cm for each layer)

• Carbon filtration for de‐chlorination

Post chlorination operations

2. Chemical Dosing

2.1. Pre‐chlorination

This section requires from the selected contractor to supply and install of chlorine injection dosing pump, using powder chlorine suitable for potable water and concentration ranging from 20 to 35% of free chlorine per liter of solution

Dosing pump shall be wall mounted or cylinder mounted type with minimum protection of IP 65, pump body material shall be acid resistant and feeder pump must be equipped with duel injection heads and shall have an adequate capacity to provide sufficient solution to disinfect water (up to 10 PPM for a flow of 90 m3 per hour).

2.2. Post‐chlorination

Supply and installation of chlorine injection dosing pump, using powder chlorine suitable for potable water and concentration ranging from 20 to 35% of free chlorine per liter of solution

Dosing pump shall be wall mounted or cylinder mounted type with minimum protection of IP 65, pump body material shall be acid resistant and feeder pump must be equipped with duel injection heads and shall have an adequate capacity to provide sufficient solution to disinfect water (up to 2 PPM).

2.3. Aluminum Sulfate

Supply and installation of Aluminum Sulfate injection dosing pump, using granulated powder Al2SO4 suitable for potable water and concentration ranging from 20 to 35% of free chlorine per liter of solution


Dosing pump shall be wall mounted or cylinder mounted type with minimum protection of IP 65, pump body material shall be acid resistant and feeder pump must be equipped with duel injection heads and shall have an adequate capacity to provide sufficient solution to allow proper coagulation.

Minimum dosing rate 30 liters per hour to allow a minimum dosage of 50 mg/l of Al2SO4 solution, dosing pump to be equipped with dosage flow regulator and electric mixer to prepare the concentrated Al2S04 solution.

3. Horizontal Booster Pump:

Supply and installation of horizontal boosters from newly rehabilitated reservoir of Hammana Village (300 m3) to pressurized sand filter.

Booster pumps shall be horizontal type providing sufficient flow for filtration and back wash at required operating pressure.

The pumps shall be horizontal, multi‐stage centrifugal pumps of standard construction for clear drinking water.

Each pump must station be capable to pump up to 90 cubic meter per hour of clear drinking water at a total dynamic head of 35 meters with a hydraulic efficiency not less than 70% at the duty point as produced by pump manufacture.

Q= 90 m3/h T.M.H=35 m

Each pumping unit shall include the pump, the electric motor, the flexible coupling and guard, and the base plate.

The characteristic curves of the pumps for quantity, versus total dynamic head, efficiency, horsepower, net positive suction head required shall be submitted with the tender.

For each pumping unit the pump shall be connected to the motor by a flexible coupling protected by a suitable guard. The pump, the electric motor and the coupling shall be connected together in perfect alignment on a rigid base plate, which shall be installed on a concrete foundation using anchoring bolts.

No materials or equipment shall be ordered and no work carried out until shop drawings has been made and approved by the EIIP Project Engineer.

The pumping units shall be designed for the following operating conditions and requirements:

Electric pump from EU manufacturer.

• Flexible coupling, base and standard motor compliance with EN 733‐ (DN 24255)

Rated total dynamic head, meters 35 minimum

Capacity at rated head, m3 / hour 5

Maximum speed 3000 rpm

Bronze or stainless impellers

Cast iron body

Stainless steel shaft


Support body from cast iron

Insulation class F

Enclosure class IP 55

Pump performance shall be stable and free from cavitation and noise throughout all of the specified operating range of the pump.

The rotating parts shall be statically and dynamically balanced.

Electrical Motors for booster pumpsets:

The motors shall be totally enclosed squirrel‐cage, fan‐cooled, induction type, class F insulation with weather protection according to IP 55.

• Power supply 3 phase, 380v, 50HZ.

• Synchronous speed 3,000 r.p.m.

Motor winding shall incorporate thermal switches as to safeguard against overheating.

The thermal switches shall be connected in the control circuit of the starter. Motors shall be weatherproof with screens suitable for outdoor use.

The motor windings shall be insulated, and motors shall operate continuously at rate voltage and frequency with a temperature rise not to exceed 40 degree Celsius above ambient when operating at 115 percent of the rate power. The motors shall be rated for a minimum of 20% above pumpset nominal power and shall be capable to drive the pump without over‐ loading through the full operating range of the pump from maximum capacity to shut off head. The motors shall have a full‐load power factor of not less than 75 percent. The locked rotor torque shall be not less than 100 percent of full‐load torque. The breakdown torque shall be not less than 200 percent of full‐load torque. All motor bearings shall be of the antifriction type suited for a 10‐year minimum life.

Drawings & Data

Complete fabrication, assembly and installation Drawings, together with detailed Specifications and data covering materials used, parts, devices and other accessories forming a part of the equipment furnished, shall be submitted with the tender. The data and specifications for each unit shall include, but shall not be limited to, the following

Pumps:

Name of Manufacture Type and Model Rotating Speed

Size of Suction Inlet

Size of Discharge Outlet; Net Weight of Pump

Complete Performance Curves Showing Capacity VS Total Dynamic Head NPSH Required

Horsepower and Overall Efficiency


Data on Shop Painting

Flexible Coupling Make and Type Sectional Drawings and Dimension Operation and Maintenance Manuals Spare Parts Manual

Motors:

Name of Manufacturer; Type and Model;

Type of Bearings and Lubrication; Rated Size of Motor,

Net Weight of Motor; Temperature Rating;

Full Load rotating Speed;

Efficiency and Power Factor at Full Load, 3\4 Load and 1\2 Load; Locked

Rotor Current;

Rated Current and Voltage;

Sectional Drawings and Dimensions; Operation and Maintenance Manuals; Spare Parts Manual.

All equipment furnished under this section shall be fabricated and assembled in proper operating conditions in full conformity with drawings, specifications, EIIP Project Engineer data, instructions and recommendations of the equipment manufacturer unless exceptions are noted by the EIIP Project Engineer.

4. Pressurized Sand Filter:

Supply and installation of pressurized sand filter for a daily treatment of 1,500 m3/day of water, maximum speed inside pressurized filter should not exceed 6 m/m2/h

The pressurized sand filter shall consist of a layer of gravel with layers of sand of decreasing coarseness above the gravel. As solids build up on top, flow decreases until it stops.

Pressure filter shall be from cast steel or from composite material that can withstand a working pressure of 10 bars.

Filtration media to be in three to four separate layers with fine granular filtration media or multilayer.

The terms "multilayer," or "mixed media" must apply to the proposed filter bed which is graded by size and density.

Coarse, less dense particles are at the top of the filter bed, and fine, more dense particles are at the bottom.

Down flow filtration must allow deep, uniform penetration by particulate matter and should provide high filtration rates and long service runs.

The four media that must be used in the multilayer filter are listed in the table below.


Media used in multilayer filtration.

Media Effective size, mm & Specific gravity to be as follow:

Anthracite 0.65 to 0.75 mm effective size and uniformity coefficient ranging between 1.65 to 1.75 the specific gravity of anthracite media must range from 1.35 to 1.45 (when required within the sand filter)

Sand 0.4 to 0.55 mm effective size and uniformity coefficient ranging between 1.25 & 1.7 the specific gravity of sand media must range from 2.4 to 2.6

• Fine gravel 0.4‐0.6 (0.016‐0.024) 3.8

• Large gravel 0.3‐0.5 (0.01‐0.02) 4.9

Filter must be equipped with multi side head valves (4 ways valves) to allow back wash, rinse and drainage mode in addition to online operation mode.

5. Carbon Filter:

Supply and installation of Pressurized carbon filters with same yield of 240 m3/d, and a maximum water speed of 6m/h/m2.

Pressure filter shall be from cast steel or from composite material that can withstand a working pressure of 6 bars and shall be treated with epoxy coating suitable for potable water, coating to be applied in two layers 75‐100 microns each layer and shall provide protection against rust.

Activated carbon (AC) must include activated charcoal that has processed for activation and must be extremely porous and provide a very large surface area available for adsorption or chemical reactions. Media must be made from raw materials such as nutshells, wood, coal, etc. all suitable for potable water and typically, 1 gram of AC must have a surface area of 1000 square‐meter or more. Proposed carbon filter must be effective against unpleasant tastes, odors (hydrogen sulfide), residual chlorine, heavy metals, organic compounds , some pesticides, gasoline, trihalomethanes, benzene.

6. Piping System:

Complete piping and accessories, valves, union coupling, joints.

Piping to be in HDPE PE100 pipes PN 10, piping system should allow all operation including:

bypass

Main filtration

Back wash

Drainage

7. Piping System:

Control panels for booster, blowers and dosing pumps must be supplied and installed e and must contain the following:

Power breakers and contactors for main power components (4 power


breakers and 3 AC 3 contactors)

Steel cabinet IP 55

Power components

Main power breaker: To withstand 1.15 In (nominal current Amps) of proposed motor under normal service.

Power breakers must have a high rupturing capacity for short circuits protection.

3 identical contactors AC3 standard

Protection relays

Thermal overload relay compensated with automatic reset 3 units

• Voltage supply +/‐ 25%. Phase sequence relay. Phase failure relay

Level control relay with electrodes (3 electrodes.)

o Flow switch / Pressure switch protection relays

Special features

Memory reset button for defaults operations

Off delay timer for consecutive start stop protection

Cables numbering and plastic rails dimensioned for 65% maximum filling

ratio

• Auto‐manual selector switch for operation mode selection

Alarm horn with On/Off selector switch

Miscellaneous components

3 Amp meters with T.I

1 Hour meter

1 voltmeter with 7 position selector switch

Indicating lamps for default and running mode

Start Stop push buttons

Ready to start announcing device

Labeling

Base frame support for electric control panel

8. Water Sampling

"Water sampling analysis before and after project implementation. Testing to include the following:


Complete bacteriological test (Pseudomonas deruginosa, Fecal Streptococcus, Total Coliforms, Fecal Coliforms)"

Complete chemical test (Conductivity, pH, TDS, Total Hardness (TH) oF, Turbidity after sedimentation, Calcium (Ca), Magnesium (Mg), Potassium (K), Sodium (Na), Bicarbonates (HCO3), Chloride (Cl), Nitrates (NO3), Sulfates (SO4), Iron, Manganese, Nitrites, Zinc, Silica"

9. Testing, Operation & Maintenance

The contractor has to submit as‐built drawings of all the installed equipment and provide Hammana Municipality a complete booklet explaining the following items:

System operation

Maintenance program

Supplier catalogue must be included within the booklet. Booklet must be supplied in both Arabic and English.

CHAGHOUR HAMMANA ‐ LOT C: GRAVITY LINE FROM SPRING TO WTP PAGE 1 OF 69

LOT C

Chaghour Hammana‐ Caza of Baabda: Construction of Gravity Line from Chaghour

Spring to Water Treatment Plant



Contents LOT C Section i general specifications ...................................................................................................................................... 5

1. Definitions: ........................................................................................................................................................ 5

section –i- general specifications ................................................................................................................................... 5

2. Location: ........................................................................................................................................................... 5

3. General requirements: ..................................................................................................................................... 6

4. Sign boards and visibility panels: ...................................................................................................................... 6

5. Method statements and time table schedule: ................................................................................................. 6

6. Safeguards to existing pipes, cables, structures: .............................................................................................. 7

7. Record drawings: ............................................................................................................................................. 7

8. Project management: ...................................................................................................................................... 7

9. Required standards: ......................................................................................................................................... 8

10. Silence of specifications: ............................................................................................................................. 9

11. Correspondence and records: ..................................................................................................................... 9

12. Units: ............................................................................................................................................................ 9

13. Intent of the contract: .................................................................................................................................. 9

14. Terms in the contract: .................................................................................................................................. 9

15. Quality control: .......................................................................................................................................... 10

16. Reporting: .................................................................................................................................................. 10

17. Refusal of delivered materials: .................................................................................................................. 10

18. Quality of supplied materials and of workmanship: .................................................................................. 10

19. Approval on materials: ............................................................................................................................... 11

20. Work on private lands: ............................................................................................................................... 11

21. Damages to utility properties: ................................................................................................................... 11

22. Access road to site: .................................................................................................................................... 11

23. Site limits premises: ................................................................................................................................... 11

24. Starting out of works – submittal of shop drawings: ................................................................................. 12

25. Levels, dimensions, benchmarks and level datum: ................................................................................... 12

26. Miscellaneous works on site: ..................................................................................................................... 13

27. Insurance: .................................................................................................................................................. 13

28. Site demobilization: ................................................................................................................................... 13

section ii particular specifications ................................................................................................................................ 14

lot c: construction of a 150 mm gravity line ............................................................................................................. 14

1. Introduction ................................................................................................................................................... 14

2. General requirements & guidelines: ............................................................................................................. 14

2.1 site mobilization: ............................................................................................................................................... 14

3. On site accommodations ................................................................................................................................ 15

4. Mobilization of equipment: ............................................................................................................................. 15

5. Operation and maintenance manuals: ............................................................................................................ 16

6. On site housing (if applicable) ......................................................................................................................... 16

layout of work: .................................................................................................................................................... 16

clean-up: .............................................................................................................................................................. 17


warranty: ............................................................................................................................................................. 17

7. Submittals: ...................................................................................................................................................... 17

7.1. Materials, product data and equipment specifications & catalogues: ................................................... 17

7.2. Shop drawings ........................................................................................................................................ 17

7.3. Manufacturer’s certifications: ................................................................................................................ 18

7.4. Recommendations from manufacturers: ............................................................................................... 18

7.5. Installation and testing: .......................................................................................................................... 18

7.6. As-built drawings: ................................................................................................................................... 18

8. Material storage and handling: transportation and handling: ........................................................................ 19

9 earth work: ...................................................................................................................................................... 20

9.1 trench excavations: ................................................................................................................................ 20

9.2 excavated materials – handling and disposal ......................................................................................... 22

9.3 dewatering, supporting & fencing of excavations .................................................................................. 23

9.4 methods of works: ................................................................................................................................. 23

9.5 earthworks in urban areas ...................................................................................................................... 23

9.6 cutting of asphalt: .................................................................................................................................. 24

9.7 ground conditions: ................................................................................................................................. 24

9.8 classifications of excavations: ................................................................................................................ 24

9.9 re-used materials: .................................................................................................................................. 25

10 pipe work: ....................................................................................................................................................... 25

10.1 ductile iron pipelines: ............................................................................................................................. 31

10.2 hdpe pipes: ............................................................................................................................................. 44

10.3 seamless steel pipes .................................................................................................................................... 49

11 manhole and chamber access covers.............................................................................................................. 49

11.1 manhole step irons ................................................................................................................................. 49

11.2 surface boxes and chamber covers (where applicable) ......................................................................... 49

12 installation of pipes inside trenches ................................................................................................................ 50

13 saddles, tees, flanges and other accessories installation: ............................................................................... 51

14- valves & accessories: ......................................................................................................................................... 51

14.1 - ductile iron gate valves ......................................................................................................................... 51

14.2 - butterfly valves: .................................................................................................................................... 51

14.3 valve accessories: ................................................................................................................................... 52

14.4 – air valves .............................................................................................................................................. 52

14.5 service boxes (where applicable) ........................................................................................................... 53

service boxes specification will be as follow: ...................................................................................................... 53

15 backfilling: ....................................................................................................................................................... 53

i- backfilling material can include one or more of the following materials a- selected fill: .............................. 53

ii- foundation & bedding material: ..................................................................................................................... 54

16 concrete .......................................................................................................................................................... 55

16.1 - composition: ........................................................................................................................................ 55

16.2 - cement: ................................................................................................................................................ 56

16.3 - aggregate – sand: ................................................................................................................................. 57

16.4 - broken rock and gravel: ........................................................................................................................ 57


16.5 - storing of cement: ................................................................................................................................ 58

16.6 - sampling of concrete: ........................................................................................................................... 58

16.7 - stockpiling of aggregates: ..................................................................................................................... 58

16.8 - ready mix concrete: .............................................................................................................................. 59

16.9 - steel for concrete reinforcement: ........................................................................................................ 59

16.10 - reinforcement of steel bars: ................................................................................................................. 59

16.11 - falsework & formwork ......................................................................................................................... 60

b- tolerance ......................................................................................................................................................... 63

16.12 - plastering works: .................................................................................................................................. 61

16.13 - waterproofing membrane .................................................................................................................... 61

17 reinstatement of surfaces ............................................................................................................................... 62

17.1. Re-asphalting: ........................................................................................................................................ 63

construction requirements for aggregate sub-base and base courses ................................................................... 65

17.2. Safety of excavations in roads ................................................................................................................ 69

17.3. Temporary reinstatement of bitumen - macadam roads ....................................................................... 69

17.4. Temporary reinstatement of unmade roads .......................................................................................... 70

17.5. Permanent reinstatement of bitumen- macadam roads ....................................................................... 70

17.6. Forming banks & filled areas: ................................................................................................................. 70

17.7. Restoration of borrow areas, spoil tips and quarries ............................................................................. 70

18 temporary diversion (if needed) ..................................................................................................................... 71


Section I General Specifications

1. DEFINITIONS:

Section –I- General Specifications

• Architect and Engineer: also referred to as Design Architect or Engineer means the individual or organization who furnished the design, which includes but not limited to the construction drawings and technical specifications.

• The “project implementer” means Employment Intensive Infrastructure Program in Lebanon (EIIP) Project

• The “EIIP Project Engineer”, means the person whose services have been engaged by EIIP

Project to technically monitor and administer the subcontract as provided therein, as will be notified in writing to the Contractor or stated in the Contract Data of the subcontract.

• The “Contractor” means the person or corporate body whose bid to carry out the work has

been accepted by the project implementer who in this case is EIIP Project.

2. LOCATION:

The project is located in Hammana, a village situated in Mount Lebanon, Caza of Baabda.

The village is positioned at an average of 1,200 meters above sea level.

The scope of the project includes the construction of a Ground Reservoir, a water treatment

plant and a gravity line.

The current tender, LOT C, will only detail the construction of a new gravity line (DN 150

millimeters) connecting the Chaghour spring to Hammana’s Water Treatment Plant.

Due to the landscape surrounding Hammana and the limited availability of roads and other

infrastructure, the project will mostly rely on manual labor (80% of the project will be

completed solely by manual labor)


3. GENERAL REQUIREMENTS:

Prior to any works; Contractor must obtain written approval from EIIP Project, the municipality of Hammana and EIIP Project Engineer.

Approval must include proposed time table schedule submitted by Contractor, and approved by EIIP Project, Beirut Office.


• Site investigation and locating of existing infrastructural installations between drilled well

and both reservoir based on the routing as shown in the attached line profile. It also includes the site inspection to assess the construction of the control & chlorination room location, to be built nearby the well.

4. SIGN BOARDS AND VISIBILITY PANELS:

Contractor must provide visibility signs (sign boards) approved by the EIIP Project.

5. METHOD STATEMENTS AND TIME TABLE SCHEDULE:

The Contractor shall provide in a reasonably timely manner a method statement to the EIIP Project Engineer for any part of works upon request from the EIIP Project Engineer.




The Contractor shall submit to the EIIP Project Engineer for approval an update schedule.

The EIIP Project Engineer of the schedule shall not alter the Contractor’s obligation to perform within the period of performance. The Contractor may revise the schedule and submit it to the EIIP Project Engineer again at any time. A revised schedule shall show the effect of change orders, where applicable.


6. SAFEGUARDS TO EXISTING PIPES, CABLES, STRUCTURES:

It shall be the Contractor’s responsibility to safeguard by means of temporary or permanent supports or otherwise all existing installations, pumps cables, panels or other things which would be liable to suffer damage if such precautionary measures were not taken.

7. RECORD DRAWINGS:

Where the Contractor executes work under the contract, including locations where the Contractor undertakes repair or rehabilitations work, the Contractor shall record the location and nature of all existing installations and their associated services.


The Contractor shall where necessary utilize appropriate equipment and where instructed by the EIIP Project Engineer excavate trial pits to confirm the location and determine the size and nature of the buried services.


8. PROJECT MANAGEMENT:


a) Planning and program preparation particularly in relation to the requirements of the Employer and the public authorities, and the requirements to maintain water supply service where careful detailed arrangements have to be made and adhered to.

b) Planning the execution of the works in a manner which minimizes disruption to the water

supply system and will permit the efficient and effective commissioning of the water supply system and their respective components.


c) Ensuring that adequate potable water supplies are maintained to all consumers, and that no contamination to those pipes might result from his ongoing works.

d) Continuous surveillance of progress and anticipation of factors likely to affect the timely

performance of the contract.

e) Making proposal for modification to forward planning and to the program at an early stage in the light of factors resulting from (d) above.

f) Continuous appraisal of the Contractor’s methods and routines particularly as to their

effectiveness relating to speed of execution and to their effect on the community and property.

g) Forward planning for resource requirements taking due account of possible shortages and

delays in the arrival on site of materials, equipment, plant and personal and their mobilization for effective usage.

h) Acquisition and process of up-to-date information for progress with the EIIP Project

Engineer. The preparation of monthly progress reports including an update of the detailed program and cash flow forecast which shall include progress pictures as directed by the EIIP Project Engineer.

9. REQUIRED STANDARDS:

Works covering the construction of new gravity line for Chaghour spring must conform to the technical specifications described later on in the tender documents.



The approval of “EIIP Project Engineer” is a must prior to any work.

Any alternative proposal on required standards covering specifications, drawings and bill of quantities, must be approved by “EIIP Project Engineer”.

Proposed standards and codes governing this contract cover piping systems, pumping units and all related accessories, hydraulic works, steel works, electrical works (cables & panels), civil works for pipes reinforcement and jacketing.


10. SILENCE OF SPECIFICATIONS:


In such case “EIIP Project Engineer” will make the necessary and relevant interpretations covering such works.

11. CORRESPONDENCE AND RECORDS:

All correspondence between Contractor and “EIIP Project Engineer” shall be made in English.

All records, sheets, drawings and documents shall be in English language.

12. UNITS:


13. INTENT OF THE CONTRACT:




Submittal of shop drawings, (plans & sections) will be approved or returned for modifications

within 8 days of submittal.

14. TERMS IN THE CONTRACT:

Expressions Like:

- Contractor refers to the entity responsible for implementing the works. - “As shown”, “as indicate”, “as detailed” as terms of the same connotation, imply that the

work should be done according to the drawings and the related specifications.

- “As approved”, “as directed”, “as required”, “as accepted” should mean and understood that the approval, direction, requirement, permission, authorization, review or acceptance of the “EIIP Project Engineer” is intended.

- “Provide”, that be understood to mean “complete in place”, “that is”, “furnish and install”.

- “Equal” or “equivalent” means that material or equipment will be acceptable when composed


of parts or equal quality, or equal workmanship and finish, designed and constructed to perform or accomplish the desired result as efficiently as the named brand, pattern, grade, class or model.

15. QUALITY CONTROL:


16. REPORTING:

Contractor in coordination with “EIIP Project Engineer” will prepare and submit a detailed measurement of works that are completed within the month frame.

Measurements are according to B.O.Q items and any addition in works greater than what is mentioned within the B.O.Q must be within an approved work order variation (V.O).



- Storage instructions. - The manufacturer’s name. - Shelf life and dates of manufacture. - Material identification. - Batch reference number. - Net weight. - Mixing instructions. - Any warnings or precautions concerning the contents and their safe use;

Add to this that Contractor shall supply with each consignment of proprietary material delivered to the site, certificate furnished by the manufacturer including: - The manufacturer’s name and address; - Material identification; - Batch reference numbers, size of each batch and the number of containers in the

consignment; - Date of manufacture;

17. REFUSAL OF DELIVERED MATERIALS:

In case delivered articles or materials are found unsound or of poor quality, such items will not be used and must be removed from site, and replaced by materials pre-inspected and approved by “EIIP Project Engineer”.

18. QUALITY OF SUPPLIED MATERIALS AND OF WORKMANSHIP:

The materials and work man ship shall be the best of their respective kinds to the approval of the “EIIP Project Engineer”.

The words “to the approval of EIIP Project Engineer” shall be deemed to be included in the description of


all materials and workmanship for the due execution of works. 19. APPROVAL ON MATERIALS:

All proposed and supplied sources of materials, construction requirements and proposed standards should be deemed to the “EIIP Project Engineer’s” approval, the “EIIP Project Engineer’s” has to approve and agree upon any standard or method of manufacture or specification whether to maintain or change these items.



20. WORK ON PRIVATE LANDS:

All works are located on public roads and there is no need to obtain clearance from private owners unless specified otherwise.

In any case, and unless clearance is given by South Lebanon Water Establishment, Contractor shall not disrupt any private or public access way without providing alternative arrangements, in such case property access affected by the works must be maintained, trench crossings must be provided via special road plates.

21. DAMAGES TO UTILITY PROPERTIES:



22. ACCESS ROAD TO SITE:


The employer does not guarantee availability of any temporary or existing road inside site premises, and will not entertain any claim in respect of the non-suitability or availability of any such road for continuous use during the contract period.

At the end of works, all temporary roads must be closed, and Contractor must restore landscape to its original form or as indicated by “EIIP Project Engineer”.

Since there are no roads along the pathway from reservoir to the Chaghour spring, all works shall be carried out by labors and no machineries are allowed on site, moreover extreme precautionary measures must be taken by contractor to protect operating crew and to prevent any damages on existing pipeline.

Earth consolidation is required all along pipeline pathway to prevent sliding of earth collapsing.

At the end of the works and after successful testing contractor must restaure the site to its initial condition.

23. SITE LIMITS PREMISES:



24. STARTING OUT OF WORKS – SUBMITTAL OF SHOP DRAWINGS:

Upon receiving clearance to start works, Contractor will submit to the “EIIP Project Engineer’s” approval, detailed drawings and data sheets required to start works. Coordination will be made between “EIIP Project Engineer” and Contractor, so as to agree on basic information supplementary to that shown on submitted drawings like base lines, borders, center lines in order to locate exact level of pipes and their relative slopes.





Accuracy of information submitted by Contractor is under his strict responsibility and any discrepancies, errors or omissions in supplied drawings must be corrected and then re-approved by “EIIP Project Engineer”.

The Contractor shall submit final as-built record drawings to the “EIIP Project Engineer” for his review by the specified date.

After review and approval by the “EIIP Project Engineer” of the final as-built drawings, the Contractor shall within 7 days thereof, produce a final set of “as-built drawings” and submit to the “EIIP Project Engineer”, one computerized disk copy and 2 printed copies.

In case there are no changes with proposed design drawings, the Contractor must obtain the approval of “EIIP Project Engineer” prior to commence works.

25. LEVELS, DIMENSIONS, BENCHMARKS AND LEVEL DATUM:

All construction drawings must be referred to the institute of national height datum. The Contractor must obtain the location of permanent bench marks.




Accuracy of established datum shall be regularly checked during the construction process. Benchmarks

in the area that appear on the drawings shall be established by Contractor.

The Contractor shall provide one sign board mounted on suitable steel frame, in positions and heights


indicated by “EIIP Project Engineer”. Wherever necessary, safety barriers must be installed to protect pedestrians and people working on site as well as visitors.

26. MISCELLANEOUS WORKS ON SITE: i. While working on site, Contractor must keep the site as clean as possible by removing

wastes, debris and other materials to approved dumping locations.


ii. On all occasions works shall be properly flagged.


27. INSURANCE:



28. SITE DEMOBILIZATION:

Upon completion of works and after getting the approval of “EIIP Project Engineer”, Contractor will start dismantling of stores, work shops, offices and will proceed to the removal of all equipment from site.



Section II Particular Specifications

LOT C: Construction of a 150 mm Gravity Line

1. INTRODUCTION

The EIIP Project is implementing the construction of a new gravity line that will connect the Chaghour spring to Hammana’s Water Treatment Plant, providing water to the village and its surrounding areas.

As was previously mentioned, Hammana’s surrounding landscape provides a challenge to the construction of the gravity line since very little or no roads and other infrastructure are available to allow for the use of machinery.

Therefore it is estimated that most of the project will be completed solely by manual labor.

The Contractor will therefore be required to present a detailed health and safety plan with the proposal to ensure the safety of the labor force that will be working on the construction of the gravity line.

Since there are no roads along the pathway from reservoir to the Chaghour spring, all works shall be carried out by labors and no machineries are allowed on site, moreover extreme precautionary measures must be taken by contractor to protect operating crew and to prevent any damages on existing pipeline.

Earth consolidation is required all along pipeline pathway to prevent sliding of earth collapsing.

At the end of the works and after successful testing contractor must restore the site to its initial condition.

2. GENERAL REQUIREMENTS & GUIDELINES:

2.1 Site Mobilization:

Mobilization of site covers all preliminary works necessary to start works on the ground.

Contractor is requested to submit a Construction Planning Program (C.P.P) with a time table schedule sheet, C.P.P must describe every task and its correlation with any other job.

Submitted time table must also cover ordering and delivering of materials and consumables.

Contractor’s time table schedule sheet will be used as the basis for progress reports during construction phase (weekly & monthly).

The Contractor shall be responsible for public safety during execution of work. He will take all steps, including where necessary the provision of ropes, picket fence, etc. on each side of the trenches and excavations with warning lights and night watchman, to ensure the safety of the public.

The Contractor will be held responsible for any damage to property or injury to persons due to his negligence.

Any instruction from the “EIIP Project Engineer” concerning the safety aspects of the work must be carried out immediately, and the Contractor shall remain responsible for the adequacy of the safety measures.


3. ON SITE ACCOMMODATIONS

Contractor must provide onsite stores offices and workshops and this, in relation with required works. Location of all constructions must be agreed by “EIIP Project Engineer” and should not hinder works on site by obstructing accesses to specific locations.

Storage buildings must be treated against moistures and water infiltration and must be of sufficient size to house all items needed to be stored within these premises and must be completed prior to delivery of any items or equipment on site.

The Contractor must provide latrines or closets to be used by working staff; they must be regularly cleaned and disinfected.

Contractor must also provide shelters and mess rooms for his workmen and supervisory staff.

Mess rooms must be regularly cleaned and disinfected.

All materials must be stored on site in a way they can be easily inspected.

Private property shall not be used for storage unless written permission is given by owner. For the whole duration of works, Contractor will provide onsite the following:

a. Offices for all his staff (as deemed necessary) and one desk for EIIP Project Engineer, and a closet equipped with a lock.

- The completion and readiness for occupancy in terms of facilities shall be achieved within 10 days after signing the contract.

b. Supply electricity, water and sanitary facilities.

c. Ensure maintenance and operation, including labor and materials.

d. The Contractor shall make available technicians, materials and safety equipment as the “EIIP Project Engineer” may require for inspections and survey work that are necessary to help achieving supervisory works.

The list of such items includes:

Testing equipment for pipes, topographical instruments (level, graduate stake 4 m height, cylinders for concrete sampling), in addition to skilled labors that will assist the “EIIP Project Engineer” with his works.

4. MOBILIZATION OF EQUIPMENT:

All equipment, machinery, and tools needed to implement works must be brought on site prior to the startup of works.


All consumables needed for machinery and equipment operation must also be brought on site and properly stored in a safe way and to the approval of the “EIIP Project Engineer”.


Fine tuning of various machinery’s engines must be implemented prior to work on site to prevent pollution during operation (Harmful gas).

5. OPERATION AND MAINTENANCE MANUALS:

The “EIIP Project Engineer” will control and supervise, and eventually approve any set of instructions, after the Contractor has submitted any draft copies of the operation and maintenance manuals. On the other hand, the Contractor shall abide and conform to any amendments on additions necessary and indispensable dictated by the “EIIP Project Engineer” in the production of the final manuals. Each installation requires a provision of a separate set of instructions.



Operation & maintenance should be supplied in a written form in both English and Arab languages. All parts and equipment listings are to be described and listed in English. The draft operation and maintenance manuals must be on site during tests and this to verify that operations comply with instructions.


6. ON SITE HOUSING (IF APPLICABLE)

For the whole duration of works onsite, Contractor must establish a field office either by renting a land parcel and equip it with pre-fabricated offices, or by renting an apartment that will be used as an office.

Field office should include at least one room with minimum size of 4x4 m with one W.C & running water and a Kitchenette. It must be equipped with desk, chairs and two lockers one to be put at the discretion of consulting and supervising staff.

Office desk for EIIP Project Engineer must also be provided.

In case Contractor decides to house some of his crew on site, considerable attention should be given to provisions for the health and wellbeing of the occupants.

Particular care should be given in providing and maintaining safe and potable water supplies and securing proper disposal of wastes both in the camp and on the site.

Layout of work:

The Contractor shall stake the water systems in accordance with the design drawings. Staking shall be erected in such a manner as to ensure permanency of the staked locations until such time as the respective system is installed. Stakes shall be placed to show location of valves, pipelines and control head. Stakes shall be flagged with bright flagging for ease of location. All staking by the Contractor shall be subject to agreement of the “EIIP Project Engineer”. Any stakes disturbed by other works shall be reinstated by the Contractor as early as practicable in the circumstances.


Clean‐up:

During the course of construction, the Contractor shall remove waste material from the site continually as is necessary to keep the site in an orderly manner. Waste material shall be removed from the work site and not to be used as back-fill material. Upon completion of the works, the Contractor shall remove all waste equipment and parts and leave the site in a neat and orderly condition.

Warranty:

All work included under this contract, shall be under Contractor’s warranty, against all defects and malfunction of materials and workmanship for a period of one year from the date of completion of works. Should problems arise with the system during the warranty period, all necessary repairs and/or replacements shall be made by the Contractor in an expedient manner at no additional cost to the employer

7. SUBMITTALS:

The Contractor shall order materials to suit the construction program and shall plan his necessary submittals to the “EIIP Project Engineer” in accordance with the required specifications in a timely manner to suit the ordering, delivery and construction timing requirements. The Contractor shall submit as a minimum the following documents for review and approval by the “EIIP Project Engineer”:

7.1. Materials, product data and equipment specifications & catalogues:

All specifications, diagrams, samples, drawings and such other data shall be provided by the Contractor, in a format to be agreed upon with the “EIIP Project Engineer”, which may be required to demonstrate compliance with the specification.


- Originals of catalogues and Supervising data sheets for manufactured items; each item and option to be provided shall be clearly marked and each item not be provided shall be deleted.

- Literature to show that products provided meet the requirements for material, construction, operation, and testing.

- Information on the following items as a minimum: pipes; pipe jointing systems, manhole covers and all other hydraulic accessories.

- Manufacturer’s installation instructions for all items. - Certified reports for all tests and inspections designated herein, showing full compliance with

referenced standards. - Maintenance requirements and procedures. - Period of guarantee for products.

7.2. Shop drawings


- Profiles of each pipe system including ground levels, invert levels, critical clearances and position of pipe work structures.


- Material, class, grade, joint type, pressure rating, dimension, location and identification number of each pipe and pipe fitting to be furnished and installed.

- Procedures for installations inside trenches. - Procedures for encasing pipes in concrete. - Class, dimensions, location and identification of each manhole cover and frame to be furnished

and installed. - Procedures for placing and fixing manhole covers and frames. - Details for handling and storage of pipes, manhole covers and frames and all hydraulic

accessories. - All other miscellaneous details required to complete the whole installation process

The review and approval of shop drawings by the “EIIP Project Engineer” shall not relieve the Contractor from any of his responsibilities under the contract for successful completion of the work.

7.3. Manufacturer’s certifications:

In case decided by the client, Contractor must submit a certification mark scheme issued by an independent third party testing organization to the satisfaction of “EIIP Project Engineer” stating that production has been carried out under a standard system for supervision, control and testing, applied during manufacture, in accordance with ISO or an equal procedure.


7.4. Recommendations from manufacturers:

The Contractor shall submit issued by the manufacturer’s recommendations for installation and commissioning of HDPE pipes and accessories.

Recommendations shall include testing methods, storage requirements and maintenance and operational data. The Contractor shall have a copy of the manufacturer’s instructions available on site at all times while works are in progress and shall strictly follow these instructions unless otherwise authorized to deviate by the “EIIP Project Engineer”.

7.5. Installation and testing:



7.6. As‐built drawings:

The Contractor shall maintain one set of contract drawings for the sole purpose of recording accurate changes made as the work progresses (“As-Built” conditions of the new potable water network).

All changes previously agreed with the “EIIP Project Engineer” and all completed work shall be recorded on these drawings.


The Contractor shall prepare as-built drawings clearly showing all location, depths, slopes, height, shapes and dimensions of all works as executed. All valves locations and piping shall be identified and recorded. The Contractor shall submit as-built drawings for all installations. Contractor shall prepare and submit as-built drawings for the pipeline profiles.

The Contractor must undertake topographical works to identify path ways for project pipeline where and when required. The Contractor shall use a total station to carry out the topographical survey and must use local geodesic points as reference.

8. MATERIAL STORAGE AND HANDLING:

Transportation and handling:

All materials shall be delivered in the manufacturers' original protective packaging and shall be inspected by “EIIP Project Engineer” upon delivery on site.


The Contractor must inspect the shipments to assure that products comply with requirements, and that delivered quantities are correct and undamaged. All products shall be handled and stored in accordance with manufacturer’s printed recommendations.

The manufacturer must package products for shipment in a manner suitable for safe transport by commercial carrier. When delivered, a receiving inspection shall be performed, and any shipping damage must be reported to the manufacturer, Contractor being obliged to replace damaged materials immediately

It is the responsibility of the Contractor to safety transport pipes to site and proceed for proper stockpiling.

Pipes on site shall be subject to 100% visual inspection.

In case more than 3% of the pipes are found with visible damages, the whole lot will be replaced.

All pipes and accessories shall be stored on flat level ground, with no rocks or other objects under the pipe. The maximum stacking height for HDPE pipes shall be in accordance with the manufacturer’s recommendations.

Manual handling of pipes

In areas where machinery cannot be used the Contractor will carry out the transportation of pipes using manual labor and light equipment and tools.

The Contractor must ensure the safety of labor and equipment by taking all precautionary measures deemed necessary for the proper implementation of works.

Storage and handling:





Materials to be supplied by Contractor:

All materials that must be provided by the Contractor, unless otherwise specified, shall include but not limited to pipes, collars, rubber rings, valves and fittings.

The materials provided by the Contractor shall include all materials for temporary works, planking and strutting, excavations, shuttering and formwork, staging and scaffolding, compliant filling materials, such as primer, coal tar enamel etc., all concrete of each required class including reinforcing steel and mesh.

All materials supplied locally by the Contractor shall be of the best quality in their class and of the respective kinds as described in the contract and in accordance with the “EIIP Project Engineer’s” instructions and to the satisfaction of the “EIIP Project Engineer”. They shall be inspected from time to time at the site during the progress of the work.

Any materials arriving on site found unsuitable shall be rejected. The Contractor shall replace the rejected material at his own expense.

9 EARTH WORK:

9.1 Trench Excavations:

All excavations shall be made without using any machinery, excavations as well as pipe transport and installation shall be implemented by workers

All trenches shall be properly opened.

Special attention, to protect civilians and vehicles, must be taken.

Trenches must be consolidated all along the pathway of the new pipeline and where instructed by EIIP Project Engineer.

Trenches dimensions must be according to section drawings.

It shall be the responsibility of the Contractor to obtain all information available from the public Authorities and this with regard to the location of existing mains and services.

Contractor must proceed for trial pits to identify any existing installation and to determine the routing of piping inside trenches.

Trial pits must have a minimum dimension of 90 x 90 x 1.5m.


The Contractor shall carry out excavation works in a manner which safeguards any existing services, including hand excavation if necessary and shall be responsible for the cost of any repair work necessitated by damages caused by his work to any main or service and shall be reliable for any costs arising from such disruption.

Where applicable, the Contractor shall obtain all information and assistance available from the Public Utility Authorities (municipality, ministries, water establishment, P.T.T., EDL) for the locating of the mains and services and shall agree with the EIIP Project Engineer for any trial excavation which may be necessary to confirm or establish these locations.

Trial excavations shall be carried out in advance of further excavation work.

To avoid the occurrence of any collapse or subsidence, the Contractor shall take all measures that he finds necessary, appropriate or adequate to ensure safety and stability of excavation

The sides of all excavations shall be adequately supported by means of timber, steel or other type, and such measures must be included in the excavation unit rate pricing.

All trenches shall be maintained in a dry condition and the Contractor shall arrange a suitable dewatering system.

In case encountered ground is found unsuitable to work with or rely on for future construction, Contractor shall proceed to excavate an extra depth and refill it with compacted granular or other approved fill as indicated by “EIIP Project Engineer”.

If any part of any excavation is in error excavated deeper and / or wider than what is required, the extra depth and / or width shall be filled with compacted granular or other approved fill to the original formation level and / or dimensions as the “EIIP Project Engineer” directs on Contractor’s expense.

Any temporary or permanent diversion of mains and services shall be agreed with the appropriate Authority.

Width of trench

The width of trench should be ample enough to permit pipe to be laid and jointed properly.

However, trench width shall be decided depending on the ground condition. In case of soft ground, trench shall be widened or sheeting shall be provided to prevent the collapse of the trench wall. When rocks are encountered during excavation, all rocks have to be removed to provide a clearance of at least 150 mm below and on each side of pipe.

Extra width should be provided to permit placement of timber supports, sheeting, bracing and appurtenance when they are employed.

In case that pipeline is deflected at the joint the trench shall be widened appropriate for the amount of deflection.

Depth of trench

The minimum depth of trench is given in attached drawings (standard details).

Special attention must be given to consolidate the trench especially where depth exceeds 2 meters.


Condition of trench bottom

Trench bottom should be true and even in order to provide support for full length of the pipe barrel. Generally pipes can be laid on the flat trench bottom directly without special bedding in normal ground condition. However bedding by sand or selected material should be provided especially when the ground is rocky or soft.

The bottom of trench shall be consolidated and leveled. Explosives:

No explosives are to be used, for whatever reason. Site location being in a highly populated area, makes the use of explosive a potential threat for general security.

Labor intensive excavation:

Where is applicable or as instructed by the EIIP Project Engineer, some parts of the trench excavation is carried out by using labour with proper hand tools and light equipment for breaking rock. The light equipment including but not limited to the following:

• Air compressors • Small size excavators • Wheel cart • Light cranes • Hoist (500kg, 1000kg, 1500kg) • Ropes and cables • Manually operated winch

When the use of Labour intensive approach is not applicable in some sections, at the approval of the EIIP engineer the use of equipment is accepted.

9.2 Excavated Materials – Handling and disposal

The Contractor’s operations in excavations shall be such as to yield the maximum of suitable materials for construction purposes, and shall be subject to the approval of the EIIP Project Engineer.

Where practicable, and as determined by the EIIP Project Engineer, suitable materials shall be excavated separately from those considered unsuitable, and the suitable materials shall be segregated by loads during the excavation operations and shall be placed in the designated final locations either directly from the excavation, or shall be placed in temporary stockpiles for later placing in the designated locations, all as directed by the EIIP Project Engineer. Excavated materials that are considered unsuitable or are in excess of those required for permanent construction shall be removed from the Site. The Contractor shall be entirely responsible for the removal of all surplus excavated material from the Site to such disposal areas as he shall have obtained at his own cost and responsibility and shall keep the Employer indemnified against any claims, charges or proceedings arising out of the transportation and disposal of such surplus excavated material.

Dumping areas must be approved by municipality.

Spoil heaps shall be located where they will not interfere with the progress of the Works, or with


the flow of water in natural streams or drainage courses, and where they will neither detract from the appearance of the completed project and environment, nor interfere with access to the structures.

Spoil heaps shall be leveled and trimmed to reasonable regular lines, as determined by the EIIP Project Engineer.

The cost of complying with all requirements of this Sub-Section shall be deemed to be included by the Contractor in his unit rates for the various items in the Bill of Quantities and shall not be paid for separately.

9.3 Dewatering, Supporting & Fencing of Excavations

The Contractor shall, during the whole period of construction, keep the work area and all excavations dry and protected from the influx of water from any source whatsoever (rain and seepage water, water from surface and subsurface streams, groundwater, etc.) and shall provide and operate all pipes, pumps, well points and other equipment and materials and all labor required for this purpose.

The Contractor shall, throughout the period of construction, prevent structures and/or pipelines from flotation either by keeping the work area dry or by temporarily filling the structure and/or pipeline with water, all as approved by the EIIP Project Engineer.

The cost of complying with all requirements of this Sub-Section shall be deemed to be included by the Contractor in his unit rates for the various items in the Bill of Quantities and shall not be paid for separately.

9.4 Methods of Works:

In addition to the information furnished by the Contractor with his tender, the Contractor shall, after award, but no later than two weeks, prior to commencement of Works, submit for the EIIP Project Engineer’s approval detailed proposed methods of excavating, transporting and placing earth fill material, watering and compacting and any subsequent modifications thereof, together with a detailed list of quantities and type of plant to be used for all these operations. Amendments shall be made by the Contractor in accordance with any instructions issued by the EIIP Project Engineer before commencement of works and from time to time.

9.5 Earthworks in Urban Areas

When working in urban areas, under heavy traffic conditions (pedestrian and/or vehicular), the Contractor shall pay particular attention to all safety measures necessary to avoid accidents resulting from open trenches, construction materials and/or equipment stored in the streets, etc. without adequate protection. The Contractor shall arrange temporary crossovers to all open excavations.

The Contractor shall co-ordinate his work with the traffic police, public transport companies and municipal authorities and makes proper and adequate traffic and safety arrangements for the duration of the Works.


The Contractor shall take into account the restrictive urban and specific local conditions and shall make due allowance in his rates in respect thereof as no claim arising from this clause or contingency will be either admitted, entertained or considered.

When excavating trenches along city streets, the storage of excavated material along the trench may be impossible or prohibited by the authorities. In such cases the Contractor shall remove the excavated materials to areas of his own choice and at his own responsibility and shall bring such materials back when required for backfill or shall import instead other suitable material for backfill from some other source.

The entire cost of such removal and return or replacement of backfill material irrespective of the hauling distance shall be included by the Contractor in his unit rates for trench excavation and shall not be paid for separately.

When conducting off-road excavations the contractor will use light tools and special equipment as well as guarantee safe access to the workers involved in excavation works.

9.6 Cutting of asphalt:

Trenches must be saw cut to the width specified by drawings and as instructed by EIIP

Project Engineer. Contractor will have to include provision for edging strips and kerbs.

In case excavations are implemented in rocky ground, Contractor will have to provide air compressor hand hammer to reduce the risk of additional damages to existing asphalt layers; where existing roads are in a poor structural condition, excavation of a trench may result in further breaking up of the road surface beyond specified limits of trench line.

In such condition the Contractor will cut out additional road surface as determined by the EIIP Project Engineer and determine the finished road levels, and exact re-asphalted surfaces.

Any curtailment shall only be implemented following approval of the EIIP Project Engineer. 9.7 Ground conditions:

The nature of the ground varies from site to site, it is sandy with some clay formation on the top, and rocky limestone layers starting 40 cm and below. While working off-road it is expected to encounter ground that is 100% rocky (limestone) and the Contractor shall include these specific rates in his prices; and no extra cost shall be applied for such condition.

9.8 Classifications of Excavations:

All excavation will be classified as one of the following:

- Common excavation: common excavation consists of the excavation and disposal of all materials of whatever character encountered in the work except rock.

Such excavations will be selected if suitable for re-use if allowed by “EIIP Project Engineer”. For this specific tests will be carried out to identify nature of soil and its plasticity.


All material those are found unsuitable for backfilling will be carried away and disposed of in authorized dumping areas.

- Rock excavation: rock is defined as a sound and solid mass, layer, or ledge of mineral matter in place and of such hardness and texture that it cannot be effectively loosened or broken down.

Rock will be crushed with jack hammer and air compressor and will be selected a side for removal.

- Unclassified excavation: unclassified excavation shall be that volume of excavation consisting of the removal of all materials regardless of their physical properties.

- Only one price will be paid for all kinds of excavations and the Contractor must price his excavation cost with regard to any type of soil he will encounter.

9.9 Re‐used materials:

Excavated materials will be classified as follow:

- Materials for immediate re-use; - Stockpiled materials for later re-use; - Materials to be disposed of;

Stockpiled materials that will be Re-used must conserve their original properties and must not be subject to segregation.

Stockpiled and disposed areas shall be stable and protected against erosion and shall not interfere with runoff or subsequent activities.

Waste piles shall fit into the landscape on completion of the works.

During excavation Contractor shall ensure that such excavations are maintained in a safe condition and he must take quick action in case they become unsafe for any reason. (Stability, run off of water…….).

In case instructed by “EIIP Project Engineer”, Contractor will immediately proceed for reparation of any apparent defect that might threaten safety.

10 PIPE WORK:

Transport of pipes to site will be made after clearance is given by EIIP Project Engineer on stockpiling land parcel.


Certificate of origin and quality control certificate for proposed pipes must be checked and approved by EIIP Project Engineer prior to delivery of material onsite.


10.1 Ductile Iron pipelines:

10.1.1 General

Ductile iron pipes & fittings shall conform to ISO 2531.

The minimum class for ductile iron pipes is C40 as for accessories & for fittings it must be of class K12.

- Ductile iron pipes and fittings shall be supplied by approved manufacturers.

- Ductile iron pipes will have an internal diameter of 150 mm and must be equipped with spigots and sockets joints.

- Spigots and socket joints shall be flexible and of an approved push-in type.

- Ductile iron pipes and fittings for water supply must comply with BS 4772 or European standard EN 545.

- Spigot and socket flexible joints shall be of the push-fit type with gaskets of ethylene propylene rubber (EPDM).

The Contractor shall supply sufficient pipes suitable for cutting on site to meet his requirements during pipeline construction.

10.1.2 Flexible joints

Spigot and socket flexible joints shall provide a 5o minimum angular deflection without leakage at the works test pressure specified.

10.1.3 External coating

Pipes and fittings shall be given an external coating of zinc in with BS 4772 and a fitting coat of either cold applied bitumen complying with the performance requirements of BS 3416 type II material, or hot applied bitumen to BS 4147 type I Grade C.

The external coating of D.I. Pipes and specials/fittings shall comprise a layer of Metallic zinc, covered by a layer of a bitumen coat.

The mean mass of zinc per unit area shall be not less than 130g / m².

The metallic zinc coating shall cover the external surface of the pipe and provide a dense continuous, uniform layer.

It shall be free from such defects as bare patches or lack adhesion. The uniformity of the coating shall be checked by visual inspection.


Bitumen coating shall not be less than 70µm. It shall uniformly cover the whole surface of metallic zinc layer and be free from such defects as bare patched or lack of adhesion.

The uniformity of the finishing layer shall be checked by visual inspection. Unless otherwise specified, the finishing layer of bituminous product shall be coated externally with either one of the following:

Coal – tar epoxy (epoxy content approximately 12%)

Standard coating materials as specified in BS 4147:1980 type I (bitumen based, hot applied) or

Standard coating materials as specified in BS 3416:1976 type II (bitumen based, cold applied)

10.1.4 Internal lining

Ductile iron pipes and fittings for water supply shall be lined internally with cement mortar and shall comply with BS 4772. The thickness of the lining shall be as stated in the following table:

Pipe Size DN

Thickness of lining Nominal (mm) Minimum

Arithmetical Mean Value (mm)

Individual Minimum Value

(mm)

Maximum (mm)

100-600 5 4.5 3.5 10

The inside of the sockets shall be coated with bitumen as used for the finishing coating of the pipes.

All Ductile Iron pipes and specials/fittings shall be mortar-lined.

The lining shall be applied by a centrifugal spinning process or a centrifugal spray head or a combination of those methods.

The cement mortar mix shall comprise cement, sand and water, chloride free admixture may be used if necessary.

The ratio by mass of sand to cement shall not exceed 3.5.

The compressive strength of the cement mortar after 28 days of curing shall be not less than 50 Mpa.

10.1.5 Rubber Ring / Gaskets

Rubber rings/ gaskets for ductile iron pipes and accessories shall be such in size and shape of manufacturers’ designs as to provide a pressure tight seal for the life expectancy of the pipeline under specified working, transient and test pressure conditions. Rubber gasket materials shall be synthetic rubber of EPDM (Ethylene Propylene Dyne Monomer) complying with the requirements of MS672:1999, AS 1646:1992 or BS EN 681 with of 55 – 85 IHRD (International Rubber Hardness Degree) with minimum volume 40% of polymer in rubber


compound.

10.1.6 Length and Dimensions

The effective length of all straight pipes shall be 6.0 meters.

The diameter and shell thickness of standard pipes shall be shown below

Pipes diameter (mm) Pipe shell thickness (mm) Nominal diameter Outside diameter Class 40 Pipes class

(K9) Specials / Fittings

Class (K12) 150 200

170 222

5.0 5.4

6.0 6.3

7.8 8.4

10.1.7 Packing

All ductile iron pipes shall be packed accordingly with proper methods and protected from damage during transit.

Pipes shall be stocked on the level ground. Timbers, having enough height to prevent direct contact of the pipe with the ground, shall be placed so that each end of pipe protrudes about one meter from the timbers. The number of the timbers will be 3 for 4 or 5 m long pipe, 4 for 6 m long pipe. Pipes shall be secured with clocks before releasing wire ropes otherwise pipes may fall off.

10.1.8 Marking of ductile Iron pipes

All ductile iron pipes shall have the following body markings:

a- The manufacturers name or mark.

b- The identification of the year manufacture.

c- The identification as ductile iron.

d- The nominal size (i.e. DN….).

e- The rating of flanges when applicable (i.e. PN…).

f- Standard reference.

g- Pipe class. 10.1.9 Installation of Ductile Iron pipes

Prior to pipe laying, any water remaining in the trench such as storm water or underground water should be removed with a sump pump. In this case, the pump should be placed in small pit provided to collect the water. If necessary, well point should be employed.

For jointing and convenient work performance, proper implements, tools and facilities should be provided. All pipes, fittings, valves and hydrants are laid along the trench on the opposite side from the excavated earth.

Lowering of pipes


All pipes should be carefully lowered into the trench by using crane, ropes or other suitable tools or equipment in such a manner as to prevent the body, coating and lining of water main materials. Under no circumstances shall water main material be dropped or dumped into the trench.

Ductile iron pipes and fittings should be lifted or lowered by using wire rope or nylon sling. When using wire rope, cushion pads or rubber sleeves must be used as a cover to protect the outside coating of pipes and fittings.

Pipe placement

As each pipe is placed in the trench, joint is assembled and pipe brought to correct line and grade. Pipe should be so placed that the manufacturer’s mark on the socket face should come on the top. Pipe is then secured in place with proper backfill materials.

Pipe plug

While laying is not in progress, the open ends of pipes should be closed off by a watertight plug or other means. The plug should be fitted with means of venting.

When practical, the plug should remain in place until the trench is pumped completely dry.

Care should be taken to prevent pipe floatation if the trench is filled with water.

Prior to removal of the plug or extending the line, or for any other reasons, air and/or water pressure in the pipeline should be released.

10.1.10 Testing of ductile iron pipe lines:

Testing instructions and requirements for Cast Iron and Ductile Iron pipelines shall be as follow:

Hydrostatic Pressure test:

After pipe laying castings of concrete structures on the line and partial backfill have been completed, the pipeline shall be subjected to a hydrostatic pressure test. The line shall be tested over its entire length or, in the case of long lines, in sections, as approved by the EIIP Project Engineer.

Pressure tests shall be performed only in the presence of the EIIP Project Engineer.

Pressure Pipeline testing:

Pressure pipelines shall undergo a hydrostatic pressure test. They shall be tested in sections not larger than 500 m, or as may be directed by the EIIP Project Engineer, and tests shall be made only on sections which are completed, except for backfilling over joints and fittings which are to be left exposed for inspection. Weights and thrust blocks intended to prevent lateral and vertical displacement of the pipes or specials must be completed and must have attained their design strength before tests are commenced.

Test sections shall be preferably carried out between shut-off or sectioning valves. Where this is not practicable, test sections shall be sealed off by suitable bulkheads, properly braced.

Prior to testing, air shall be evacuated from the line by filling it with water with all valves and taps open. After the first filling and the closing of all valves and taps, the water shall remain in the line for at least 48 hours to allow for absorption, and water being added as required to make up for


losses. During this period the Contractor shall inspect the line and all fittings and valves installed on it for leaks.

Any leaks found shall be promptly repaired by the Sub Contractor, who shall then proceed with the test, unless otherwise noted on the drawings, in the particular specifications, or by the EIIP Project Engineer, the “Test pressure” measured at the lowest point of the section shall be equal to one of the following values:

For pressure gravity driven pipelines:

a) (1.5 x rated working Pressure) for rated working pressure equal to or less than 10 kg/cm2 or the static pressure whichever is higher.

b) (rated working Pressure + 5.0 Kg/cm2) for rated working pressures exceeding 10 kg/cm2 or the static pressure whichever is higher.

The pressure shall be slowly raised by pumping to the required “Test Pressure”. Pumping shall then be discontinued, the pump disconnected, and the line kept under pressure for at least 15 minutes. For the line to be accepted, the pressure shall not drop by more than 10% during the said 15 minute period and there shall be no visible leaks at joints, fittings, valves, etc. Should the drop of pressure exceed this value, the Contractor shall search for the defects causing such pressure drop, shall make all necessary repairs and repeat the test until the section under test meets the requirements. Provided always that all visible leaks must be repaired whatever the loss of pressure. The Contractor shall at his own cost provide all necessary test pumps, pressure gauges, cocks and other accessories and shall make such temporary connections as may be required for filling and testing the line in the manner herein specified.

The water used for pressure testing shall be provided by the Contractor and shall be free from impurities and of such a quality which will not pollute or injure the pipeline. The Contractor shall be responsible for obtaining the water, transporting it and for its safe disposal on completion.

10.2 HDPE pipes:

HDPE pipes are selected for special conditions that prevent the use of ductile iron pipes.

Pipes will be manufactured according to the most recent ISO standards or North American or European Norms (EN).

Pipes manufacturer shall have manufacturing and quality control facilities capable of producing and assuring the quality of the pipes and fittings required by tender specifications.

10.2.2 Raw materials:

The polyethylene compounds used in the manufacture of products furnished under this specification shall be made from compounded pellets obtained by the addition of the correct type and amount of carbon black and necessary antioxidants and other additives to protect the pipe during extrusion and assure the life expectancy of the pipe. Pipe produced by the addition of black master batch to polyethylene is strictly forbidden.

Polyethylene pipes shall be manufactured from approved raw materials in conformity with EN


12201. 180 mm external diameter pipes relative to this project will be produced from PE 100 (HDPE) material.

10.2.3 General characteristics of HDPE pipes: Physical appearance

Pipes surface shall be smooth, free from scoring, pinholes and any other surface defects.

Pipes ends must be cut clean and perpendicular to the axes of the pipes.

Ends caps at pipes extremities are required in order to prevent unwanted matter entering the pipe during storage.

Mechanical characteristics:

Produced pipes at manufacturer facilities must pass the internal pressure test (acceptance test) required by EN 921. For PE 100 it must withstand 12.4 MPa at 20oC for 100 hours minimum.

Marking of Pipes:

Marking on pipes must include:

- Nominal Size (external diameter)

- Standard PE designation.

- Applicable standard designation.

- Date of manufacturing and manufacturer name.

- Nominal diameter and wall thickness.

Other Manufacturing requirements:

- Pipes shall be manufactured from polyethylene containing only those antioxidants, UV stabilizers and pigments necessary for the manufacture of pipes and conforming to this specification and for its end use, including weld-ability, when it is possible.

- When used under conditions for which they are designed, pipe materials shall not constitute toxic hazard, shall not support microbial growth and shall not give rise to unpleasant taste or odor, cloudiness and discoloration of the water.

- The pipe shall be homogeneous throughout and essentially uniform in color, opacity, density, and other properties. The inside and outside surfaces shall be semi-matte or glossy in appearance (depending on the type of plastic) and free of chalking, sticky, or tacky material. The surfaces shall be free of excessive bloom, that is, slight bloom is acceptable. The pipe walls shall be free of cracks, holes, blisters, voids, foreign inclusion, or other defects that are visible to the naked eye and that may affect the wall integrity.

10.2.4 Pipe fittings & pipe jointing:

Proposed pipes will be assembled by butt-fusion.

Butt fusion outlets shall be made to the same outside diameter, wall thickness and tolerance at the mating pipe.


All fittings and custom fabrications shall be fully rated for the same internal pressure as the mating pipe.

For valve chambers outlets, tapping saddles will be used with 4 inches intakes.

Saddles must be equipped with adaptive seal that provides water tightness at intake level.

10.2.5 Operating pressure:

Polyethylene pipes shall be manufactured and tested in accordance with ISO 4427.

Pipes must sustain a minimum strength of 10 MPa.

Wall thickness of pipes shall be established based on a nominal pressure of PN16.

10.2.6 Jointing:

The jointing system for HDPE pipes and fittings shall be in accordance with the butt-fusion method and the pipe manufacturer’s recommendations subject to acceptance by the “EIIP Project Engineer”. When the pipes supplied under these Specifications are installed and joined by this method, the work shall be carried out only by well-qualified personnel who adhere strictly to prescribed working conditions, using tools and procedures recommended by the manufacturer and accepted by the “EIIP Project Engineer”.

Equipment:

The equipment needed shall be as described in ASTM D-2657 General Procedure:

The following procedure shall be followed when making a butt-fusion joint unless agreed otherwise with the “EIIP Project Engineer”:

i. Wipe each pipe-end clean, inside and out to remove dirt, water, grease and other foreign material.

ii. Square off the end of each pipe section to be used using a facing tool. Remove cuttings and burrs from pipe ends.

iii. Check line-up of the pipe-ends in fusion machine to see that pipe ends meet squarely and completely over the entire surface to be fused. Two clamps should be used on each end of pipe to be fused for sizes 100mm and above.

iv. Insert the heater plate between the aligned pipe ends. Bring and hold the pipe ends in contact with the heater plate. Maintain contact and allow pipe to heat and soften until a bead of molten plastic rolls back from the ends. This bead will be about 1.5mm to 5.0 mm back from the end of the pipe depending on size. Soften approximately 1.5mm on all sizes up to 75mm; on 75 mm to 150mm heat to 3 mm and for the above 150mm heat to 5mm. softening can be judged by the appearance of the pipe end as the material softens.

v. Both surfaces of the heater plate shall be clean and the temperature maintained at 2460C-2600C.

vi. Carefully move the pipe ends away from the heater plate and remove the plate. If the softened material sticks to the heater plate, discontinue the joint. Clean heater plate, re-


square pipe ends and start over.

vii. Bring the heated pipe ends together with the specified pressure to form a uniform double bead about 3 mm to 5 mm wide around the entire circumference of the pipe.

viii. Allow the joint to cool and solidify while maintaining the pressure for the specified time. Inspect the joint for a uniform non-porous appearance. If the joint appears faulty, cut the joint out and repeat the procedure.

10.2.7 Pipe & accessories manufacturer’s quality control:

The pipe manufacturer shall have an established quality control program responsible for inspecting incoming and outgoing materials. Incoming PE materials shall be inspected for density, melt flow rate, and contamination. The cell classification properties of the material shall be certified by the supplier, and verified by manufacturer’s Quality Control. Incoming materials shall be approved by Quality Control before processing into finished goods. Outgoing materials shall be checked for:

o Outside diameter and wall thickness as per EN 12201 – Part 2 at a frequency of at last once / hour or once / coil, whichever is less frequent.

o Out of roundness at a frequency of at least once / hour or once / coil whichever is less frequent.

Quality Control shall verify production checks and test for:

o Melt Index as per ISO 1133 at a frequency of a least once per extrusion lot.

o Hydrostatic Strength testing (up to ∅ 110 mm) as per EN 921 at a frequency of at least once per day per line.

o All fabricated fittings shall be inspected for joint quality and alignment.

10.2.8 Testing of HDPE pipes:

HDPE pipelines must be hydrostatically tested.

Pipes testing pressure is fixed at 12 bars or 1.5 times working pressure.

The Contractor must give a preliminary notice of 24 hours prior to start pipe testing.

Pressure testing shall be carried out as the work proceeds with convenient lengths.

No length greater than 500 meters can be tested at a time.

Pipeline ends shall be closed by means of securely anchored caps or blank flanges.

Pipeline valves shall not be used for this purpose.

All washout valves shall be fitted with blank flanges and the valves opened before the starting of pressure test.

The pipeline to be tested must be filled slowly with water so that air is properly and completely expelled.

Air vent must be checked to ensure that no air is trapped at high points.


All pipes must be backfilled and Contractor must take all necessary precautions to prevent floatation or movement of the pipeline where needed Contractor must secure an extra anchoring to perform the test.

Joints shall be left exposed until pressure testing has been satisfactory completed.

While testing, the pressure in the pipes must be gradually increased and once test pressure is reached a minimum of 24 hours must be given to air in the pipeline to be expelled and pipe works to become saturated and expansion to have reach its ultimate value.

At the end of this period, pressure test will start and a minimum of 24 hours are required to consider the test as successful one.

Throughout this period the pressure in the pipeline shall not be allowed to fall or rise more than 6m head of water below or above the test pressure and his shall be accomplished by pumping water into or releasing water from the pipeline as required. The volume of water pumped into or released from the pipeline shall be carefully measured. At the end of the test period the pressure in the pipeline shall be adjusted to the test pressure by pumping water into or releasing water from the pipeline as required. The apparent leakage from the pipeline shall be ascertained from the net volume of water that was lost from the pipeline during the test period.

The permissible loss shall not exceed 2 liters per meter nominal bore per kilometer length per m head per 24 hours.

During the pressure test, exposed joints shall be inspected and any leaking or seeping joints shall be remedied.

All signs of leakage shall be remedied whether total apparent leakage from the pipeline under test is less than the apparent allowable leakage or not.

Should any length or pipeline fail to pass the pressure test the Contractor shall at his own expense carry out all work necessary to locate and remedy the faults and to retest the pipeline until it satisfactorily passes the test.

A low pressure air test (not exceeding 0.3 bars) may be used as a preliminary joint tightness test prior to backfilling and hydrostatic testing.

The water used for pressure testing shall be provided by the Contractor and shall be free from impurities and of such a quality which will not pollute or injure the pipeline. The Contractor shall be responsible for obtaining the water, as well as transporting it for its safe disposal on completion.

10.2.9 Warning tapes:

The Contractor must supply and install warning tapes as indicators within pipe bedding material indicating that below is laid potable water pipe belonging to SLWE.

Warning tapes shall be made of pigmented low density polythene in a bright color (blue) or other approved material not less than 100 mm wide and 0.15mm thick.

The tapes shall be continuously and alternatively labeled in Arabic and French. (Danger potable water network- South Lebanon Water Establishment).


10.3 Seamless Steel Pipes

Seamless steel pipe specifications shall be of API 5L grade B quality and shall be internally and externally coated with epoxy paint suitable for potable water.

Seamless steel pipes must be assembled by welding and shall be used for bridge crossings and whenever deemed necessary by the EIIP Project Engineer.

11 MANHOLE AND CHAMBER ACCESS COVERS

The manhole and chamber access covers shall comply with BS 497 Part 1 [Class D 400 (Breaking load 40 tons)] and be obtained from an approved manufacturer and shall be to the internal minimum clear opening as detailed in contract.

All manhole and chamber access covers in road shall be to an approved Heavy Duty pattern and in footpaths shall be medium/heavy duty unless otherwise specified. The frame and lid shall have key holes formed with sealed pockets underneath to prevent ingress of sand, grit and surface water and shall be of an approved non-rocking pattern.

The covers and frames shall have accurate seating faces to prevent rocking and the ingress of sand or water, and shall be tight fitting to resist overflow conditions or unauthorized removal. The seating faces shall be coated with graphite grease before installation of the cover.

A supply of keys for use with every type of manhole cover and surface box shall be handed over by the Contractor at the completion of the contract on the basis of one set of keys for each 50 covers or part thereof.

Manhole and chamber cover frames shall be set in cement mortar and hunched with Class C30/100 concrete and shall be set to the camber or fall of the finished road surface.

It shall be the Contractor’s responsibility to establish the finished road surface. It shall be the Contractor’s responsibility to establish the finished road surface levels from the appropriate authority and fix the covers accordingly.

11.1 Manhole step Irons

Manhole step Irons shall be of galvanized malleable iron and shall conform in all particulars to BS 1247.

11.2 Surface boxes and chamber covers (where applicable)

Surface boxes and chamber covers shall be either cast iron or ductile iron and coated with a black bituminous solution.

Surface boxes over gate valves shall be hinged and chained and shall comply with BS 5834.

- In road, tracks, verges: Heavy duty with 150 x 150 mm nominal clear opening. - In fields and areas subjected to tight wheeled or pedestrian traffic: Medium duty with

150x150mm nominal clear opening.


Surface boxes for hydrant chambers shall have a 380x230 mm clear opening and shall comply with BS 750 and shall be suitable for heavy traffic loading.

Covers to air valves and other chambers shall be to the dimensions and loading requirements shown on the drawings or as stated in the Bill of Quantities.

Covers shall be suitable for the following maximum safe center static loads:

Heavy duty – 5000 kg

Where applicable, covers shall comply with BS 497 or other appropriate standard.

Lifting keys shall be provided for each type of surface box or cover supplied. One set of keys shall be provided for every ten surface boxes or covers subject to a minimum of ten sets of keys or the actual number of covers if less than ten.

12 INSTALLATION OF PIPES INSIDE TRENCHES

Pipe installation shall be in accordance with the general pipe laying requirements of the Ministry of Energy and Water Standard Specifications and the specific requirements as follows:

- Except as otherwise specified in this Clause, pipe bedding shall conform to the requirements

specified later on.

- Necessary facilities including slings shall be provided for lowering and properly placing the pipe section in the trench without damage. The pipe sections shall be laid to the line and grade shown and they shall be closely jointed to form a smooth flow line.

- Trench bottom must be leveled to reach required slope.

Level instrument will be used to construct rigid and inclined bedding as per required values on pipe section profiles.

Contractor must include with his working staff a qualified geometer (topographer) that will check at all time the slope of the bedding materials that are placed beneath pipes.

Installation of pipes shall respect all depth and inclination to reach identical profile as per drawings.

- Immediately before placing each section of pipe in final position for jointing, the bedding for the pipe shall be checked for firmness and uniformity of surface.

- No pipe shall be rolled into the trench except over suitable timber planking free from roughness

likely to damage any coatings.


- 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 trench.

- At all times when the work of installing pipes is not in progress, all openings into the pipe and

the ends of the pipe in trenches shall be kept tightly closed to prevent entrance of animals and foreign materials. The Contractor shall take all necessary precautions to prevent the pipe from floating due to water entering the trench from any source, shall assume full responsibility for any damage due to this or any other cause, and shall at his own expense restore and replace the pipe to its specified condition and grade if it is displaced. The Contractor shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until handover.

- All piping and fittings shall be installed true to alignment and rigidly supported. Anchorage

shall be provided where required. - Each length of pipe shall be cleaned out before installation. All of manufacturer's

recommendations shall be complied with. - When pipe cutting is acceptable to the “EIIP Project Engineer”, the cutting shall be done by

abrasive saw, leaving a smooth cut at right angles to the axis of the pipe. Any damage to the lining shall be repaired to the satisfaction of the “EIIP Project Engineer”.

- The pipes shall be laid bedded in granular bedding material except where concrete bedding or protection is required. The granular material shall extend from not less than 100 millimeters beneath the pipes to 200 millimeters above the crown of the pipes or as approved by the “EIIP Project Engineer”.

- It shall be the Contractor’s responsibility to ensure proper operation of existing distribution

systems without creating disruption in water supply for customers and subscribers, for this a temporary diversion must be provided using gate valves from appropriate diameter to connect new network with still existing one that is yet not replaced, and this in full coordinate with EIIP Project Engineer.

13 SADDLES, TEES, FLANGES AND OTHER ACCESSORIES INSTALLATION:

Saddles, joints, flanges, tees… shall be installed in accordance with the manufacturer’s recommended procedures.

Flanges faces shall be centered and aligned to each other before assembling and tightening bolts.

In no case shall the flange bolts be used to draw the flanges into alignment.



Bolts shall be evenly tightened according to the tightening pattern and torque step recommendations of the Manufacturer at least 1 hour after initial assemble, flange connections shall be re-tightened following the tightening pattern and torque step recommendations of the Manufacturer. The final tightening torque shall be 135 Nm or less as recommended by the manufacturer.

Saddles will be installed on pipes with tightening ring providing complete water proofing.

14‐ VALVES & ACCESSORIES:

All valves related to irrigation network shall comply with international standards mainly (ISO, DIN).

Proposed valves must be manufactured in an ISO 9001 certified quality factory. 14.1 ‐ Ductile Iron Gate valves

The valves shall be made of ductile iron, of resilient seated type and non-rising stem and straight passage, and sustain nominal pressure of 40 bars (P. max. Allow 40bars).

The valves and components must pass the hydrostatic pressure test at the manufacture and sustain the maximum allowable pressure to NFE-29-311, ISO 5208 for different PN selects, and must be approved and certified by known quality control office i.e. Bureau VERITAS or other.

The ductile Iron Gate valves and components shall comply with:

• Ductile iron valves to ISO 7259 type A, BS 5163 type A, NF 29-324, IN 3352 section 4A/B, NFE 29-311

• The spacing between the two flanges of the valve complies with ISO 5752, the drilled holes in the flanges to ISO 7005-1/2, ISO 2531.

• Body and bonnet is made of ductile iron to GS 400-15 with powder epoxy coating, minimum 150 microns to ISO 8501 grade SA 2.5.

• Nut and yoke to SG 400-15 ductile iron, coated with ethyl vinyl acetate. • Bolts and nuts shall be of galvanized steel with rubber washers reinforced with steel rings. • Gate to GS 400-15 ductile iron, fully covered with EPDM rubber. • Stem 12% chromium stainless steel • Seal bush is made of bronze. • Bonnet and bush seals, 70 shore a nitrite rubber. • Hydrostatic pressure test for body: passes “1.5 valve nominal pressures”. • Hydrostatic pressure test for components: passed”1.1 x valve nominal pressure”.

14.2 ‐ Butterfly valves:

Butterfly valves shall conform to BS 5155 and used where expressly mentioned.

Butterfly valves shall have a high grade cast iron body to BS 1452 designed to the specified working and test pressure. The pressure rating of the valves shall be cast in the valve body.

The disc shall be of high grade cast iron to BS 1452 or nodular cast iron to BS 2789 to the defined working and test pressures. It shall have a convex shape designed to achieve low head loss characteristics. The valve shafts shall be of stainless steel to BS 431 S29 operating in self-


lubricating bushes in the body.

The valve seat shall be of gunmetal to BS 140. The sealing ring shall be a renewable Ethylene Propylene Dienne Monomer (EPDM) rubber attached to the disc edge by a sectional bronze retaining ring to form a resilient and durable seal.

In all cases, the gearing shall be designed to close the valve, from fully open to fully close in a period of not the hand wheel is turned in a clockwise direction; the direction of closing shall be clearly cast on the hand wheel. Position indicators shall be fitted to all actuators.

A performance curve, relating percentage valve travel, open area and discharge coefficient shall be submitted to the “EIIP Project Engineer”. The head loss coefficient with valve fully open shall be defined.

All valves are tested in accordance with BS 5155 and pressure and material test certificates shall be submitted to the “EIIP Project Engineer” or approval.

All butterfly valves must withstand a nominal pressure of 40 bars. 14.3 Valve accessories:

• Steel operating hand wheels: BS 5163 for cast iron and BS 1452 for grade 10. Hand wheels are to be marked “CLOSE” with an arrow to indicate clockwise direction for closure.

• Valve caps: BS 5163, of cast iron BS 1452 grade 12 or malleable iron to BS 310. The set screw of valve cap is to be mild steel M12.

• Operating keys: combination prizing bar and lifting key tube, with 1.5m vertical bar and 0.5m horizontal bar.

• Extension spindles for gate valves: steel to BS 2470-M12, hot dip galvanized to BS 1287, size 18x18m for valves up to 200mm and 24x24mm for valves 250mm to 400mm diameter.


• Protection tubes: Either UPVC, cast iron, or pre-cast concrete. Shape, sizes and other constructional details are to be manufacture’s standards and / or as shown on the drawings.

• Surface boxes: BS 1426, frame and cover are to be cast iron to BS 1452 grade10, studs, bolts nuts and hinge pins are to be mild steel M12, chains are to be mild steel or made of wrought iron and lid is to have “W” cast on.

• Lifting keys: Are to be made of mild steel. 14.4 – Air valves

Air valves shall be either:

a) Single (small) orifice valves (SAV), for the discharge of air during the normal operation of the pipeline.


or

b) Double orifice valves (DAV), consisting of a large orifice and a small orifice.

These shall permit the bulk discharge of air from the main during filling and air inflow when emptying in addition to the discharge of small quantities of air during normal operating conditions.

Air valves shall be supplied with an independent isolating butterfly valve (DAV) or cock (SAV) which permits the complete removal of the air valve from the main, without affecting the flow of water in the main.

Each air valve assembly shall be suitable for connection to a flange on the pipeline.

At the connection between the air valve and its isolating valve a BSP tapping shall be made suitable for fitting of a pressure gauge. All tapings shall be sealed by a Brass plug and copper compression ring gasket.

Air valves shall operate automatically and be constructed so that the operating mechanism will not jam in either the open or closed positions.

14.5 Service boxes (where applicable)

Service boxes will extend from the pipe line newly installed to the existing building within the parcel limit to a length not exceeding 18 meters.

Service boxes shall be buried, cross roads or alleyways and the Contractor shall locate and agree with the EIIP Project Engineer the location of manifolds in order that this can be achieved.

Service boxes pipe works should be kept short with the minimum of bends.

In General the new service boxes will include the following accessories:

- Intake coupling, (saddle). - Ball valve 25 mm to 40 mm. - Up to 18 meters of 25 to 40 mm HDPE pipelines (PN25) with all related civil works including

excavation, laying of pipes, backfilling and re-asphalting. • Service boxes specification will be as follow:

Service box body must be in grey cast iron, and must be manufactured in accordance to EN1561.

All casted items within service box must be coated with a black bituminous solution, and service box cover must be equipped with a steel bar for protection against theft and vandalism.

Service box cover must be labeled W (for water) and must have a minimum depth of 25 cm, it must be cylindrical or octagonal with a net clear diameter of 10 cm and an outside diameter of 12 cm.

15 BACKFILLING:

I- Backfilling material can include one or more of the following materials a-


Selected fill:

Defined as being sands or gravels or sand and gravel mixtures with fines of low plasticity obtained from excavation of the pipe trench or elsewhere with a particle size not greater than 50mm

b- Ordinary fill:

Bedding material obtained from excavation of the pipe trench and containing not more than 20 per cent by mass of stones with a size between 50 mm and 100 mm and not larger than 100 mm.

c- Fine Crushed rock:

Shall be composed from crushed rock material with particle size not exceeding 10 cm. Backfilling

of trenches will take place after completing the installation of bedding layer.

Backfilling material must be approved by “EIIP Project Engineer” and special attention must be given so that the backfill material is not polluted with debris or other strange materials that could harm or damage the pipe.

Backfilling material shall be as shown on the relevant standard drawings and shall be placed in layers not exceeding 150mm thick when completed.

The degree of compaction must be to the optimum proctor density test of 90%. II- Foundation & Bedding material:

Pipes shall be laid on grade and on a stable foundation.

Unstable or mucky trench bottom soils shall be removed, and a 150 mm foundation or bedding of compacted Class I material shall be installed to pipe bottom grade.

Excess groundwater shall be removed from the trench before laying the foundation or bedding and the pipe.

A trench cut in rock or stony soil shall be excavated to 150mm below pipe bottom grade, and brought back to grade with compacted Class I bedding. All ledge rock boulders and large stones shall be removed.

The bedding shall be placed after the trench bottom is compacted so as to provide proper support.

Minimum compaction of the bed shall be 90% of Standard Proctor Density.

The finished bed shall be plane, and must provide a uniform and continuous support for the pipes.

Pipe bedding material must be clean sand, gravel or crushed rock, free from organic matter and clay lumps and conform to the grading given in the following table:

Sieve (mm) Percentage passing by mass


9.5 100

2.36 25-10

0.425 0-60

0.075 0-10

Pipe bedding material must have a sand equivalent of at least 60.

16 CONCRETE

Concrete will be used for valves chambers, pipe anchoring, and retaining walls. Concrete must have a minimum compressive strength of 250 kg/cm2 at 28 days.

16.1 ‐ Composition:

Concrete shall be composed of cement, sand, broken rock or gravel, and water all well mixed and brought to the proper consistency. In case of adverse weather conditions (freezing temperature), powdered admixture shall be added to decrease concrete curing period. The exact proportions, in which these materials are to be used for different parts of the work, shall be as determined from time to time during the progress of the work and as analysis and tests are made of samples of the aggregates and the resulting concrete.

The m3 of concrete shall be composed as follows:

o 350 Kg of cement Portland o 800 Liters of gravels as per required specification with maximum gravel size of 20 mm. o 400 Liters of sand free from organic materials (marine sand is strictly forbidden) These proportions may be modified to suit the work or the nature of the materials used or to comply with the water cement ratio limitation hereinafter specified.





The amount of water used shall be changed as required to secure concrete of proper


consistency and to adjust for any variation in moisture content of the aggregate as it enters the mixer, provided that a water cement ratio of 0.60, by weight, shall not at any time exceeded.

Contractor is responsible for the design of concrete and shall take the approval of “EIIP Project Engineer” for the mix proportions.

The proportion of cement, aggregates and water shall be determined in accordance with (2, 3&4) BS 5328.




Uniformity in concrete consistency from batch to batch will be required. Slump tests will be made in accordance with the Tentative Method of Test for Consistency of Portland-Cement Concrete (A.S.T.M. Designation: D138-32T) of the American Society for Testing Materials.

16.2 ‐ Cement: Cement for concrete shall comply with the Standard Specifications for Portland cement, and shall be C-S 42,5 according to the Lebanese norm, also the heat of hydration of cement measured by the method of “ Bouteille isolante” defined by “ Centre d’Etudes et de Recherches de l’industrie des liants hydraulique” shall not exceed 70 calories / gram of cement at t= 7 days


The quality of the Portland cement shall be equivalent to AASHTO M85, type I, II, III or V.

Cement will be delivered in bags of 50 kg each.


16.3 ‐ Aggregate – Sand:






16.4 ‐ Broken Rock and Gravel:



The suitability of the broken rock or gravel will be determined with the aid of tests made in accordance with the standard practices. Any crushing, blending, screening, washing, or other operation on the broken rock or gravel required to meet these specifications shall be done by the Contractor, and the cost thereof shall be included in the unit prices bid in the schedule for the items of work in which the broken rock or gravel is used.

The broken rock or gravel shall be washed unless specific authority is given to use unwashed broken rock or gravel.




The relative amounts of each size of broken rock or gravel to be used in each mix of concrete and in all parts of the work will be based on securing concrete having the required workability, density, impermeability, strength, and economy, without the use of an excess


of sand, water, or cement, and using, insofar as practicable, the entire yield of suitable material from the natural deposits from which the broken rock or gravel is obtained.


16.5 ‐ Storing of cement:


Cement must be transported to the mixer in its original sacks.

Each batch shall contain the full amount of cement for the batch.

In case cement is placed in contact with the aggregates it must be mixed within 60 minutes or it will be rejected.

16.6 ‐ Sampling of concrete:


Approval of “EIIP Project Engineer” on mix proportions must be obtained at least one week prior to the beginning of concrete work.

Mixing proportions of cement, aggregates and water must be done in accordance with BS 5328.

Concrete must have a minimum compressive strength of 250 kg/cm2 at 28 days. For each cast a minimum of two cylinders must be taken and stored in adequate places as specified by “EIIP Project Engineer”.

Cylinders on site will be stored in a locked place and key will be put at the disposal of “EIIP Project Engineer”.

16.7 ‐ Stockpiling of aggregates:




In any case stockpiling of aggregates must be approved by “EIIP Project Engineer” and every precaution must be taken to prevent segregation like not making layers above 1.5 m and in case additional layer is brought to site it is forbidden to cone down new layer above old one.

Also aggregates must be protected against contamination from water diverted from site or


from water pumped during dewatering of ponds.

If instructed by “EIIP Project Engineer”, aggregate stockpiles will be sprinkled with water 12 hours before use and this in order to maintain moisture content in the aggregates equivalent to the water absorption value of the aggregates as determined by AASHTO T84 & 85.

16.8 ‐ Ready mix concrete:

Ready mix concrete cannot be used under any circumstance in the absence of access roads

16.9 ‐ Steel for concrete reinforcement:


Contractor must submit a certificate of origin for steel used on site.

For each lot of billet steel certificate must include identification of process used in the manufacturing of steel.

Steel bars shall be tagged by the manufacturer and tag must show manufacturer’s test number and lot number that identify the material.

16.10 ‐ Reinforcement of steel bars:

All reinforcement bars shall be free detrimental dirt, mill scale, rust, paint, grease, oil or other foreign substance, fins or tears. The Contractor will not be required to remove slight rusting which discolors the metal, but he shall remove all loose mill scale and scales rust.


Supports, metal supports, approved by the “EIIP Project Engineer”, shall be provided and used to retain the reinforcement at proper distances from the forms. Supports under horizontal bars slabs shall be spaced at not more than eighty (80) diameters of the bar.

All reinforcement shall be so rigidly supported and fastened that displacement will not occur during construction. Reinforcing steel shall be inspected in place and must be approved by the “EIIP Project Engineer” before any concrete is deposited.

Reinforcing steel shall be stored above the ground on plate forms, skids, or other supports. It shall be stored in such a manner and adequately marked to facilitate inspection and checking.

When placed in the work, the reinforcing steel shall be free from dirt, detrimental scale, paint, oil or other foreign substance.

All cutting and bending of reinforcement bars shall be done by competent workmen and with equipment approved by the “EIIP Project Engineer”.



Bent bar reinforcement shall be cold bent to the shapes shown on the plan, and unless otherwise provided on the plans or by written authorization of the “EIIP Project Engineer”, bends shall conform to the following requirements:

D= 6d for five (5) millimeter through twenty two (22) millimeter bar sizes.

D= 8d for twenty four (24) millimeter through twenty eight (28) millimeter bar sizes.

D= 10d for thirty (30) millimeter and over bar sizes.

Where:

D= minimum pin diameter around which a bar may be bent

d= bar diameter.

All reinforcing steel shall be accurately placed and, during the placing of concrete, firmly held by approved supports in the position shown on the plans. Reinforcing bars shall be securely fastened together; reinforcement placed in any member shall be inspected and approved before any concrete is placed.


All horizontal reinforcement shall be supported on metal supports or spacers as approved by the “EIIP Project Engineer”.



The adequacy of the supports and ties to secure the reinforcement properly shall be subject to the approval of the “EIIP Project Engineer”.

16.11 ‐ Falsework & Formwork


Work consist in furnishing and placing Portland cement concrete for structures in accordance with the specifications and conformity with the lines, grades and dimensions of drawings and plans.

Falsework






Spacing of false work columns in the general framing must be approved by “EIIP Project Engineer”.


The Contractor shall submit calculations to support this requirement for all spans over 3 meters and other spans if requested by the “EIIP Project Engineer”.


Note:



In designing forms, concrete will be regarded as a liquid having a weight of 2,400 kg per m3, and not less than 1,400 kg per m3 shall be assured for horizontal pressure.

Formwork









The width and thickness of the lumber, the size and spacing of studs and Wales shall be determined with due regard to the nature of the work and shall be sufficient to ensure rigidity of the forms and to prevent distortion due to the pressure of the concrete.


When the Contractor instructed by the “EIIP Project Engineer” shall submit formwork drawings and calculations to the “EIIP Project Engineer” in advance of the concreting.








b- Tolerance Unless otherwise indicated on the drawings, the tolerances of the finished concrete with respect to the dimensions shown on the drawings shall not exceed the limits set out in the following table. Formwork shall be constructed to ensure completed work within the following tolerance limits:

• Departure from established alignment: 0.5 cm • Departure from established grade: 0.5 cm • Variations from plumb or specified batter in lines and surfaces of columns, piers and

walls: 0.5 cm in 3 meters, if exposed



• Variations from level or indicated grade in slabs, beams etc...:


• Variation in cross-sectional dimension of columns, piers, slabs, walls, beams : -0.5 cm + 0.5 cm

• Variation in slab thickness: -0.5 cm + 0.5 cm • Footing: plan dimensions: -0.5 cm + 0.5 cm • Eccentricity: 2 percent of footing width, not exceeding 5 cm • Reduction in thickness: 2 percent of specified thickness



16.12 ‐ Plastering works:

Plastering works must be implemented by experienced staff.

Sand & cement that compose plaster must be according to specifications of concrete works.

Proportions must be 50 Kg of cement for 0.14m3 sand.

Plastering shall be at least 15 mm thick and will not exceed 20 mm thickness.

Plastering works must be carried out in a minimum of two coats;

The first coat must be a render coat which shall be left scratched to receive the finishing coat.

The finishing coat must be worked to a true and even surface and polished to a smooth surface using a steel trowel.

Plastered surfaces shall be perfectly leveled and shall be to the specified thicknesses. All edges must be straight.

Sample plastering must be made and approved by “EIIP Project Engineer” prior to any commencement of plastering.

Before applying plastering and screeds, the surfaces that are to be coated shall be thoroughly cleaned they shall be kept wet for several hours before plastering.

A 3 meters ruler placed on the surface shall not show a tolerance more then 3 mm. The maximum deviation in verticality shall not exceed 7 mm over 3.0 m.

In case waterproofing of plaster is required, waterproof rendering slurry shall comprise a 50 to 120 Kg cement sand mix with an approved waterproofing admixture such as styrene acrylate copolymer. The material shall block capillarity and minor shrinkage cracks (micro-cracking) to prevent water ingress while allowing the passage of water vapor through the structure.

The render shall be applied to a total thickness of not less than 20 mm the first coat shall be applied leveled scratched and left to dry for not less than 72 hours.

16.13 ‐ Waterproofing membrane

For main booster valve chamber a waterproofing protective membrane must be applied on backfilled concrete services that comes in contact with water table.

General:

The following Specification covers the furnishing and applying of waterproofing protective membrane in the presence of water table.

The Contractor shall furnish the “EIIP Project Engineer” evidence that the personnel applying the


material are qualified and manufacturer- approved. Submittals:

The Contractor shall submit to the “EIIP Project Engineer” for approval samples of the materials he will propose and certificates that those materials to be furnished comply with specification requirements and are suitable for the intended purpose.

Products shall be stored in an approved dry area with roll goods laid flat, one pallet high, and protected from contact with soil and from exposure to the elements. Products shall be kept dry at all times.

Products shall be handled in a manner that will prevent breakage of the containers and / or damage to the products.

Materials:

Waterproofing membrane, primer and protection boards shall all be in accordance with the requirements of ASTM standard.

Applied waterproofing membrane must have a minimum of 4mm thickness and be conform to the general requirements of ASTM standard.

17 REINSTATEMENT OF SURFACES

All surfaces whether public or private who are affected by the Works shall be reinstated temporarily in the first instance and when the ground has fully consolidated the Contractor shall reinstate the surface permanently.

Temporary reinstatement and permanent reinstatement of all surfaces, affected by the operations of the Contractor shall be carried out and maintained to the satisfaction of the EIIP Project Engineer and the responsible authority or owner.

Temporary reinstatement shall be carried out immediately once the trenches are backfilled.

Permanent reinstatement shall not be carried out until the ground has settled completely. In the event of further settlement occurring after the completion of the permanent reinstatement the Contractor shall forthwith make good the reinstatement to the approval of the EIIP Project Engineer or responsible authority.

For the purpose of temporary and permanent reinstatement by Bitumen and surfaces roads the surface width of trenches shall be increased by 150mm on each side of the trench for a depth of 75mm to provide a solid abutment for the surfacing material.

Reinstatement of surfaced roads shall be carried out to the approval of the relevant authority.

The responsible authority shall have the right to carry out permanent reinstatement at the Contractors expense.

Trenches in open ground shall be reinstated to the condition in which the ground was before excavation was commenced. The final surface of the trench shall be flush with the surrounding ground.


If at any time any reinstatement deteriorates the Contractor, shall restore it to a proper condition immediately.

Should the Contractor not remedy the defect to the EIIP Project Engineer’s satisfaction forthwith any remedial work considered necessary may be undertaken by the Employer and/or the responsible authority at the Contractor’s expense.

Topsoil shall be carefully set aside and replaced at the surface of the backfilling.

The trenches shall be refilled and rammed solid as specified in the Contract and shall not be topped up above the original surface level to allow for settlement.

If any trench becomes dangerous the EIIP Project Engineer may call upon the Contractor for its reinstatement at three hours’ notice and failing this to have the work done by others at the Contractor’s expense.

Road Reinstatement:

(This item shall not be applicable where jacketing and manual backfilling is required)

Crushed rock sub-base: Under all structures and also where specified and indicated on the drawings a minimum of 200 mm thickness of crushed rock sub-base material type 1 is required (Tout venant).

The material shall comply with BS 812 part 121 and 103 and shall have the grading range as follow:

BS Sieve Size Percentage by Mass Passing 75 mm 100 37.5 mm 85-100 20 mm 60-100 10 mm 40-70 5 mm 25-45 600 micron 8-22 75 micron 0-10

17.1. Re‐asphalting:

Once backfilling completed and upon “EIIP Project Engineer’s” instruction Contractor must proceed for re- asphalting according to required specifications.

Contractor must abide with the latest addition of ASTM standards mainly:

ASTM C 88, C 131, D 156, D 1883, D 2167, D 2940.

All the materials that will be used in the work must meet “EIIP Project Engineer’s” approval and must complied with the requirements of the Contractor.


17.1.1 Sub base & base course:

Aggregate sub-base and base courses shall be in compliance with ASTM D 2940 and shall consist of crushed mineral aggregates or natural mineral aggregates of the gradation and thickness indicated in the specifications and on the drawings; Contractor must coordinate with local Municipality as to requirements of re-asphalting works in order to meet existing conditions on the ground.

17.1.2 Natural aggregate sub‐base and base courses:

Shall consist of coarse and fine mineral aggregates, which have been screened and blended to the various grading and constructed to the thickness as indicated on the drawings and in the specifications.

17.1.3 Crushed aggregate sub‐base and base courses:

Shall consist of crushed coarse aggregate and crushed or natural fine aggregate screened and blended in accordance with the required gradation and constructed to the thicknesses as indicated on the drawings and in the specifications.

Materials requirements for aggregate sub-base and base course

Fine aggregates used for aggregate sub-base and base Courses.

Fine aggregate passing the No.4 (4.75mm) sieve shall normally consist of fines from the operation of crushing the coarse aggregate; where available and suitable, natural sand or finer mineral matter, or both, may be added. The fraction of the final mixture that passes the No.200 (75 µm) sieve shall not exceed 60% of the fraction passing the No.300 (600 µm) sieve.

The fraction passing the No.40 (425-µm) sieve shall have a liquid limit no greater than 25 and shall not have a plasticity index greater than 4. The sand equivalent value of the fine aggregate shall be no lower than 35.

17.1.4 Coarse aggregate Used for aggregate sub‐base and base courses

Coarse aggregate retained on the No.4 (4.75 mm) sieve shall consist of durable particles of crushed stone, gravel, or slag capable of withstanding the effects of handling, spreading and compacting without degradation productive of deleterious fines. Of the particles which are retained on a 3/8 – in (9.5 mm) sieve, at least 75% shall have two or more fractured faces.

17.1.5 Types of aggregate sub‐base and base courses

The combined gradation including fine and coarse aggregates shall conform to the gradation for sub-base and base courses as indicated in the following table. The continuous smooth gradation of materials used shall be kept within the specified gradation limits and gap grading must be avoided.

Sub-base material shall have a 4-day soaked CBR of not less than 30% when compacted at 100% modified proctor (AASHTO T 180-D) and tested in accordance with AASHTO T193.


The base material shall have a 4 day soaked CBR of not less than 80% when compacted at 100% modified Proctor (AASHTO T 180-D) and tested in accordance with AASHTO T 193.

Sieve Size:

(square openings) Bases Sub-bases Bases Sub-bases

2 in (50 mm) 100 100 -2 -3 1-½ in. (37.5 mm) 95-100 90-100 ±5 +5 ¾ in. (19.0 mm) 70-92 - ±8 - 3/8 in. (9.5 mm) 50-70 - ±8 - No. 4 (4.75 mm) 35-55 30-60 ±8 ±10 No. 30 (600 µm) 12-25 - ±5 - No. 200 (75 µm) 0-8 0-12 ±3 ±5

Construction requirements for aggregate sub-base and base courses

17.1.6 General methodology for asphalt installation:

Prior to commencing the construction of the sub-base and base courses, it is necessary to make sure that the sub-grade conforms to the specifications and is compacted to the maximum dry density as indicated in these specifications and that the surface there of conforms to the levels and slopes indicated in the drawings.

In all cases the approval of the “EIIP Project Engineer” must be obtained before commencing spreading for the sub-base and bases courses.

The material shall not be handled in such a way as to cause segregation. If the spreader causes segregation in the material, or leaves ridges or other objectionable marks on the surface which cannot be readily eliminated or prevented by adjustment of the spreader operation, the use of such spreader shall forthwith be discontinued and it shall be replaced by a spreader capable of spreading the material in a proper manner.

All segregated material shall be removed and replaced with well-graded material. “Skin” patching will not be permitted. Only minor surface manipulation and watering to achieve the required surface tolerances will be permitted during the compaction process.

Hauling; or placement of material will not be permitted when, in the judgment of the “EIIP Project Engineer”, the weather or surface conditions are such that hauling operations will cause cutting or rutting of the sub-base or sub-grade or cause contamination of the base course material.

Compaction shall be tested in accordance with these specifications. If there is a delay between the construction of any layer and the following layer, if necessary and required by the “EIIP Project Engineer” the compaction of the lower layer may be re-verified to ensure that it has not loosened due to traffic, passage of construction equipment, adverse weather conditions or otherwise.

17.2.6 a Screening and Mixing of the Materials:

Screening shall be required for the materials used in aggregate sub-base and base courses. Screens shall be of the size and number required to remove oversize aggregate and, if necessary, to separate


the materials into two or more fractions so that they may be combined to meet the required gradation. When conveyor belt samples from the end of the screening and/or crushing screening operation yield a product consistently within the specified gradation, no further mixing shall be required and the material may be loaded and hauled directly to the road. If stockpiled, it shall be performed so as to prevent segregation.

Mixing of material can be achieved through the use of the central mixing plant or travel mixer. Where separate size materials are to be blended to meet the gradation, such blending shall be as directed by the “EIIP Project Engineer” and shall be accomplished prior to delivery to the roadway. Mixing of separate materials on the roadway by motor grader will not be permitted.

17.2.6 b Spreading and Compacting:

After carrying out the screening and mixing of aggregate material, samples of the approved material shall be taken in order to determine the optimum Moisture Content.

Material shall then be spread on the trench surface to thicknesses that would result in layers not more than 200 mm thick after compaction.

The natural moisture content of materials constituting the sub-base and base courses shall be determined.

If the natural moisture content is less than the optimum moisture content, the necessary amount of water must be added to obtain the optimum content allowing for the quantity which may be lost by evaporation in the process of raking, leveling and compacting, depending on atmospheric temperature, quantity of material and the equipment and plant to be used in this operation provided that the layer shall be compacted when the moisture content therein is within +/-2% of the optimum moisture content in order to obtain Maximum Dry density and the moisture content is uniform in all parts of the section where the work is being carried out and in the various depths of the layer thickness.

Compaction shall start immediately thereafter, by means of pneumatic and steel rollers or vibratory rollers and in accordance with the instructions of the “EIIP Project Engineer”.

17.2.6 c Asphalt works:

Once sub-base & base course completed & compacted Contractor shall proceed for asphalting work.

The materials used in the work shall meet all contract requirements.

Contractor shall notified the “EIIP Project Engineer” of the sources of materials and the “EIIP Project Engineer” shall approved the sources prior to any delivery to site.

In case a source of material does not meet specification requirements, the Contractor shall furnished material from another source.


17.2.7 Material requirement for asphalt works:

- Fine aggregates:

Consisting of a natural sand or crushed sand passing the No. 8 Sieve.

Fine aggregates shall be of such gradation that when combined with other aggregate in proper proportions, the resultant mixture will meet the required gradation.

Fine Aggregate shall be clean and free from organic matter, clay, cemented particles and other extraneous or detrimental materials.

Individual stockpiles of natural sand when tested in accordance with AASHTO T176 shall have a sand equivalent of not less than 45.

Individual stockpiles of crushed sand shall a sand equivalent of not lea than 30.

Individual stockpiles of aggregate containing more than 10% by weight of fine aggregate shall be tested for sand equivalent.

- Coarse aggregate:

Consisting of crushed natural stones and gravel in cubic and angular shapes, that are not flaky or elongated.

The gradation of these coarse aggregates shall be such that when combined with other aggregate fractions in proper preparations, the resultant mixture will meet required gradation.

Coarse aggregate shall be clean and free from organic matter, clay, cemented particles and other detrimental material.

Sampling of coarse aggregate shall be in accordance with AASTHO T27 and AASHTO T11.

The degree of crushing shall be such that at least 80% by weight of the material retained on the No.8 sieve has at least one fractured face. The flakiness of each individual stockpile shall not exceed 30% when tested in accordance with BS 812.

The percentage by weight of friable particles shall not exceed 2%.

The coarse aggregate to be used in asphalt concrete mixes shall consist of blend of limestone and basalt crushed stone.

- Commercial Mineral Filler:

Commercial mineral filler shall consist of finely ground particles of limestone, cement or hydrated lime in accordance with AASHTO M17. It shall be thoroughly dry and free from lumps and shall meet the following graduation requirements:


U.S Standard Sieve Size

Minimum Percent Passing by Dry Weight

No. 30 100 100 85 200 75

Where hydrated lime is used as mineral filler, the hydrated lime shall conform to these specifications. When cement is used as mineral filler, it shall meet the requirements of Type I, II or V in accordance with AASHTO M85 (ASTM C150).

- Asphalt cement:

The asphalt cement specified for use in the asphalt mixes shall be 60-70 penetration grades in accordance with AASHTO M20.

- Liquid Asphalts:

Liquid asphalt for use in asphalt works shall be emulsified asphalt in accordance with ASTM D 977 and ASTM D 2397 or medium and rapid curing cutback asphalt in accordance with AASHTO M82 and M81 respectively.

17.2.8 Major equipment used for Asphalt works:

The machinery and tools required for re-asphalting of road must be in good working conditions.

Special attention must be given to rollers that will compact the spread layers of asphalt.

The use of small wheel loaders (Bob cat) will be necessary to allow spreading of asphalt above trenches.

Labors with shovels will proceed for additional transportation of hot asphalt will be competed in two layers of 5 cm each or one layer of 7cm as per “EIIP Project Engineer’s” instruction.

Spreading by hand will be implemented, special attention must be given to prevent incident on workers.

Rolling must be made with suitable machines and a minimum of 6 passes (half a roll overlap) is required.

17.2.9 Temperature:

Special attention must be given while to bituminous materials temperature.

The minimum temperature allowed prior to rolling is 85o.

Any mixture arriving on site must have its temperature above 120o while on truck. 17.2.10 General requirements:

The asphalt course shall be constructed to proposed levels and shall be homogeneous, providing after compaction an even surface free from undulations, rises or depressions and within the tolerance stipulated. In no case shall construction of a new asphalt concrete course (type) begin until the previously laid course has been tested and approved in accordance with the specifications.

Immediately after the asphalt mix has been spread and struck off, the surface shall be checked and


any irregularities adjusted and then compacted thoroughly and uniformly by rolling.

Prime coat will be used by applying liquid asphalt and blotter material.

Liquid asphalt shall be of the medium curing type MC-30 grade or emulsified asphalt type SS-1, SS-1H, CSS-1h and shall conform to the requirements of the specifications. The application rate shall be between 0.45 to 1.50 l/m2 for the medium curing type and 2.30 to 3.20 l/m2 for the emulsified type, as directed by the “EIIP Project Engineer”.

Blotter material, if required, shall be clean natural sand and shall conform to the requirements of the specified requirements for fine aggregate for asphalt mixes.

17.2. Safety of Excavations in Roads

Where the surface of the road (other than that which lies immediately above the trench) is damaged either by the concentration of traffic caused by an open trench, by subsidence or other causes arising from the operations of the Contractor, he shall permanently reinstate the whole of the surface so damaged to its original condition.

The Contractor shall ensure that trenches and reinstatement are maintained in a safe condition and shall take immediate action to remedy any deterioration which renders the works unsafe.

If in the opinion of the EIIP Project Engineer any excavation or reinstatement is in a dangerous condition the Contractor shall immediately remedy the defect.

Should the Contractor fail to carry at the reinstatement promptly the work may be carried out by others at the Contractor’s expense.

17.3. Temporary Reinstatement of Bitumen ‐ Macadam Roads

In all Bitumen-macadam of bitumen sprayed roads the trenches shall be fitted and compacted to the underside of the original road surface.

A sub-base layer shall then be laid consisting of approved free drainage granular material conforming to the following grading limits:

A base layer shall then be laid consisting if approved crushed limestone material conforming to the following grading limits: 100% by weight passing 50 mm sieve

60% - 80% by weight passing 20 mm sieve

25% - 40% by weight passing 5 mm sieve

The material shall have a plasticity index of not exceeding 6%.

The materials forming the sub-base and foundation shall be laid in layers, brought to optimum moisture and compacted to 95% of the maximum dry density as determined by Part 4 Clauses 3.3/3,4 BS 1377:1990

Prior to application to the temporary reinstatement the surface of the road foundation shall be cleared of all dust, debris and other deleterious matter and shall then be primed with one


application of prime coat MC-70 or similar approved. All joints with adjacent road surfacing shall be cut straight and vertical and primed.

The road surfacing shall be temporarily reinstated with 60 mm finished thickness of 40 mm nominal size dense base course macadam. The coated macadam shall be laid and compacted so as to achieve a dense smooth and even surface using a roller of not less than 12 tones mass.

The surface shall be maintained until the end of the period of Maintenance or until instructions are given for the permanent reinstatement to be carried out. The surface shall not be topped up above the original surface level to allow for settlement.

17.4. Temporary Reinstatement of Unmade Roads

In all unmade roads the trenches shall be refilled and compacted as specified in the Contract to within 150 mm of the surface.

The trench shall be surfaced with 150 mm compacted thicknesses of base layer materials as specified above.

The surface shall be maintained until the end of the Period of Maintenance and shall not be topped up above the level of the original surface to allow for settlement.

17.5. Permanent Reinstatement of Bitumen‐ Macadam roads

Where instructions are given that permanent reinstatement is to be carried out then the temporary macadam surface and part of the foundation layer shall be removed to 100 mm depth and the surface of the foundation shall be rolled, all dust and debris removed, joints cut straight and vertical, and the surfaces primed with MC-70 or similar approved.

The permanent reinstatement shall comprise two layers of bitumen macadam to a total compacted thickness of 100 mm. The base course layer shall consist of 60 mm compacted thickness of 50 mm nominal size dense base course macadam and the wearing course of 40 mm compacted thickness of 14 mm nominal size dense wearing course macadam.

The laying and finishing of the coated macadam shall be carried out so as to achieve a dense, smooth and even surface using a roller of not less than 12 tones mass.

17.6. Forming Banks & Filled areas:

The filling to be used in the embankments and filled areas shall be material selected from that arising from surplus excavation, the material being placed according to its nature as shall be directed by the EIIP Project Engineer. The fill shall be placed in layers not exceeding 150mm thick, each layer being thoroughly compacted by an approved roller to the satisfaction of the EIIP Project Engineer.

17.7. Restoration of Borrow areas, Spoil tips and quarries

Any spoil tips, quarries or other borrow areas developed by the Contractor for the purpose of the Works shall be finished to safe and fair slopes to the approval of the EIIP Project Engineer.


18 TEMPORARY DIVERSION (IF NEEDED)

In order to provide continuous potable water supply to subscribers during on-going works, the Contractor must carry out temporary diversion between old & new pipelines.

For this he must proceed to the following: Install temporary gate valve from adequate size to divert water from new completed network to existing system where works have not started yet.

Valve installation includes cutting of old pipe lines and installation of tees, bends coupling and Gibault joint to new completed network. At all-time Contractor will have to preserve old distribution system in service until new pipe line is tested commissioned and accepted, then connection on both new lines will be completed as instructed by EIIP Project Engineer.

ilo itb no 58/2017 annex 2 technical specifications lot a

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