DETAILED ENGINEERING DESIGN

HAULING ROAD & INFRASTRUCTURE (BRIDGE & RAMP)

Engineering Consultancy Services

REPORT

TECHNICAL SPECIFICATION

Doc. No.: 2447-R-001Rev. A

March, 2011

Prepared by :

PT BRITMINDO

Jl. Kemang Timur Raya No. 60A Kemang,Jakarta 12730 INDONESIA

PT BITA ENARCON ENGINEERING

ENGINEERS • ARCHITECTS • CONSULTANTS

Jl. Pahlawan No.74 Bandung 40124 INDONESIA

BITA

TABLE OF CONTENTS

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1. DIVISION 1 GENERAL REQUIREMENT 01320 Surveying Services 01400 Concrete Test

01510 Temporary Facilities and Controls 2. DIVISION 2 SITE CONSTRUCTION

02200 Site Preparation and Grading 02230 Site Clearing

02315 Excavation, Backfilling and Compaction 02330 Embankment 02335 Subgrade Preparation 02372 Filter Fabric 02375 Riprap 02459 Precast Prestressed Concrete Piles 02462 Wood Piles 02721 Subbase

02722 Base Course 02845 Guardrails 3. DIVISION 3 CONCRETE 03200 Concrete Reinforcement 03300 Cast-in-Place Concrete

03400 Precast Concrete 03600 Grout

4. DIVISION 5 METALS 05120 Structural Steel 05500 Miscellaneous Metals 05800 Expansion Control

DIVISION 1 GENERAL REQUIREMENTS

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SPECIFICATION

01320

SURVEYING SERVICES 1.0. DESCRIPTION OF WORK. This work shall cover the limits and extent of the survey works of lines and elevations for site

preparation and other works as specified in the Drawings and/or as determined by the Project Manager and shall include technical personnel and precise scientific surveying instruments which shall be in accordance to this Specification.

2.0. REFERENCE STANDARDS. None. 3.0. GENERAL PROCEDURES.

3.1. Basic Survey Data. A basic survey data based on fixed triangulation polygon points and Bench Marks

(BM) shall be provided by the Owner and shall be at the disposal of the Contractor and shall serve as a base for the surveying and setting out which he has to carry out.

Should the Contractor have any objections to this basic survey and the relevant drawings, he shall inform the Project Manager in writing within one (1) week after the submittal of the basic survey data.

3.2. General Survey Requirements.

The Contractor shall perform all surveying calculations and setting out necessary to

establish the accurate location of the position in accordance with the drawings and shall be approved by the Project Manager. Horizontal and vertical control shall be by closed loop traverses.

Maximum permissible errors of closure shall be:

- Horizontal Traverses:

· Angular error = 10 N · Relative error < 1/1000

(N = number of stations)

- Vertical Traverses:

· Elevation difference error = 10 D Km (mm) · D = total shortest distance

All slope distance shall be reduced to level distances.

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3.3. Bench Marks (BM).

3.3.1. The Contractor shall protect, preserve and keep accessible the BM of the basic survey and those provided by himself.

3.3.2. Removal with intent of BM's, including other BM established by other

institutions or companies shall be prevented. Tying a rope for working animal is strictly not permitted. Any damage of BM accidental or other non-surveying purposes shall be immediately brought to the attention of the Project Manager. The Contractor at all times shall be responsible for timely replacement or repair of the damaged BM's. The costs of rebuilding BM's shall be the Contractor's responsibility without additional compensation.

3.3.3. BM's shall be made of mild steel or cast iron encased in an appropriate size of

concrete block as described below:

Plain Concrete

Stone Bedding

Compacted Subgrade90-95% Soil Density

d

e

c

fb

a10

a b c d e f Soft Soil : 100 90 15 20 45 2.5 cm Hard Soil : 70 50 15 15 15 2.5 cm

Cost of BM’s construction shall be the Contractor’s responsibility.

3.3.4. The inscriptions shall be clearly legible and durable. Underground BM's shall be protected by concrete pipes and other acceptable

structures and shall be kept free from water and earth.

3.3.5. Horizontal traverse pegs shall be wood pegs, 50mm x 50mm by 300mm long, firmly driven into the ground, protruding 20mm above the ground surface with nails at the center to mark the point.

3.4. Survey Personnel and Equipment.

The Contractor shall recruit only qualified surveyors, who prior to the engagement in

the project area shall be approved by the Project Manager, and they are directly responsible and bound to supply the Project Manager with any required information on questions relating to the survey. The Contractor shall use a sufficient number of reliable, accurate and certified scientific instruments and shall be approved by the Project Manager.

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4.0. MATERIALS. None. 5.0. CONSTRUCTION REQUIREMENTS. 5.1. Survey Record and Computations. Complete records shall be maintained of all field surveys, neat and orderly. Survey

shall be clearly identified by project, location, dates and names. Bound books shall be used for permanent records.

Separate field records shall be kept for each of the following categories:

- Control traverse and secondary traverses. - BM levels. - Location surveys. - Construction surveys. - Cross-sections.

Coordinates of all BM's, control points, traverse stations, center-line alignments and

points of intersections shall be calculated prior to surveying. Sketches shall be prepared for each BM control point and reference point that shows

distances and azimuths to each reference point. Profile and topographic elevation shots shall be recorded in the field book. All records and computation shall be made a permanent record, maintained in a safe

place. Permanent storage of inactive field records shall be maintained by the Project Manager.

5.2. Verification of Accuracy. All the survey elements, controls and setting out shall be checked by the Project

Manager at irregular intervals during the execution of this project. The Contractor shall give timely assistance to the Project Manager during the field survey verification.

The following computations shall be used in reviewing the original field notes: Traverse angular error e1 = 1' n Traverse linear error e2 = (L² + D²) L = difference between North latitude and South latitude. D = difference between East departures and West departures. e Precision = --------------- Perimeter Any improper survey done by the Contractor shall be corrected and reworked upon

discovery without any extra compensation. The Contractor shall keep all marks and line of sights clear which are required during

the verification. Any control made by the Project Manager shall not relieve the Contractor of his entire responsibility for the minute accuracy of the alignment, elevations, slopes, dimensions and positions of any structure or facilities.

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SPECIFICATION

01400

CONCRETE TEST

1.0 DESCRIPTION OF WORK

This specification shall cover the procedure for making concrete test of all concrete works as indicated in the Drawings. The work shall include but not be limited to the following: - Laboratory tools and equipment needed. - Storage provision. - Mixing platform near storage area. - Non-absorptive moulds with base. - Steel tamping-rod bullet pointed at the bottom, the dimensions shall be 16mm (5/8")

diameter by 600mm (2') long. - Slump cone. - Air content test. - Shovel and hand-scoop. - Boxes for shipping the specimens.

2.0 REFERENCE STANDARDS

2.1. Standar Nasional Indonesia (SNI):

- SNI 03-1972-2008 - Metode Pengujian Slump. - SNI 03-1974-1990 - Metode pengujian kuat tekan beton - SNI 03-2458-1991- Metode pengambilan contoh untuk campuran beton segar. - SNI 03-2492-2002 - Metode pengambilan dan pengujian beton inti - SNI 03-2493-1991- Metode pembuatan dan perawatan benda uji beton di

laboratorium. - SNI 03-3403-1994 - Metode pengujian kuat tekan beton inti pemboran - SNI 03-4810-1998- Metode pembuatan dan perawatan benda uji beton di

lapangan.

2.2. American Society of Testing and Materials (ASTM):

- ASTM C31 - Test Method of Making and Curing Concrete Test Specimens in the Field.

- ASTM C39 - Test Method for Compressive Strength of Cylindrical Concrete Specimens.

- ASTM C42 - Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.

- ASTM C143 - Test Method for Slump of Hydraulic Cement Concrete. - ASTM C172 - Practice of Sampling Freshly Mixed Concrete. - ASTM C192 - Standard Practice for Making and Curing Concrete Test Specimens

in the Laboratory - ASTM C231 - Test Method for Air Content of Freshly Mixed Concrete by the

Pressure Method.

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2.3. American Concrete Institute (ACI):

- ACI 308 - Standard Practice for Curing Concrete.

2.4. Specification 03300 - Cast-in-Place Concrete. 3.0 GENERAL PROCEDURES.

3.1. Concrete samples shall be taken in accordance with ASTM C172 and/or SNI 03-2458-1991 or as specified below.

3.2. The specimens shall be representative of the batch and shall consist of portions from

different points in the batch.

3.3. The specimens shall be taken in three (3) or more regular increments throughout the discharge of the entire batch except at the beginning or end, and placed in a metal container such as a boggie or wheelborrow.

The specimens for compressive test shall be taken for every 30m3 or less of concrete placing.

The rate of discharge of the batch shall be regulated by the rate of revolution of the drum and not by the size of the gate opening. Sampling shall be worked out by passing a receptacle repeatedly through the entire discharge stream or diverting the entire stream into the container. Care shall be observed not to restrict the flow in such a manner not to cause segregation of concrete.

3.4. Sample shall be mixed thoroughly with a shovel to ensure uniformity. The slump test

and the test specimens shall be made immediately. 4.0 MATERIALS. Refer to section 5.0 Construction Requirements of this Specification. 5.0 CONSTRUCTION REQUIREMENTS.

5.1. Content of Chloric Ion. Amount contents of chloric ion in the structural concrete from cement, aggregates,

water and admixtures shall not exceed 0.30kg/m3. Content test of chloric ion shall be performed at a concrete plant and site prior to concrete placing, and the result shall be submitted to the Project Manager for approval.

5.2. Slump Test.

A slump test shall be taken for each set of specimen taken. The method shall conform

to SNI 03-1972-2008 and/or ASTM C143, or as describe below:

- Properly clean and wet the slump-cone. - Fill the slump-cone in three (3) nearly equal layers. - Puddle each layer with twenty five (25) strokes of the tamping-rod. Distribute the

strokes evenly over the cross-section of the slump-cone. - Strike off the top smoothly so the slump-cone is exactly filled. - Clean off all concrete that may have spilled around the base of the cone.

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- Remove the slump-cone from the concrete in approximately five (5) seconds, being careful to raise it in a vertical direction only.

- Measure the slump immediately. This is the difference between the height of the slump-cone and the height of the concrete specimen.

Slump shall not be less than 50mm but not more than 125mm as specified in SNI 03-

1972-2008 or as determined by the Project Manager.

5.3. Molding. The method of molding shall conform to SNI 03-4810-1998 and or ASTM C31

standard. The specimens shall be made as close to the point of delivery as possible. If the material is to be transported a distance from the source, the concrete shall be re-

mixed with a shovel before making the molds. The procedure as follows:

- Place the molds on a heavy base plate, preferably metal. - Fill the mold in three (3) nearly equal layers. - Puddle each layer with twenty five (25) strokes of the tamping rod. Take care not

to dent the bottom of the container in rodding the bottom layer. - Strike off the top smoothly and cover with a glass or metal plate to prevent

evaporation. Never use a piece of wood.

5.4. Laboratory-Cured Specimens

5.4.1. Samples for strength tests shall be taken in accordance with ASTM C172.

5.4.2. Cylinder for strength tests shall be molded and laboratory-cured and tested in accordance with SNI 03-2493-1991and or ASTM C192.

5.5. Handling and Storage

5.5.1. The curing of the specimens shall conform to ACI 308 and ASTM C31.

5.5.2. The first 24 hours after molding are important. The specimens should be

moved only from the place of molding to the storage designated place, taking care to keep them in an upright position and avoiding vibration and jarring. Specimens maybe stored in tightly-constructed, firmly-braced wooden boxes, damp sand pits, or temporary buildings as long as the temperature adjacent to the specimens can be maintained between 15.6C and 26.7C and loss of moisture from the specimens can be prevented.

5.5.3. At the age of one (1) day each set of specimens should be sent/ analyzed to a

recognized laboratory for proper curing and testing. Pack the specimens in a sturdy box for shipment, leaving the specimens in the containers. The space between the specimens and the box should be filled with wet sand or sawdust. Each set of specimens should be accompanied by the data recorded at the time of making the specimens.

5.5.4. If it is impossible to ship the specimens at the age of one (1) day, it should be

stored in thoroughly damp sand at the end of the initial 24 hour period, and shall be maintained in a moist condition at 21C - 24.5C until shipment is made. The specimens shall be shipped as soon as possible and at least several days before the seven (7) days period is up, as the laboratory must have the specimens a day or so before the seven (7) days test.

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5.5.5. The Contractor shall provide a shed and an insulated locked box of sufficient size to store equipment and specimens at the site, and whatever labour is required in the preparation of specimens.

5.6. Testing.

5.6.1. Inspection and testing will be performed by a firm engaged by the Contractor.

Tests of cement and aggregates may be performed to ensure conformance with specified requirements in Specification 03300.

5.6.2. Test for air content each time a set of specimens is prepared for compression

testing. Test shall be in accordance with ASTM C231. 5.6.3. The Contractor shall cooperate with the Testing Laboratory to facilitate their

work. The Contractor shall notify the Testing Laboratory and the Project Manager at least 24 hours in advance of placing concrete for inspection and testing of concrete at the plant and at the field, and for inspection of formwork and reinforcement. The Contractor shall provide a shed and an insulated locked box of sufficient size to store equipment and specimens at the Project site, and whatever labor is required in the preparation of specimens.

5.6.4. The actual making, handling, transporting, and curing of specimens shall be

done by the staff of Testing Laboratory only.

5.6.5. Plant tests and inspections shall include the following minimum requirements:

- Sampling and testing concrete ingredients. - Reviewing and checking Contractor's proposed design mixes. - Inspecting plant and equipment for measuring, mixing and delivering

concrete. - Inspecting batching and mixing operations. - Inspecting concrete mix.

5.6.6. Field tests and inspections shall include the following minimum requirements:

- Checking truck number and/or delivery tickets of plant mixed concrete. - Checking amount of water added to concrete mix, if permitted, in field. - Making samples and test for air-content in concrete. - Making slump tests according to SNI 03-1972-1990 and or ASTM C143. - Making specimens for laboratory testing of compressive strength. - Taking temperatures of as-mixed concrete, of as-deposited concrete, and

of concrete during curing period. - Taking air temperatures during placing and curing of concrete. - Checking concrete placing and curing procedures.

The field test shall be made for each 30m3 or for each arrival of truck.

5.6.7. Laboratory tests and inspection shall include the following minimum requirement:

- Compressive strength tests in accordance with ASTM C39 and or SNI 03-

1974-1990:

· Three (3) pieces of specimens cured at laboratory for seven (7) days strength.

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· Three (3) pieces of specimens cured at laboratory for twenty eight (28) days strength.

· Three (3) pieces of specimens cured at site for seven (7) days strength.

· Three (3) pieces of specimens cured at site for twenty eight (28) days strength.

· Other strength as occasion demands. · Three (3) pieces of specimens cured at laboratory and site for three

(3) days strength and the expected day which the strength have reached specified strength, if hardening acceleration is used.

- Weighing of all specimens.

5.6.8. Core tests of hardened concrete shall be as follows:

- Core test shall be performed in case compressive strength tests of

laboratory are not satisfactory or detection of failure in placed concrete. - The Project Manager reserves the right to direct that samples be cored

from any portion of works for the purpose of examination and testing. The cutting equipment and method of coring shall be approved by the Project Manager. Specimens shall be taken and tested in accordance with SNI 03-2493-1991, SNI 03-3403-1994 and or ASTM C42. The cored portion of the work shall be made good to the satisfaction of the Project Manager.

- The Contractor shall bear the costs for the core tests if they are required because of test specimen failure, or if the core test fails.

5.6.9. If the tests and reports indicate that the placed concrete does not meet the

specified strength, the Project Manager will notify the Contractor in writing. Additional curing as specified by the Project Manager may be required and modifications may be required in the concrete mix design for the remaining concrete work; or the concrete may be required to be removed and replaced; in either case at the expense of the Contractor.

5.7. Environmental Conditions.

Do not pour concrete during rain or when rain is expected unless the work can be

protected from rain and/or flowing surface water.

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SPECIFICATION

01510

TEMPORARY FACILITIES AND CONTROLS

1.0 DESCRIPTION OF WORK This work shall consist of providing, operating and maintaining all temporary facilities and controls to public utilities in locations acceptable to the Owner, Project Manager and local authorities having jurisdiction thereof. This work shall include, but not be limited to the following: - Temporary light and power, - Temporary cooling, ventilation and enclosures, - Temporary water, - Temporary drainage, - Temporary fire fighting services, - Site offices and sheds, - Temporary praying room, - Temporary washroom/toilet, - Temporary domestic waste, - Temporary parking lots, - Temporary fencing, - Environmental controls, - And others as directed by the Project Manager.

2.0 REFERENCE STANDARDS

2.1. Special Terms and Conditions. 2.2. Specification 02200 - Site Preparation Grading

3.0 GENERAL PROCEDURES

3.1. Make all installations in a manner subject to the acceptance of such authorities and the Project Manager.

3.2. Remove temporary connections when no longer required and restore the services and

sources of supply to proper operating conditions. 4.0 MATERIALS

Refer to section 5.0 of this Specification

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5.0 CONSTRUCTION REQUIREMENTS

5.1. General

5.1.1. Provide, operate and maintain all temporary connections to public utilities and services in locations acceptable to the Client, Project Manager and Local Authorities having jurisdiction thereof. Make all installations in a manner subject to the acceptance of such authorities and the Project Manager.

5.1.2. Locate facilities where they shall serve Project adequately and result in

minimum interference with performance of the Work. Relocate and modify facilities as required. Provide each facility ready for use when needed to avoid delay. Maintain and modify as required. Do not remove until facilities are no longer needed or are replaced by authorized use of completed permanent facilities.

5.1.3. All temporary facilities and controls shall be properly calculated and drawn to

avoid overloading of personnel on site in the future.

5.2. Temporary Light and Power

5.2.1. The Contractor shall make arrangement to provide and maintain a temporary electrical supply to the satisfaction of the Project Manager in order to complete the works.

5.2.2. Provide and maintain power distribution as required throughout the works for

plant and power tools of all kinds and for temporary buildings. Termination of power distribution shall be at locations approved by the Project Manager. Termination shall be provided complete with circuit breakers, disconnect switches and other electrical devices as required to protect the power supply system.

5.2.3. Provide and maintain a temporary lighting system as required throughout the

works and to satisfy the minimum requirements of safety and security. Provide adequate lighting to all temporary buildings, out-door lighting to illuminate staging, stockpiles, trenches and others to the satisfaction of the Project Manager, and general illumination throughout, adequate for watchmen and emergency personnel.

5.2.4. Temporary equipment and wiring for power and lighting shall be in accordance

with the applicable provision of the Electrical Works Section and governing codes. Temporary wiring shall be maintained in a safe manner and utilized so as not to constitute a hazard persons or property.

5.2.5. The permanent power and lighting system, or a portion thereof, may be used

provided the Contractor obtains the approval of the Project Manager and assumes full responsibility for the entire power and lighting systems.

5.3. Temporary Cooling, Ventilation and Enclosures

5.3.1. Provide adequate ventilation as required to keep the temperature of the

building within 6C less than the ambient outdoor temperature when such ambient temperature exceeds 30C and to prevent accumulation of excess moisture and to prevent excess thermal movement in the building.

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5.3.2. The permanent air circulation system or a portion thereof may be used provided the Contractor obtains the approval of the Project Manager and assumes full responsibility for the entire circulation system.

5.3.3. Provide temporary watertight enclosures as require during construction to

protect work from damage by sand, wind, heat and sun and as necessary to ensure suitable working conditions for construction operations. Permanent door enclosures shall not be used as temporary enclosures, instead provide temporary batten doors with proper temporary self-closing hardware approved by the Project Manager.

5.3.4. In the event that joinery (or other finishing works which could be damaged by

exposure to high temperatures) forming part of the permanent works are programmed for installation during periods of high ambient outdoor temperatures, the Contractor shall provide temporary controlled cooling in the concerned rooms or spaces, and also provide temporary partitions

5.4. Temporary Water

5.4.1. Provide adequate supply of water for all construction operations, temporary

building requirements and individual storage and pipe net system for fire fighting facilities, and pay all fees and expenses in respect thereof. All water shall be clean, clear, and free of deleterious substances. No brackish water to be used for construction operations. Water outlets shall be conveniently located about the site at ground level for the use of all trades including sub-contractors.

5.4.2. Provide and maintain a network for water distribution to the various outlets

including storage tanks, pumps, and to all necessary water for plumbing installation required for temporary buildings.

5.4.3. Make provisions for drainage or collection of excess or spilled water.

5.4.4. Provide potable water in gallon bottle size for drinking, locally available.

5.5. Temporary Drainage

5.5.1. Upon taking possession of the site, the Contractor shall assume full

responsibility for drainage rain water, ground water and water arising from construction processes, and shall provide and maintain such temporary drainage installations as may be necessary during the period of constructions in a manner approved by the Project Manager and so as not to adversely affect the permanent works or adjacent areas and properties.

5.5.2. The Contractor shall prepare an Erosion/ Sedimentation Control and

Temporary Drainage Plan and submit to the Project Manager for approval. Plan shall show as a minimum all temporary drainage facilities including but not limited to: temporary drains, swales, diversion channels, sedimentation ponds and other sediment control structures.

5.5.3. Temporary drainage installations (storm water and foul water) may be

connected to existing drains provided written permission is obtained from the local authorities having jurisdiction thereof, and provided such connection work is executed and maintained in strict accordance with those authorities’ regulations and directions.

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5.6. Temporary Fire Fighting Services 5.6.1. Ensure that no fires are lit in or about the site and take all reasonable

precautions to avoid out-breaks of fire on the works, temporary works, offices, stores and other places and things connected therewith, especially with respect to the safe storage of petroleum products, paints, explosives and other combustible, dangerous or hazardous goods. Comply with all rules regulations and orders made by any local authorities having jurisdiction and provide and maintain in good order and hold available at all times and in all places connected with the works a sufficiently of efficient fire fighting facilities and equipment together with personnel trained in its use.

5.6.2. The type, location and sufficiency of the fire fighting facilities and equipment

shall be to the Project Manager's satisfaction. Such facilities/equipment shall include, but not be limited to the following:

- A temporary fire water tank which shall be of a non-corrosive material. - Temporary fire pumps which shall be provided in duplicate and shall be

automatically controlled by pressure switches. Capacity of pumps shall be to satisfy fire department requirements.

- Provide one 4.5kg dry powder fire extinguisher adjacent to each hose station, each individual office compartment and at any other location requested by the Project Manager.

5.7. Site Office and Sheds

5.7.1. Project Manager’s Site Office Accommodation

Provide and maintain, throughout the period of construction, weather-proof and good/healthy air ventilating accommodation for the use of the Project Manager and other representatives of the Owner, to the following requirements:

- Minimum floor space of 12m², - Provide two (2) desks with minimum dimensions 600 x 1200mm, two (2)

office chairs and one (1) three-drawer lockable filing cabinet of metal construction, one (1) electric fan.

- Provide access to computer equipment including printers and accessories. - Telephone and facsimile lines where available, - Provide toilet facilities and supply of fresh drinking water.

5.7.2. Contractor’s Site Office

Provide and maintain throughout the period of Construction adequate good/healthy air ventilating office accommodation for the Contractor’s use and of the sub-contractors. This shall include the provision of a fully furnished meeting room to provide seating for a minimum of 10 persons around a meeting table.

5.7.3. Contractor’s Site Stores

- Provide adequate enclosed and lockable storage facilities on site for

temporary storage of such plant and materials as are required for the timely execution of the permanent works, including the plant and materials of sub-contractors. Provide stores with floor raised off the ground and provide air-conditioned spaces for any materials that require regulated temperature storage.

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- If space in or about the site is insufficient to maintain such adequate storage the Contractor shall make arrangements to erect off-site stores or rent warehousing space elsewhere. The location of such stores/warehousing and its suitability shall be subject to the Project Manager’s approval and in all cases the Contractor shall obtain all necessary permits required by local and governmental authorities having jurisdiction, and shall submit to the Project Manager all the necessary related documents as required. The Contractor also has to confirm in writing that the same is considered a part of the job site and bind with all the related conditions of Contract, and shall pay all fees, rental, charges, insurance premiums, transport costs, loading, unloading and double handling charges, utility charges, protection and security costs and others as may be levied or as may become due to respect of such off-site storage facility.

5.7.4. Janitorial Services

Provide janitorial services on a daily basis for site office and sheds, first-aid stations, washroom/toilets and similar areas.

5.8. Temporary Praying Room

Provide and maintain throughout the period of construction adequate good/healthy air ventilating temporary praying room. This shall include the provision of a fully furnished floor to provide a minimum of 10 persons praying.

5.9. Temporary Washroom/Toilet

5.9.1. Provide and maintain sanitary facilities for persons on the job site; comply with

the regulations of State and local departments of health.

5.9.2. Enforce the use of sanitary facilities by construction personnel at the job site. Such facilities shall be enclosed. Pit-type toilets will not be permitted.

5.9.3. Locate toilets near the Work site and secluded from view insofar as possible.

Keep toilets clean and supplied throughout the course of the Work.

5.10. Temporary Domestic Waste

Temporary domestic waste shall use a prefabricated sewage treatment unit consisting of the following: - Treatment tank (body and cover) made of fiberglass reinforced plastic (FRP) in

size according to the Drawings. - Chambers for anaerobic. - BioCell made of high density polyethylene (HDPE), consisting of L and M type. - Filter. - Transfer hole and exhaust pipe. - Manhole cover made of cast iron. - Pipes for inflow and outflow.

such BT Series Biotech from PT Fibertech Internusa or equal.

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5.11. Temporary Parking Lots

Designate temporary parking areas to accommodate construction personnel. When site space is not adequate, provide additional off-site parking. Locate as approved by Project Manager.

5.12. Temporary Fencing

5.12.1. Provide and maintain a 240cm high (unless otherwise directed by the Project

Manager) closed-type temporary fence made of corrugated hot-dip galvanized steel sheet installed horizontally around the perimeter of the site to effectively secure and close in the designated site area (s). Provide at access points gates of substantial construction, cross-braced, hung on heavy strap hinges and lockable with suitable padlock. Submit Shop Drawings for the fencing and gates for review and approval of the Project Manager.

5.12.2. Prime and paint the fence and gate with two coats of suitable paint in blue and

white colour or as directed by the Project Manager. 5.12.3. Adapt and re-position fencing and gates as necessary during the construction

period to suit the conditions of the work and remove on completion or as directed by the Project Manager.

5.13. Environmental Controls

5.13.1. Provide and maintain methods, equipment, and temporary construction as

necessary for controls over environmental conditions at the construction site and adjacent areas.

5.13.2. At all times, measures shall be taken to prevent oil or other hazardous

substances from entering the ground, drainage areas, and local bodies of water.

5.13.3. The Contractor shall transport all waste off the site and dispose of it in a

manner that complies with local requirements. The Contractor shall secure a permit or license prior to transporting any materials off the site. Burning of rubbish, debris or waste materials is not permitted.

5.14. Removal

At the completion of the works, or at such times as the Project Manager may direct, remove all temporary utilities installations and equipment and replace all worn or damaged parts of the permanent systems, leaving such systems in first-class conditions equal.

DIVISION 2 SITE CONSTRUCTION

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SITE PREPARATION AND GRADING 1.0. DESCRIPTION OF WORK. This work shall include but not be limited to the following:

- The Contractor shall furnish adequate equipment, accessories and enough manpower. - Subgrade preparations, road pavement, open ditch, culvert, utility lines and others as

shown in the Drawings. - Clearing, grading, sloping, compaction of ground surface, spreading and compaction of

sand layer and/or sand gravel according to the Drawings. 2.0. REFERENCE STANDARDS. 2.1. American Association of State Highway and Transportation Officials (AASHTO). 2.2. American Society for Testing and Materials (ASTM). 2.3. All applicable local rules and codes, the highest or most stringent value to apply. 2.4. Specification 02315 - Excavation, Backfilling and Compaction. 3.0. GENERAL PROCEDURES. 3.1. General. 3.1.1. The Contractor shall submit samples of materials for all of the works to the

Project Manager for testing and approval. The Contractor shall also submit Shop Drawings as requested by the Project

Manager. 3.1.2. The Contractor shall strictly study and follow all the details/sections, elevation,

profiles, dimensions and alignments shown in Drawings. Should the Contractor have any absolute doubt of the dimensions which may not be readable, the Project Manager must be consulted prior to execution of the work. Any errors or omissions done by the Contractor shall be his own responsibility and such due negligence shall be paid under his own account and will not be reimbursed to the Owner.

3.1.3. The Contractor shall advise the Project Manager in writing duly signed by his

authorized/designated representative, where and when to start any portion of the work and this must be approved by the Project Manager.

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3.1.4. The Contractor shall submit to the Project Manager, his work schedule every two (2) weeks and which includes the following:

- equipment list, - manpower list, - volume to be accomplished.

Such schedule shall be approved by the Project Manager, before any work will

be started. 3.1.5. The Contractor shall not be permitted to transfer any equipment or manpower

assigned to the portion of work which was mentioned in the work schedule already approved unless otherwise reconsideration is made prior to the shifting and approved by the Project Manager.

3.1.6. The Contractor shall obtain all government permits and other requirements for

such operation. Delay of work due to untimely acquisition of the permits from government

authorities shall not be considered for requested extension of the time to complete work as stipulated in the contract.

3.1.7. During bad weather and/or occurrence of rain or if the ground to be worked on

is wet, the Contractor shall not be permitted to operate unless otherwise determined by the Project Manager.

3.1.8. Night shift operation will not be permitted, unless approved by the Project

Manager. 3.2. Inspection and Testing.

3.2.1. Standby survey team must be on site during the course of the operation. 3.2.2. Testing shall be conducted with following steps:

- before work starts, - before work stops daily.

3.2.3. All equipment and survey instruments that shall be used in this particular job

must be inspected and tested before permitted to work. 3.3. Clearing and Grubbing.

The area above natural ground shall be cleared of all vegetable growth, such as trees, logs, upturned stumps, roots of downed trees, brush, grass, weeds and all other objectionable material, within the limits designated in the Drawings or as directed by the Project Manager.

Within the limits of clearing, the areas below natural ground surface shall be grubbed to a depth necessary to remove all stumps, large roots, buried logs and other objectionable material.

3.4. Stripping and Stockpiling Topsoil.

Topsoil shall consist of organic soils reasonably free of admixtures of subsoil, refuse, stumps, roots, rocks, brush, weeds or vegetable growth.

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Stripping of topsoil shall comprise the excavation of suitable material from the natural ground cover on those portions of the site designated on the plans or as directed by the Project Manager.

Topsoil shall be segregated and stockpiled in designated locations for subsequent use in landscaping and/or reclamation.

4.0. MATERIALS. Refer to section 5.0 Construction Requirements of this Specification. 5.0. CONSTRUCTION REQUIREMENTS.

5.1. General.

5.1.1. Finished levels of embankments that are finished sub-grade levels shall not be more than 100mm higher nor 100mm lower than the required grade and shall allow free run-off surface water.

Side slopes shall be neatly trimmed to the lines and inclinations shown in the Drawings.

5.1.2. The Contractor shall be responsible for the stability of all embankments and

replace any portions that have been damaged or displaced due to carelessness or neglect on the part of Contractor or to such natural causes as storms.

5.1.3. All unnecessary structures such as trees, drains, culverts and temporary

structures not specified to remain in place shall be demolished and removed to a depth of 900mm below the finished grade and the holes shall be backfilled and tamped immediately.

5.1.4. All construction materials shall not be stored in the prepared site until the

grading and site preparation works are completely turned over and accepted by the Project Manager.

5.1.5. Prior to site preparation and grading, all top soil, clearing and grubbing shall

have been done and accepted by the Project Manager.

5.1.6. Equipment used for site preparation and grading shall be approved tools, road graders or compactors suitable for such soil condition of the site.

5.1.7. Any complete portion of the work area found to be unstable or below grade

and not acceptable shall be repaired and re-graded by the Contractor with no additional compensation.

5.1.8. All bench marks designated in place shall stay and must never be altered in

any manner.

5.1.9. After the work is completed, all stakes or vertical controls destroyed or damaged shall be re-established to the points chosen by the Project Manager.

5.1.10. During the final grading, only expert grader operators shall be allowed to

conduct the operation in order to maintain the requirements of this specification, except on areas to be done by hand tamping.

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5.1.11. At the end the day's work, all holes must be sealed or filled and areas composed of loose soil fragment must be leveled off and compacted.

5.1.12. Any excavation, backfilling or compacting needed in this work shall be carried

out in accordance with the requirements of Specification 02315.

5.2. Clearing and Grubbing.

The limits of clearing and grubbing shall be as defined and shown in the Drawings or as directed by the Project Manager. Generally clearing and grubbing shall be in all the construction areas of buildings, structures, roadways, embankments, material sites located on the Site, areas through which ditches and channels are to be excavated and such other areas as may be specified. Clearing and grubbing shall be performed in advance of grading operations.

5.3. Stripping and Stockpiling of Topsoil.

5.3.1. The Contractor shall remove topsoil and unsatisfactory surface material from

portions of construction area where existing grades will be changed, to a minimum depth of 300mm or to greater depths as directed by the Project Manager.

5.3.2. The Contractor shall excavate soft spots encountered during stripping unless

these spots occur in areas where deeper excavation will be required later for construction.

5.3.3. Topsoil shall be segregated and stockpiled for subsequent use in landscaping

and/or reclamation.

5.3.4. Stripping will be required at the locations where swamplands exist. They shall be stripped to the bottom of the organic soil and rootmat as directed by the Project Manager.

5.3.5. Topsoil to be reused shall be classified and stockpiled by type at slopes no

greater than 3 : 1 at designated locations in such a manner which will facilitate the measurement of volume.

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02230

SITE CLEARING 1.0. DESCRIPTION OF WORK. This work shall consist of all necessary topsoil stripping and stockpiling in accordance with the

location, height and spacing as determined by the Project Manager. It includes but is not limited to the following:

- Furnishing of all the required equipment and accessories. - Supply of the experienced operators, skilled workers and labourers and Project Manager of

an adequate background in earthworks. - Loading, hauling and dumping of the stockpiled soil to places designated by the Project

Manager. 2.0. REFERENCE STANDARDS. Any applicable standards and codes, the most stringent values to apply. 3.0. GENERAL PROCEDURES. 3.1. Topsoil shall consist of organic soils reasonably free of admixture of subsoil, refuse,

stumps, roots, rocks, brush, weeds or vegetative growth. Stripping of topsoil shall comprise the excavation of suitable material from the natural

ground cover on those portions of the site designated on the plans or as directed by the Project Manager.

Topsoil shall be segregated and stockpiled in designated locations for subsequent use in landscaping and/or reclamation.

3.2. The Project Manager shall establish the points for all the areas intended to be worked

on, and the Contractor shall place his reference stakes from these permanent points. 3.3. After the stake out, the actual area shall be estimated together with the Project

Manager and Contractor and shall be issued by the Project Manager for execution. However, the issuance of such calculation will not relieve the Contractor's respon-sibility of any errors and omissions.

3.4. The Contractor shall plan and locate the stockpile at every 50meters distance on

centers and such shall be placed at the road side for easy hauling. 3.5. All the excavated materials to be disposed shall be transported to the areas

designated by the Project Manager. 3.6. The Contractor shall allow 50 to 70mm depth of soil to remain uncut as the Project

Manager may direct for the purpose of compaction and the balance shall be totally or evenly cut as shown on drawings. Any excess in cutting shall be repaired.

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3.7. Where particular locations of low depression occur as considered by the Project Manager, these shall be filled from the excavated soil and compacted to the necessary maximum soil density requirements.

4.0. MATERIALS. Not applicable. 5.0. CONSTRUCTION REQUIREMENTS. 5.1. Top soil stripping depths shall be 200mm, unless otherwise specified by the Project

Manager. Minimum stripping distance shall be 50meters radius or as determined by the Project Manager.

5.2. No objectionable materials such as branches or roots and boulders or stones shall be

mixed in the stockpile. If there are any unsuitable materials, these must be segregated and disposed of at the site designated by the Project Manager.

5.3. Good and functional temporary drainage system shall be provided around the

stockpile area. 5.4. Only light weight dozer or motor scraper shall be applied in the stripping operation.

Substitution of equipment shall be allowable as approved by the Project Manager. 5.5. Prior to knock-off time, all holes and loose earth shall be filled or sealed, pulverized

and leveled off to the ground elevation. Temporary grading and drainage necessary to keep the work area free of ponding water shall be constructed and maintained by the Contractor.

5.6. Topsoil storage piles shall be provided with erosion control and shall be seeded as

directed by the Project Manager.

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SPECIFICATION

02315

EXCAVATION, BACKFILLING AND COMPACTION 1.0 DESCRIPTION OF WORK. This work shall include, but not be limited to the following:

- Furnishing adequate equipment and tools, materials, enough manpower to finish all the work including temporary retaining wall and cofferdam, if required.

- Excavation, backfilling and compaction all the works that require excavation and/or backfilling such as foundation, ditches, culverts, utility lines and others as shown in the Drawings.

- Removing all unsuitable backfill material to disposal place as determined. - Excavation and hauling backfill material from an excavation place. - To complete the work as required in this Specification.

2.0 REFERENCE STANDARDS.

2.1. American Association of State Highway and Transportation Officials (AASHTO).

2.2. American Society for Testing and Materials (ASTM).

2.3. Any applicable local codes and standards, the highest or most stringent to apply. 3.0 GENERAL PROCEDURES.

3.1. Excavation.

3.1.1. Excavation shall be done in accordance with the lines and depth indicated on the plans or as established by the Project Manager. The width of excavation shall be made wide enough to give easy movement in doing the work.

3.1.2. Elevation as shown in the Drawings is approximate only and the Project Manager

can instruct any change if necessary.

3.1.3. After each excavation is completed, the Contractor shall notify the Project Manager to that effect, and no follow up operation shall be executed until the Project Manager has approved the depth of excavation and the soil layer character of the excavation bottom.

3.1.4. All hard layers or other hard surfaces to be excavated shall be free from loose

materials, clean and to be cut horizontally or incline according to the Drawings or as directed by the Project Manager prior to compacting backfill material.

3.1.5. Where unsuitable material is exposed at the elevations of planned excavation, the

Contractor will be required to perform additional excavation, as directed by the Project Manager, to depths where suitable bearing is reached.

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3.1.6. For soft layers, final surface of the excavation shall not be finalized before the next work is ready to be done, so that the rain water or other surface water cannot damage the excavation surface.

To excavate the soft soil, Contractor shall install temporary retaining wall to avoid the soil falling into the excavation hole.

Contractor shall protect the excavation hole from water or rain water by providing temporary drain or pump.

3.1.7. Materials excavated below required elevations, through Contractor error or

carelessness shall be corrected as directed by the Project Manager at no cost to the Owner.

It is assumed that materials at the job site can be excavated with normal equipment such as power shovel or bulldozer.

If rock is encountered, the Contractor shall notify the Project Manager who will render a decision before further excavation can be proceeded.

After the end of each excavation, the Contractor shall notify the Project Manager, and the work can be proceeded after the Project Manager approve the depth and the type of the soil layer at the bottom of the excavation.

3.2. Backfilling and Embankment.

3.2.1. Backfilling and embankment can only be started when backfill material and

location of the work have been approved by the Project Manager.

3.2.2. Contractor shall not proceed the backfilling work before the Project Manager approves the former work.

3.2.3. Excavated material suitable for use as backfill and embankment material may be

deposited by the Contractor in storage piles at points convenient for re-handling of the material during the backfilling and embankment operations. The location of storage piles shall however, be subject to the approval of the Project Manager.

3.2.4. Backfilling of concrete work shall only be carried out when the age of the concrete

work is 14 days minimum, and when the masonry work is 7 days minimum, or after the approval from the Project Manager.

3.3. Compaction.

The Contractor shall furnish satisfactory power-operated or power driven hand operated

compactor wherever possible to compact fill, as well as cut areas. For the compaction of cohesive soils, self-propelled tamping rollers or towed sheep foot rollers shall be used. Smooth steel wheel vibratory rollers shall be used to compact granular fill materials. Compaction by flooding or jetting shall not be permitted.

If the fill or degree of compaction is unsatisfactory, necessary adjustment shall be made until the appropriate compaction requirements are met. Material placed over layers not satisfactorily compacted shall be removed and unsatisfactory areas re-compacted as directed by the Project Manager.

4.0 MATERIALS. Refer to section 5.0 Construction Requirements of this Specification.

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5.0 CONSTRUCTION REQUIREMENTS.

5.1. Excavations.

5.1.1. Excavation work is final when the bottom of the excavation has reached the required elevation as shown in the Drawings or has been approved by the Project Manager.

5.1.2. All excavated material shall be deposited at designated place as determined by the

Project Manager so when needed and suitable that excavated material can be used for backfilling or shall be disposed as determined by the Project Manager.

5.1.3. Over excavated outside the required lines and grades as shown in the Drawings or

as directed by the Project Manager through Contractor error or carelessness, the over-excavated material can not be paid and the Contractor shall correct the work according to the Drawings at his expense.

5.1.4. Excavation shall be carried out in a manner as not to damage the benchmark or

other finished works. All damages caused by this work shall be the Contractor's responsibility and shall be corrected by the Contractor without any additional cost and time.

5.1.5. The Contractor shall remove any rock encountered in areas of final elevation to a

depth of at least 150mm below the planned final elevation. Rock shall be defined as stone or hard shale in its original ledge, and boulders over half cubic meter in volume or over one meter in greatest dimension, which will require removal by special equipment and/or explosives.

5.2. Backfilling and Embankment.

5.2.1. Backfill Material.

- The approved material used in backfilling shall be free of any appreciable

amount of gravel or stone particles more than 100mm in greatest dimension and of such gradation as to permit thorough compaction.

- Soil and cement mix that is compacted at site is used to gain a better soil layer than the original one. Minimum cement content that is required to gain enough shear strength is 4 % (approximately 1 cement bag of 50 kg for 1 m3 soil). 1kg/cm2 of minimum cohesion value, 18 degree of minimum friction angle and 40 kg/cm2 of minimum end bearing DCPT shall be achieved for soil cement mix. Therefore, trial mix shall be carried out to ensure the required condition can be complied.

- When, in the opinion of the Project Manager, such material is not readily available, the use of rock or gravel mixed with earth will be permitted, in which case no particles larger than 150mm in greatest dimension and 50mm in least dimension may be used, and the percentage of fines shall be sufficient to fill any void and ensure a uniform and thoroughly compacted mass of proper density.

- All excavated material except earth shall not be used as backfill material except approved by the Project Manager as mentioned in point 5.1.2 of this Specification.

- Backfill material that is deposited near the working place for more than 12 hours shall be protected with polyethylene sheet so as not to damage the material which has been approved by the Project Manager.

- Each layer of backfill material, if dry, shall be wetted uniformly to the moisture content required to obtain the specified density.

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5.2.2. Preparation. Prior to placing of backfill material, the following works shall have been carried out

in advance:

- Clearing the location and/or excavating in accordance with the Drawings or as directed by the Project Manager.

- The Contractor shall notify the Project Manager prior to placing of backfill material and the Project Manager will examine the condition of the location that is being prepared for the purpose.

- Location that is being covered by backfill/embankment material shall be dried from surface water by using pump or other equipment approved by the Project Manager.

5.2.3. Placing of Backfill Material.

- Backfill material shall not be spread out or compacted when the rain comes. - Backfill within or not within embankment area shall be placed layer by layer

with maximum thickness of 200mm (loose measurement) and shall be compacted.

- Backfill not within the embankment area shall be compacted to a density comparable with the adjacent, undisturbed material or as stipulated in section 5.3. of this Specification.

- Backfill within embankment areas shall be compacted in accordance with density as stipulated in section 5.3 of this Specification.

Unless otherwise provided by the plans or special provisions, hand tamping will not be accepted as an alternate for mechanical compaction.

- The Contractor shall not place new layer of backfill material until the former layer has been approved by the Project Manager.

- No backfilling shall be done without the approval of the Project Manager.

5.3. Compaction.

5.3.1. General.

- When necessary, each layer before being compacted shall be processed as required to bring the moisture content sufficiently close to optimum to make possible its compaction to the required density. The material shall have uniform moisture content through the entire layer of material to be compacted.

Each layer of material shall be compacted uniformly by use of pneumatic tire rollers, grid rollers, three-wheeled power rollers, vibratory, sheep foot or tamping rollers or other approved type compactors.

- The rolling shall be done in a longitudinal direction along the embankment and shall generally begin at the outer edges and progress towards the center in such a manner that each section receives equal compaction effort.

- At least one roller shall be operated continuously for each 600m3, or fraction thereof, of material placed per hour. When several small embankments, each of small area, are so isolated from each other that one roller cannot compact them satisfactorily, additional rollers shall be provided.

- Hauling equipment shall be operated over the full width of each layer insofar as practicable.

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5.3.2. Maximum Dry Density and Optimum Moisture Content. Maximum dry density and optimum moisture content of soils shall be determined

by one of the methods described in ASTM D1557 (AASHTO T180) commonly known as the Modified Proctor Test.

5.3.3. Moisture Control.

At the time of compacting areas where high density is required, fill material and the

surface on which it is placed shall be within the specified range of moisture content. The Contractor shall not compact fill until it is within the range required for moisture content. He shall add an accurately determined and carefully measured amount of water to materials or surfaces that are too dry.

He shall pile or spread out to dry, material which is too wet, and if necessary, disk, harrow or pulverize it by hand or mechanical means.

5.3.4. Proofrolling.

- The Contractor shall proofroll stripped and cut areas under Project Manager's

direction, to determine if soft spots exist in the area. He shall use a loaded dump truck, compaction roller, or similar approved compacting equipment. The type, size and weight of the equipment to be used shall be as directed by the Project Manager.

- The Contractor shall place and compact fill material in low spots. If wet or spongy areas are revealed, he shall notify the Project Manager so that corrective measures may be determined. Areas that support structures shall be inspected during proofrolling and approved by the Project Manager before further earthwork operations are performed.

5.3.5. Density for Cohesive Soils.

For soil having 30% or more, by weight, of particles passing a No. 200 sieve,

required relative compaction, as determined by one of the method described in ASTM D1557 (AASHTO T180), and expressed as a percentage of maximum dry density, and moisture content, at the time of compaction shall be as follows :

Fill Areas

Relative Compaction (%)

Moisture Range (%)*

General Fill

90

-3 Wo +3

Main Roads and Heavy Vehicle Parking (Top Meter)

95

-4 Wo +2 Connecting Roads and Light Vehicle Parking (Top Half Meter)

95

-4 Wo +3 Production Module, Power Plant, Warehouse and Workshop Floors (Top Half Meter)

95

-4 Wo +2 Trench Backfill (Except where superseded by higher compaction requirement)

90

-3 Wo +3 *Wo = Optimum Moisture Content.

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5.3.6. Density for Cohesionless Soils. Soil having less than 30% by weight, of particles passing a No. 200 sieve, required

relative compaction as determined by one of the methods described in ASTM D1557 (AASHTO T180), and expressed as a percentage of maximum dry density as follows:

Fill Areas Relative Compaction (%) Drainage blanket beneath embankment

No requirement. Compact with light buldozer (eg. D-6) traffic

Cushion fill beneath floor slabs

95 May be inspected by proofroling, at Project Manager’s option

Road base

95

Trench backfill

92

Trench or chimney drains

No requirement

5.4. Disposal of Excavation Material. All suitable excavated material as approved by the Project Manager shall be used for

backfill. Material that is not needed or not suitable for backfill shall be disposed off at designated areas.

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SPECIFICATION

02330

EMBANKMENT 1.0 DESCRIPTION OF WORK This work shall consist of the construction of embankment including safety bern by placing and

compacting all borrow materials of acceptable quality obtained from the site and access road preparation excavation in accordance with these Specifications and to the lines, grades and cross-sections shown in the Drawings and as directed by the Project Manager.

2.0 REFERENCE STANDARDS

2.1. American Association of State Highway and Transportation Officials (AASHTO).

2.2. American Society for Testing and Materials (ASTM).

2.3. Any applicable local codes and standards, the highest or most stringent values to apply.

2.4. Specifications:

- 02200 - Site Preparation and Grading. - 02315 - Excavation, Backfilling and Compaction.

3.0 GENERAL PROCEDURES

3.1. General

3.1.1. A report describing the soil conditions encountered during investigation of the site may be inspected at the office of the Project Manager. The accuracy of this report cannot be guaranteed as present conditions since those found in other locations of the site may vary from those discussed. The Contractor shall be fully responsible for all on-site soil conditions whether or not furnished in above-mentioned report.

3.1.2. Stripping, cutting, proof rolling, filling and compacting procedures shall be

approved by the Project Manager. Any work found unsatisfactory shall be corrected in a manner approved by the Project Manager at no additional cost to the Owner.

3.2. Embankment

Embankments and/or fill areas shall be constructed using only the material obtained

from stockpiles of cut material which is approved by the Project Manager. The material shall be free of debris, organic material, rocks over 150mm in maximum dimension and excessive moisture or dryness.

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3.3. Compaction. The Contractor shall furnish satisfactory power-operated or power driven hand

operated compactor wherever possible to compact fill, as well as cut areas. For the compaction of cohesive soils, self-propelled tamping rollers or towed sheeps foot rollers shall be used. Smooth steel wheel vibratory rollers shall be used to compact granular fill materials. Compaction by flooding or jetting shall not be permitted.

3.4. Inspection.

3.4.1. All materials and each part or detail of the work shall be subject to inspection

by the Project Manager. The Project Manager shall be provided with access to all parts of the work and

shall be furnished with such information and assistance by the Contractor as is required to make a complete and detailed inspection.

3.4.2. Earth-work and compaction shall be suspended within the particular area

during field density testing as required by the Project Manager.

3.4.3. The Project Manager may direct the Contractor to remove or uncover portions of the work. After examination, the Contractor shall restore said portions of the work to the standard requirements of this Specification.

3.4.4. The Contractor shall not proceed to execute the work until the lines, grades

and/or structure locations have been established. Any work done by the Contractor contrary to the Drawings, Specifications or instructions of the Project Manager, or any extra work done without authorization of the Project Manager, may be ordered to be removed or replaced at the Contractor's expense.

4.0 MATERIALS. Materials for embankment and/or backfills shall consists of suitable material approved by the

Project Manager and shall contain no muck, roots, sod or other deleterious material, as specified in Specification 02315.

5.0 CONSTRUCTION REQUIREMENTS.

5.1. General. The Contractor shall proof roll to the required soil density those areas that have been

stripped, prior to placing fill material. He shall remove undesirable material and replace it with approved material. Fill material shall be deposited in horizontal layers to a maximum loose depth of 200mm and each layer shall be properly compacted. The Project Manager may alter maximum depth of the layer if, because of equipment, material, or other conditions, he deems it necessary to assure the required degree of compaction. All fill shall be placed in level lifts. Where fill is to be placed over a sloping subgrade, the subgrade shall be benched so a sloping subgrade or fill interface is avoided.

Fill surfaces shall be sloped to drain at all times. Grades shall slope away from fill crests to minimize fill face erosion.

The subgrade or fill interface net inclination shall be 1.5 (horizontal) to 1 (vertical) or flatter.

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5.2. Preparation of Foundation for Embankment.

5.2.1. Prior to placing any embankment to any area, all clearing and grubbing operations shall have been completed in accordance with Specification 02200.

All sod, grass, and decayed vegetable matter shall be removed from the upper portion of the ground surface, and the top 150mm shall be compacted to 90% of the maximum dry density determined by AASHTO Method T180 (ASTM D1557-90).

5.2.2. When embankments are to be constructed on hillsides or slopes, the existing

slopes other than rock shall be loosened by scarifying or plowing to a depth of not less than 100mm to ensure a good bond between the embankment and the existing embankment foundation.

The material which has been loosened shall be recommended simultaneously with the first layer of embankment material placed.

5.2.3. Where existing embankments are to be widened or included in new

embankment, the slopes of the existing embankment shall be plowed or scarified to a depth of not less than 100mm, or when this is impracticable, steps in horizontal and vertical faces shall be cut in the existing slope to a depth not more than 200mm and the embankment built up in successive layers, as hereinafter specified, to the level of the old foundation bed before its height is increased.

5.2.4. Unless otherwise shown in the plans, where existing subgrades are to be

covered with less than 300mm of fill, the top of the old subgrade shall be scarified and re-compacted with the next layer of the new embankment. The total depth of the scarified and added material shall not exceed the permissible depth of layer, compact to at least 95% of the maximum dry density as determined by AASHTO T180 (ASTM D1557-90).

5.3. Placing Embankment.

5.3.1. General.

Unless otherwise specified, all embankments shall be constructed in layers

approximately parallel to the finished grade of subgrade or roadbed. During construction of embankment, a smooth grade having an adequate crown shall be maintained at all times to provide drainage. Embankments shall be constructed in accordance with grades and the general shape of typical sections shown in the Drawings. After completion of the embankment, it shall be continuously maintained to its finished section and grade until the project is accepted.

5.3.2. Earth Embankments.

Earth embankments shall be defined as those composed principally of

material other than rock, and shall be constructed of accepted material from designated or approved sources.

Except as specified for embankment in swamps, earth embankment shall be constructed in successive layers, for the full width of the cross section and in such length as are suited to the sprinkling and compaction methods utilized.

Prior to compaction, the layers shall not exceed 150mm where pneumatic tire rolling is to be used and shall not exceed 200mm in depth for rolling with other approved types of rollers.

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5.3.3. Placing Over Ground with Shallow Groundwater. Embankments in rice fields, or where water is present shall be constructed as

indicated in the Drawings and/or as specified herein.

5.3.4. Fill Adjacent to Culverts. Embankments adjacent to culverts which cannot be compacted by using of the

blading and rolling equipment used in compacting the adjoining sections of embankment, shall be compacted in the manner prescribed under Specification 02315.

Material placed adjacent to any portion of any structure and in the first two layers above the top of any culvert or similar structures, shall be material free of any appreciable amount of gravel or stone particles more than 100mm in greatest dimension and of such gradation as to permit thorough compaction.

5.4. Compaction.

Compaction shall be done to a density comparable with adjacent, undisturbed material

or as stipulated in Specification 02315. If the fill or degree of compaction is unsatisfactory, necessary adjustment shall be

made until the appropriate compaction requirements are met. Material placed over layers not satisfactorily compacted shall be removed and unsatisfactory areas re-compacted as directed by the Project Manager.

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SPECIFICATION

02335

SUBGRADE PREPARATION 1.0 DESCRIPTION OF WORK. This work shall cover support of the gravel and sand base course. It shall extend to the entire

area including walkways, roads, park areas or aprons as shown in the Drawings. 2.0 REFERENCE STANDARDS. 2.1. American Association of State Highway and Transportation Officials (AASHTO). 2.2. All applicable local standards, regulation and codes, the most stringent values to

apply. 3.0 GENERAL PROCEDURES. 3.1. Protection of completed work as described in the Drawings. 3.2. Prepared subgrade shall be protected against drying out and cracking. Any damage

resulting from the negligence thereof shall be repaired at Contractor's own expense. 4.0 MATERIALS. Refer to Section 5.0 of this Specification. 5.0 CONSTRUCTION REQUIREMENTS.

5.1. General. The areas covered by the subgrade shall be carefully cleaned so that no objectionable

material is incorporated in the next item to be worked out. The subgrade shall be made to conform to the prescribed lines, grades and slopes,

and compacted to 90% - 95% proctor density at the Project Manager's satisfaction so that base or bedding material, when placed and compacted will give the same formation of the grades and lines of the subgrade.

All materials to a depth of 150mm below the subgrade level in cut and to a depth of 300mm in embankment shall be fully compacted to at least 90% - 95% of the dry density requirements of AASHTO T99 with minimum CBR value as noted in the Drawings.

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5.2. Subgrade in Earth Cut. When the subgrade is in earth cut, it shall be formed to the correct traverse and

longitudinal profiles. The soil shall be compacted with approved tamping rollers. Prior to compaction, the

soil moisture content shall be adjusted by wetting with approved sprinkler trucks or by drying out, as may be required, in order to attain the desired degree of compaction.

If soil property is such as to make it impossible to obtain the minimum CBR required by the project, the unsuitable soil shall be removed upon written notice from the Project Manager.

The removal and disposal of unsuitable soil in earth cuts shall be classified as common excavation. At the subgrade level, the Contractor shall fill the holes caused from removal of stumps, roots and boulders with suitable and approved fill material. Such work shall be covered by the contract price and shall not be chargeable to the Owner.

5.3. Subgrade in Fill/Embankment.

When a subgrade shall fall on fill areas, the following procedures must be strictly

observed:

- Prior to filling, the area shall be compacted and rolled in accordance with the requirements and/or satisfaction of the Project Manager.

- The approved backfill material shall be spread evenly to a maximum thickness of 300mm per layer with a road grader and rolled continuously. The required travel rate of the road roller will be at 5km/hr and this speed shall be maintained throughout until completed. During compaction or rolling, the desired soil moisture content must be carefully controlled. The passes shall be six (6) times minimum to eight (8) times maximum and/or as determined by the Project Manager.

- Compaction or rolling operation will proceed with the same procedure above and until the backfilling work is satisfactorily completed and accepted by the Project Manager.

5.4. Subgrade in Rock Cut.

If the subgrade falls on rock cut, the rock shall be neatly excavated to the correct

traverse and longitudinal profiles. The Contractor shall remove all loose materials and bring the grade up to the correct level by addition of approved granular fill material compacted and shaped to requirements as shown in the Drawings. No rock cut shall project above the grade level. There shall be no extra payment for excavation below the correct grade elevation.

5.5. Protection of Completed Work.

Any portion of the subgrade that has been completed and accepted by the Project

Manager shall be protected against drying out and cracking. Any damage from default of the Contractor will be repaired as directed by the Project Manager without additional payment.

5.6. Subgrade Tolerance.

The completed surface shall vary not more than 10mm higher nor 10mm lower than

the required grade and shall allow free run-off surface water.

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SPECIFICATION

02372

FILTER FABRIC 1.0. DESCRIPTION OF WORK. The work shall cover the supply, delivery and installation of filter fabric material at the

designated places and other incidentals necessary to complete the work in conformance with the lines, location and depth as shown in the Drawings and/or as directed by the Project Manager.

2.0. REFERENCE STANDARDS.

2.1. American Society for Testing and Materials (ASTM).

2.2. Deutsche Industrie Norm (DIN).

2.3. Specification 02335 - Subgrade Preparation. 3.0. GENERAL PROCEDURES.

3.1. Sample and Technical Data.

Prior to delivery, the Contractor shall submit sample and technical data of the

specified material to the Project Manager for approval.

3.2. Delivery The Contractor shall be responsible for the material delivery to the jobsite in

accordance with the quality and quantity as required by the Project Manager.

3.3. Preparation

3.3.1. Areas to be applied with filter fabric material shall be thoroughly prepared, free of sharp projections or objects that may harm the fabric during the installation or as directed by the Project Manager.

3.3.2. Stockpile for selected fill material on the jobsite shall be arranged or spaced in order to minimize traffic hindrances during the hauling of other project materials for the project.

The minimum stockpile shall be spaced at 400cm on center or as determined by the Project Manager. If the material shall be delivered on the road, the stockpile shall be placed on the road side.

3.3.3. All the filter fabric material and necessary accessories must be adequate prior to the execution of the installation.

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4.0. MATERIALS.

The filter fabric for pavement works shall be of high quality and sophisticated twill weaving woven geotextile made of propylene slit film with certain characteristics to suffice the reinforcement purposes, with minimum tensile strength of 56kN/m, such as Geo-Reinfox of HRX 300 type. The colour shall be black or approved by the Project Manager.

5.0. CONSTRUCTION REQUIREMENTS

5.1. General

5.1.1. Surface area to be applied with fabric shall be clean, level and free of projections or sharp pointed objects. Coarse irregularities shall be leveled off by road graders or approved grading and rolling equipment before laying the filter fabric.

Oversize gravel/stones shall be segregated or be thrown out of the prepared surface.

5.1.2. Soil bearing capacity shall be investigated in every 20 to 50meters distance depending on actual site conditions or as determined by the Project Manager.

5.1.3. Weight of materials or equipment passing through the filtered fabric road or pavement shall be computed or investigated according to its capacity and weight.

5.1.4. For road structures, if possible, surface shall be dry when the fabric is being placed.

5.2. Laying of the Fabric

The fabric shall be unrolled directly onto the prepared subbase or ground where it is approved and accepted by the Project Manager.

The width of an overlap shall be designed or dimensioned in accordance with the soil foundation conditions.

The longitudinal joints are overlapped to at least 300mm for the transverse joints. The adjacent width must be laid underneath the unrolled fabric, in order to prevent the fabric from being pushed back when dumping the fill material on it.

5.3. Welding of the Fabric

On top of the laid fabric width, the next roll shall be overlapped approximately 100mm

unrolled and at the same spot be fixed by welding. The gas flame which must be as wide spread as possible shall be approached towards the previously unrolled fabric layer to about 100 – 200mm having a low temperature.

Immediately after, the fabric width which is laid on top of each other is pressed down by hand or by walking over it.

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5.4. Laying and Compaction of Fill Material

5.4.1. The laying of fill material shall be in the sequence required by the Project Manager.

First layers of filling shall be applied by overhead dumping. Filling height shall correspond to the bearing capacity of the ground or soil and to the load of con-struction.

Driving directly on the fabric shall not be permitted.

5.4.2. Fill material shall be graded by qualified road grader operators. The minimum thickness of the first layer for the compaction shall be 200mm and construction vehicles shall roll on it only after full compaction has been done. Rolling shall start from the sides towards the road centerline.

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SPECIFICATION

02375

RIPRAP 1.0 DESCRIPTION OF WORK This work shall consist of grouted and non-grouted stone slope protection, foundation, cut-off

walls and any stream banks furnished and constructed until completed in conformity with the lines, grades and dimensions shown in the Drawings.

2.0 REFERENCE STANDARDS

2.1. American Society for Testing and Materials (ASTM).

2.2. Specifications:

- 02315 - Excavation, Backfilling and Compaction. - 03300 - Cast-in-Place Concrete.

3.0 GENERAL PROCEDURES

3.1. Drawings and Other Data Requirements The Contractor shall submit neatly prepared Shop Drawings for grouted and

non-grouted rip-rap and shall show all dimensions, elevations, sections, and grout thickness for the Project Manager's approval.

3.2. Inspection and Testing

Inspection and testing shall be done upon particular jobs as follows:

- Lay out. - Excavation. - Material on site includes tools and equipment. - Stone bed placing. - For every 120cm in height installed.

During the testing, the Contractor shall provide qualified Quality Assurance personnel

and facilities to the Project Manager without extra costs to the Owner. 4.0 MATERIALS.

4.1. Stone for rip-rap shall be river stone or approved quarry stone and as closely as possible being regular in configuration.

Material shall be sound, durable, tough, and dense and shall not easily break into pieces, due to excessive spalling or flaking.

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4.2. Stone pieces for protecting slopes, shoulders, ends of fills and others shall range in weight of 10kg minimum to 70kg maximum, with not less than 50% of the stones weighing more than 30kg.

4.3. Stone for protecting river face and walls shall range in weight from a minimum of 20kg

to 100kg maximum, with no less than 60% of the stones weighing more than 40kg.

4.4. Grout made of concrete shall conform to the requirements of Specification 03300. 5.0 CONSTRUCTION REQUIREMENTS

5.1. Preparation.

5.1.1. Excavation or embankment construction shall be executed according to planned shapes and dimensions, as if there were no slope protections and in a manner which shall allow for some excavation immediately, prior to the placing of the slope protection.

5.1.2. The Contractor shall coordinate with the Project Manager and supplier of

materials, prior to excavation or embankment construction in areas to be covered, so that appropriate construction methods and procedures can be decided upon in consideration of prevailing soils data and in conjunction with the Drawings.

5.1.3. Embankment or backfill shall be properly compacted by approved tamping

tools/equipment to the satisfaction of the Project Manager, and in accordance with Specification 02315.

5.2. Installation.

5.2.1. Prior to placing of rip-rap, the compacted bed shall be dampened. Stakes,

reference points and barrier boards shall be established after a measure of drying of bed material has taken place.

5.2.2. Except where the foundation for grouted riprap is in water and cannor be

drained, and is not rock or hard pan, it shall be founded and sealed on the bottom with a cut-off wall of at least 200mm thick. Cut-off walls shall also be placed at the end limits of grouted riprap unless otherwise directed by the Project Manager. Excavation of cut-off walls shall be made in advance of the fine grading. The trench shall be dewatered and cut-off wall shall be constructed by filling the dry trench with grout to a depth of 60% percent of the maximum dimension of the stones and immediately thereafter placing stones in the unset grout or concrete to make a solid dense wall. Additional grout or concrete shall be added and the process repeated until trench is fully filled and the wall formed to the satisfaction of the Project Manager. Additional grout or concrete shall then be added to the top to form a leveling screed at the upper surface. Only pre-established limited lengths of trench shall be worked out at a time, to ensure that all stones are inserted in good grout or concrete.

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5.2.3. Stones shall be placed in tight contact with the cut-off wall or other foundation and be laid from bottom and work towards the top. Stones shall be firmly bedded into the slope and shall be laid in close contact to a thickness of at least 200mm. Interstices may be partially filled with spalls or small stones afterwards in the case of grouted riprap. All remaining cavities or spaces shall be filled solidly with grout which shall be finished flush with the stone surface. Weep holes shall be as shown in the Drawings or determined by the Project Manager.

5.2.4. Immediately after laying stone with fresh grout the surface of grouted riprap

shall be brushed clean of all grout stains. The work shall be shaded and kept damp for a period of not less than 3 days minimum, after the work is completed.

5.2.5. Curing shall be performed by periodic application of water to the exposed

surface of riprap or by using wetted jute sacks placed on the riprap surface.

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SPECIFICATION

02459

PRECAST PRESTRESSED CONCRETE PILES 1.0 DESCRIPTION OF WORK. This work shall consist of providing materials, labour, tools, equipment, transportation and piling

precast prestressed concrete piles and furnishing them in accordance with this Specification and in close conformity to the requirements stipulated in the Drawings.

2.0 REFERENCE STANDARDS.

2.1. Association Concrete International (ACI).

2.2. American Welding Society (AWS).

2.3. American Society for Testing and Materials (ASTM).

2.4. Standar Nasional Indonesia (SNI):

2.5. Japanese Industrial Standard (JIS). 3.0 GENERAL PROCEDURES.

3.1. Technical Data and Mill Certificate. Prior to supplying and transportation, the Contractor shall submit a brochure or technical

data complete with mill certificate certifying the precast prestressed concrete piles meet the specified requirement, for approval of the Project Manager.

3.2. Work Method.

The Contractor shall, before the commencement of any piling work, submit his proposal of

the work method for the Project Manager's approval, including transportation, storing, handling, driving of piles, driving equipment, crews, and also the detail of pile extension.

3.3. Fabrication of Piles.

All piles shall be fabricated to dimension, length and with material of thickness as shown in

the Drawings. All piles which have passed the test at factory shall be marked with the following data in a

manner not to be easily destroyed or erased.

- Grade of pile. - Dimensions. - Production number. - Name of manufacturer.

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3.4. Storage and Handling.

3.4.1. All piles shall be stored and handled in such manners as will not inflict any damages thereupon.

3.4.2. The piles shall not be stacked more than 3 (three) tiers high.

3.5. Driving Equipment.

3.5.1. Prior to mobilization of driving equipment, the Contractor shall submit a detailed

working plan of driving operation. Failure to do so the Project Manager has the rights to reject such equipment and the Contractor shall bear all the cost associated with such action.

3.5.2. The Contractor shall consider the type of the soil with its boulder when choosing the driving equipment.

3.5.3. The Contractor shall propose the hammer type and the driving equipment so that the piles can be driven to the specified depth or the desired bearing value indicated by final set is attained, without any damage to the piles due to overstress caused by driving.

4.0 MATERIALS.

4.1. General.

4.1.1. The precast prestressed concrete piles shall be manufactured and constructed in accordance with the details shown in the Drawings and to any other requirements, as far as applicable, stipulated in the reference standards.

4.1.2. The length of precast prestressed concrete pile for the permanent work to be

fabricated and driven shall be determined by the load test results which shall be carried out in advance to the permanent piling work in accordance with the specification stated hereinafter and/or all the soil investigation results.

4.2. Precast Prestressed Concrete Piles.

4.2.1. Type of Pile.

- The type of piles shall be the spun piles as shown in the Drawings, hereinafter

referred to as the PC Piles. - The size and length of piles shall be as shown in the Drawings. - The pile concrete shall have a minimum compressive strength 600kg/cm² by

cube specimens tested at 28 day-age. - The standard spiral reinforcement shall be of round steel bar grade BjTP-24

conforming to the requirements of SNI 07-2052-2002 with a nominal diameter of 6mm.

- The standard prestressing steel shall be of seven-wire high tensile strength, uncoated, stress relieved, low relaxation, grade 270 strand, in continuous length without splices or couplings, conforming to the requirements of ASTM A416-87a or SNI 07-1154-1989 or JIS G 3536 (SWPR 7B).

- The longitudinal prestressing steel should be enclosed in a steel spiral with a maximum 150mm pitch and with closer spacing at each lifting point and minimum 20 close turns of 50mm at the tip and butt of the pile.

- The cross sectional dimensions of the pile shall be within the tolerance of ± 5mm.

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4.2.2. Pile Tip. The tip of precast prestressed concrete pile shall be shaped and reinforced in

accordance with the Drawings. The pile tip shall be provided with a steel shoe that shall be consisted of a steel

plate of a minimum tensile strength of 34kgf/mm² and a minimum thickness of 2mm.

The steel pile shoe shall be made in a standardized form as shown in the Drawings.

4.2.3. Concrete Cover.

The standard concrete cover shall be as follows:

- Normal exposure minimum 50mm. - Marine exposure minimum 75mm.

4.3. Splices.

The pile splices or joints are necessarily required in the case of segmental PC Piles. The splices shall be made of steel plates with a minimum tensile strength of 37kgf/mm²

conforming to requirements of SNI 07-0722-1989, and shall be formed and shaped as shown in the Drawings.

The piles splices are designed to resist any kind of forces that may be applied to the piles section as to ensure the integrity of the pile.

Welding materials to be used shall conform to the requirements of AWS E 6013 or equal. 5.0 CONSTRUCTION REQUIREMENTS.

5.1. Pile Testing.

5.1.1. General.

- The Contractor shall conduct a program of Static Load Test and Dynamic Load Test to demonstrate the suitability of the proposed pile driving system and to ascertain the capacity of the installed piles. Both compression and lateral pile testing are required.

- All operations shall be constantly supervised by a qualified Project Manager of the Contractor and personnel employed must have the required ability and training. Complete testing data shall be recorded.

- Test piles shall be driven in advance of other piles for the project and load tested in order to determine the load-carrying capacity of the pile. The Project Manager will advise to the Contractor of the maximum acceptable "set" of the pile at final driving.

- Test piles shall not be driven nor tested without the presence of the Project Manager.

- If the working load test pile is satisfactory it may be incorporated into the structure. If the test pile is found unsatisfactory or misallocated, the pile shall be removed or abandoned.

- The maximum test load which shall be applied on a pile is 2 (two) times the designed working loads for working compression pile test and 3 (three) times the designed working loads for preliminary compression pile test.

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5.1.2. Preparation.

The Contractor shall provide all the equipment, materials, labours and temporary works to execute the pile load test.

The work method shall be submitted by the Contractor for the approval of the Project Manager, which includes anchoring and reaction systems, testing equipment details, testing procedure, pile head treatment and others related.

The pile to be tested shall be driven down in the same manner as the Contractor intends to execute the piling work subsequently.

5.1.3. Position.

The positions of piles to be tested shall be designated by the Project Manager,

when the time comes.

5.1.4. Load Measuring Equipment. - The equipment used for applying load shall consist of one or more hydraulic

ram or jacks. The total capacity of the jacks shall be at least equal to the required maximum load. The jack or jacks shall be arranged in conjunction with the reaction system to deliver an axial load to the test pile. The complete system shall be capable of transferring the maximum load required for the purpose of the test.

- The load shall be measured by a load measuring device and also by means of a calibrated pressure gauge included in the hydraulic system. Readings of both the load measuring device and the pressure gauge shall be recorded. In interpreting the test data the values given by the load measuring device shall normally be used. The pressure gauge readings are required as a check for gross error.

- The load measuring device shall be calibrated before and after each series of tests, whenever adjustments are made to the device or at intervals appropriate to the type of equipment. The pressure gauge and hydraulic jack shall be calibrated together. Certificates of calibration shall be supplied to the Project Manager.

5.1.5. Preliminary Pile Testing

a. General.

- The Contractor shall submit to the Project Manager for approval a full method statement describing the testing equipment and procedures at least 14 days prior to the commencement of construction of any preliminary pile.

- If requested by the Project Manager, the Contractor shall provide preliminary piles for ultimate compression load tests before the installation of the working piles. The test piles shall be installed separately from the working piles in positions determined by the Project Manager and shall be installed in an approved manner to a predetermined depth and/or set. The Project Manager may order the interruption of the test pile installation for the purpose of instrumentation.

The performance of the test piles under driving and later under test load will be used to determine the compression capacities of the working piles, driving criteria as well as suitability of using pile followers.

- The preliminary pile shall be tested by both maintained load and dynamic testing method.

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b. Abandonment of Preliminary Pile Test.

A test shall be abandoned if it has to be discontinued due to:

- Pre-loading before the commencement of the test. - Improper setting of datum. - Disturbed or unstable bench marks or scales. - Faulty gauges. - Failure of piles cap or instability of the kentledge. - Failure of the pile materials. - Failure of instrumentation.

The cost of the abandoned test shall be borne by the Contractor and he shall

carry out a replacement test to the Project Manager's instruction.

Preliminary Compression Pile Test/ Failure Load Test Procedure

ASTM D-1143

Cyclic

Load Stage

%

Action to be

taken after Load Stage

0 I 25 A 50 1 hour 25 20 mins 0 1 hour 50 20 mins 75 A II 100 1 hour 75 20 mins 50 20 mins 0 1 hour 50 20 mins 100 20 mins 125 A

III 150 1 hour 125 20 mins 100 20 mins 50 20 mins 0 20 mins 50 20 mins 100 20 mins 150 20 mins 175 A

IV 200 1 hour 175 20 mins 150 20 mins 100 20 mins 50 20 mins 0 1 hour 50 20 mins 100 20 mins 150 20 mins 200 20 mins 225 A

V 250 1 hour 225 20 mins 200 20 mins 150 20 mins 100 20 mins 50 20 mins

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0 1 hour 50 20 mins 100 20 mins 150 20 mins 200 20 mins 250 20 mins 275 A

VI 300 B 275 1 hour 250 1 hour 200 1 hour 150 1 hour 100 1 hour 50 1 hour 0 12 hours

A: Minimum 1 hour, leave until rate of statement has levelled out to less than 0.25mm per

hour or 2 hours, whichever is the longer.

B: Minimum 12 hours, leave until rate of settlement has levelled out to less than 0.25mm per hour or 24 hours, whichever is the longer.

5.1.6. Working Load Test.

a. General.

Working load tests shall be carried out on working piles as designated by the Project Manager. A load test may be conducted on a single or on a group of two or more piles.

The test load of a working load test shall be 2 (two) times the designed working load of the pile for compression pile test and 3 (three) times the designed working loads for preliminary compression pile test.

The Contractor shall supply everything necessary for the performance of the tests. Pile caps for load tests, if used, shall be designed and constructed by the Contractor to the approval of the Project Manager. The cost of such pile caps shall be the responsibility of the Contractor.

The number of working load test that shall be carried out is 1 (one) percent the total number of piles. The location of the working load test will be determined and shall be approved by the Project Manager.

b. Failure of Pile.

A pile or pile group shall be deemed to have failed the load test if at least four of the following eight criteria are not satisfied: - The load at which settlement continues to increase without any further

increase of load. - The load causing a gross settlement of 10% of the least pile width. - The load beyond which there is an increase in gross settlement

disproportionate to the increase of load. - The load beyond which there is an increase in net settlement

disproportionate to the increase of load. - The load that produces a plastic yielding or net settlement of 6mm. - The load indicated by the intersection of tangent lines drawn through

the initial, flatter portion of the gross settlement curve and the steeper portion of the same curve.

- The load at which the slope of the net settlement is equal to 0.25mm per 10kN of test load.

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- One - half of the load at which, when maintained for 24 hours, the net settlement after the removal of the load does not exceed 0.25mm per 10kN of test load.

Any pile or pile group which fails under the above stated conditions shall

be replaced at Contractor's cost by one or more piles to be installed as directed by the Project Manager. If, in the opinion of the Project Manager, it is impractical or inadvisable to install substitute piles in place of a failed pile, the Contractor shall submit proposals to rectify the defect. The proposals are subject to the approval of the Project Manager.

In addition, the Contractor shall at his expense carry out 2 more tests with a total test load not exceeding 2 times the test load of the failed test. The piles for these tests shall be selected by the Project Manager.

If 2 or more piles fail out of a piling area containing up to 150 piles, or 3 or more piles fail out of a piling area containing 151 to 750 piles, that part of the whole piling works shall be deemed to have failed.

c. Abandonment of Pile Test.

The load test shall be deemed to have failed if any of the following observations is reached:

- The test cannot be completed due to instability of the kentledge. - Pre-loading before the commencement of the test. - Failure of the pile cap. - Improper setting of datum. - Disturbed or unstable bench marks or scales. - The scales and/or measuring instruments used are found to be

defective or have been tampered with. - Faulty gauges.

For any load test abandoned under the above stated conditions, the

Contractor shall at his expense carry out two more tests with a total test load not exceeding 2 times (compression tests) the test load of the failed test.

The piles for these tests shall be selected by the Project Manager.

Working Compression Pile Test/ Working load Test Procedure

ASTM D-1143

Cyclic

Load Stage

%

Action to be

taken after Load Stage

0

25 A I 50 1 hour 25 20 mins 0 1 hour 50 20 mins 75 A

II 100 1 hour 75 20 mins 50 20 mins 0 1 hour 50 20 hour 100 20 mins

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125 A III 150 1 hour 125 20 mins 100 20 mins 50 20 mins 0 1 hour 50 20 mins 100 20 mins 150 20 mins 175 A

IV 200 B 175 1 hour 150 1 hour 100 1 hour 50 1 hour 0 12 hours

A: Minimum 1 hour, leave until rate of settlement has levelled out to less than 0.25mm per

hour or 2 hours, whichever is the longer. B: Minimum 12 hours, leave until rate of settlement has levelled out to less than 0.25mm

per hour or 24 hours, whichever is the longer.

5.1.7. Measurement and Report.

- The Contractor shall make all observations and take measurement under

the presence of the Project Manager. - The Contractor shall submit a complete set of reports, which will include a

graph of load/time/settlement and a bearing capacity of piles.

5.1.8. Clearing.

After completion of the tests, the Contractor shall remove all preliminary pile tested framing, bracing and other temporary facilities for the tests unless otherwise permitted by the Project Manager.

5.2. Driving.

5.2.1. Preparation Works.

The Contractor shall carry out all the necessary preparation works such as

setting out, marking on piles, temporary staging and other works related, prior to the commencement of pile driving works.

5.2.2. Location of Piles.

Piles shall be driven in the position as indicated in the Drawings. The

Contractor shall be responsible for the true and proper setting out of piles, and for the correctness of the position, levels, dimensions and alignment of all parts of the works. The setting out shall be carried out by a qualified surveyor engaged by the Contractor before commencement and on completion of the piling work.

5.2.3. Equipment.

All the equipment such as driving rigs, hammers, leaders cushions, helmets

and others and workmanship shall be of first class and be suitable to the driving work at the site.

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The Contractor shall provide all others, if necessary to execute the work such as temporary staging, guide, follower and others related.

5.2.4. Driving Procedure and Redrive Checks.

- The heads of all piles shall be protected by caps of approved design

having a suitable cushion next to the pile head and fitted into castings which in turn support a timber shock block.

- Each pile shall be driven continuously until the top of the pile shall be at a depth so that the pile and pile cap connection can be constructed as shown in the Drawings. The depth of the pile head driven shall be approved by the Project Manager.

- The Contractor may use pile follower to drive the pile to the specified depth. The Contractor shall propose pile follower and driving equipment so that the piles can be driven to the specified depth or the desired bearing value indicated by final driving is attained. The use of the pile follower in combination with the driving equipment shall not damage the piles and pile splices.

- The Contractor shall inform the Project Manager without delay if an unexpected change in driving characteristics is noted. A detailed record of the driving resistance over the full length of the next nearest available pile shall be taken if required.

- At the start of work and in a new area or section sets shall be taken at intervals during the last 300cm of the driving to establish the behavior of the piles.

- The Contractor shall give adequate notice and provide all facilities to enable the Project Manager to check driving resistances. A set shall be taken only in the presence of the Project Manager unless otherwise approved.

- Redrive checks, if required, shall be carried out to an approved procedure.

5.2.5. Extension. - Whenever possible, pile splicing should not be used. In case piles without

splicing are unavoidable, the location of the pile splicing shall be at least 6 m below the pile-pile cap interface.

- If the pile has not reached the required penetration rate per blow and if the top of the pile is approximately 300mm above the ground level, it shall be stopped for splicing and driven to a depth sufficient to develop the required penetration rate per blow as directed and approved by the Project Manager.

Splicing work refer to section 5.2.6.

5.2.6. Splicing.

- Where required length is greater than the length of pile, the extension of such pile shall be extended by welding a pile of the same section.

- Piles shall be spliced in accordance with the manufacturer's instruction. The equipment, materials and method for splicing the pile and the timing of splicing the pile in connection with the overall pile driving operation from setting out to cut-off shall be subject to the Project Manager's approval.

- The joint part shall be equipped with guide ring and edges of piles shall be in the shape as shown in the Drawings. The edges to be welded shall be carefully matched and the root opening shall be kept precisely even with the use of spacers and stoppers.

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- Welding works shall be continuous along the entire area of joint plate using low-hydrogen welding electrodes, and in accordance with the requirement of AWS.

- All welding shall be carried out by welders holding certificates or corresponding grades issued by the approved organizations.

- In order to avoid breaking the weld on the joint during driving, the driving can only be continued after the welding has cooled sufficiently.

5.2.7. Uplifted Piles

Should the driven piles be observed to be uplifted, they shall be re-driven to

the required penetration.

5.2.8. Damaged Piles

Any pile damaged by reason of improper driving or driven out of its proper location or driven below the elevation fixed by the Drawings or by the Project Manager shall be corrected at the Contractor's expense by one of the following methods approved by the Project Manager for the pile in question: - The pile shall be withdrawn and replaced by a new and if necessary longer

pile. Any hole from which piles are withdrawn shall be packed with approved non-plastic material before redriving takes place.

- A second pile shall be driven adjacent to the defective or low pile.

5.3. Record.

The Contractor shall submit a complete pile driving report of each pile to the Project Manager daily, which shall include, but not be limited to, the pile number, location, position, the date of fabrication and driving, hammer details, elevations, and blow counts, rebound.

5.4. Tolerance.

5.4.1. The piles shall be installed in their exact positions and to the plumb within a

tolerance of 100mm in any direction from the true position and 1 : 100 from the true vertical axis of the pile.

5.4.2. Should the piles be out of the tolerances, these piles shall be extracted for replacement by the new piles or the superstructure of the pile caps and beams shall be enlarged to accommodate the pile deviated, which however shall be entirely to the Project Manager's direction and that no additional costs shall be due to the Contractor.

5.5. Pile-Head Treatment.

5.5.1. The pile heads shall, after driven down completely to the requirement, be cut-

off, trimmed and treated properly in accordance with the Drawings.

5.5.2. Cut-off lengths of piles shall become the property of the Contractor, and shall be disposed off to the satisfaction of the Project Manager.

5.5.3. After the piles are completely driven to the specified depth and prior to construction of pile cap, any gap between the piles and the soil shall be filled with sand material approved by the Project Manager.

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SPECIFICATION

02462

WOOD PILES 1.0 DESCRIPTION OF WORK The work shall cover the furnishing of labour, equipment and tools, material, and installation of

wood piles as shown in the Drawings and this Specification. 2.0 REFERENCE STANDARDS

2.1. Peraturan Konstruksi Kayu Indonesia (PKKI, NI-5, 1961).

2.2. Standar Nasional Indonesia (SNI).

2.3. Petunjuk dari Balai Penyelidikan Geoteknik Pengairan Pusat Penelitian dan Pengembangan Pengairan, Departemen Pekerjaan Umum: Cerucuk sebagai Perbaikan Tanah Fondasi Bangunan.

3.0 GENERAL PROCEDURES

3.1. Samples Prior to delivery of materials to the site, the Contractor shall submit samples to the

Owner for approval.

3.2. Shop Drawings.

3.2.1. Contractor shall prepare and submit Shop Drawings giving complete information necessary for driving and erecting. State on approved list of type and number of fasteners required for each field connection.

3.2.2. Approval of Shop Drawings will be adherence to overall basic design, and will not

relieve the Contractor of responsibility for correctness of dimensions, proper design of details, quantities, field fit, and proper connection with other work.

3.3. Storage.

All materials shall be stored and handled in appropriate manner to prevent damage.

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4.0 MATERIALS.

4.1. Piles. Piles shall be made of Ulin wood that complies with the following requirements:

- Hardwood and good in quality, of class 1A according to PKKI (NI-5, 1961), - Free from crack and other damages, - Straight as possible, - Minimum diameter of 100mm, except otherwise specified in the Drawings, - Length of piles up to hard soil/earth ± 400cm, or as required.

Pile tip shall have shape according to the Drawings.

4.2. Anchor

Anchor shall be made from plain reinforcing steel of grade BjTP-24 with minimum yield strength of 2400kg/cm² complying with the requirements of SNI 07-2052-2002.

5.0 CONSTRUCTION REQUIREMENTS

5.1. General

5.1.1. Prior to driving work, Contractor shall submit a proposal of working method including transportation, storage, handling, driving, detail of cutting and other necessary details, for Owner’s review and approval.

5.1.2. Contractor shall provide all equipment, materials, labour, temporary works that

are required to complete the driving work.

5.2. Position Position and distance of pile installation shall be according to the requirements as

shown in the Drawings, and the position of pile to be tested will be determined by the Owner.

5.3. Execution

5.3.1. Piles shall be driven down/grounded to the specified elevation/depth as shown

in the Drawings or as determined by the Owner. Driving can be carried out by using hammer.

5.3.2. All piles to be driven shall be in full length as shown in the Drawings, except

otherwise according to the Owner that several certain piles have unpractical length or have to be modified, those certain piles shall be cut at determined elevation.

5.3.3. Joint of piles that do not use bolts (if required), shall be connected with

minimum 4 galvanized nails as shown in the Drawings. 5.3.4. Pile that is damaged during driving or transportation that can impair its

structural strength shall be replaced by the new one.

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5.4. Inspection and Acceptance The Owner will inspect piling work and either accept it or order corrective measures.

5.5. Clean-Up After completion of the piling work, remove all excess material and debris from the site.

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SPECIFICATION

02721

SUBBASE 1.0 DESCRIPTION OF WORK. The work shall consist of furnishing, hauling, placing and compacting subbase materials on the

prepared subgrade in accordance with lines, grades, dimensions and cross sections as shown and as directed by the Project Manager.

2.0 REFERENCE STANDARDS.

2.1. American Association of State Highway and Transportation Officials (AASHTO).

2.2. American Society for Testing and Materials (ASTM).

2.3. Any applicable local codes and standards, the highest or most stringent to apply.

2.4. Specification 02315 - Excavation, Backfilling and Compaction. 3.0 GENERAL PROCEDURES.

3.1. General Subbase construction shall not be worked out unless the subgrade has been properly

prepared in strict compliance with the lines, grades and profiles as shown and as directed by the Project Manager.

3.2. Testing.

The density of compacted material shall be determined by AASHTO Test T191 or T181.

The test shall be made to the full depth of the layer at locations determined by the Project Manager, which shall be not more than 200m apart.

Test holes shall be backfilled and compacted by the Contractor without any delay. 4.0 MATERIALS.

4.1. Material for subbase shall be a natural or artificial mixture of hard durable particles of mineral aggregates selected from an approved borrow pit source. It shall be free from clay lumps, vegetable matter, and organic soil, and shall not easily break under prevailing climate and cycles of moisture change.

Any material which is surplus to backfilling of work under Specification 02315 may be used in the preparation of subbase, provided it meets the above requirements and is approved by the Project Manager.

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4.2. If the thickness of required subbase exceeds 200mm, it shall be divided into a layer of upper subbase of 150mm thick and a layer of lower subbase to a minimum of 50mm thick.

The grading of material for upper subbase shall comply with the following requirements:

Sieve Designations

Standard (mm)

Alternative (inch)

Percentage by

Weight passing

50

2 in

100

25 1 in 60 – 100

9.5 3/8 in 30 – 100

4.75 No. 4 15 – 100

2.00 No. 10 10 – 70

0.425 No. 40 5 – 40

0.075 No. 200 2 – 25

5.0 CONSTRUCTION REQUIREMENTS.

5.1. Subbase Preparation. Subgrade and all drainage works shall be completed in accordance with this

Specification for at least 50meters ahead of the placing of the subbase material. Subbase may be spread and shaped by any acceptable methods which shall not cause the segregation of the fine and coarse aggregate. The material shall be brought to correct moisture content in achieving the specified degree of compaction by sprinkling a controlled amount of water and thoroughly mixing with a road grader until the moisture content is uniform.

5.2. Rolling and Compaction.

Immediately after proper mixing and shaping, each layer of 200mm maximum shall be

evenly compacted with suitable compacting equipment approved by the Project Manager. Rolling operation shall start along the sides or edges and progress toward the area center line.

The rolling shall continue until roller marks are slightly visible and uniformly compacted to a hard dense surface. Speed of compacting equipment shall be constant rate of 5km/hr. Dry density shall be 90-95% as determined by AASHTO Test T180 Method D.

5.3. Subbase Tolerance.

The completed surface shall vary not more than 15mm above or below the design

grade at any point, and the minimum thickness of subbase shall not be less than 15mm below the required thickness at any point.

Subbase which does not conform to these tolerances shall be corrected by loosening, reshaping and recompacting to the satisfaction of the Project Manager.

5.4. Compaction Standard.

All of the subbase shall be compacted to not less than 93% of the maximum dry

density as determined by the methods set out in Specification 02315.

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5.5. Sand Blanket. After the building pads have been compacted and approved by the Project Manager,

the sand blanket shown in the Drawings shall be applied and spread by the Contractor in a way which will produce a plane surface and result in completed floor slabs not less than those shown in the Drawings.

Sand for this purpose shall be clean granular material of 6mm maximum particle size.

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SPECIFICATION

02722

BASE COURSE 1.0 DESCRIPTION OF WORK. This work shall consist of furnishing, hauling, spreading, watering, rolling and compaction of graded

aggregate material on a completed and accepted subgrade in accordance with the established lines, grades and cross sections as shown in the Drawings.

It shall include but not be limited to supplying of labour, equipment, plants or rock crushers equipped with the required screens and other accessories necessary to satisfactorily complete this work.

2.0 REFERENCE STANDARDS.

2.1. American Association of State Highway and Transportation Officials (AASHTO).

2.2. Any applicable local codes and standards, the highest or most stringent values to apply. 3.0 GENERAL PROCEDURES. Refer to section 5.0 Construction Requirements of this Specification. 4.0 MATERIALS.

4.1. Aggregate base material shall be selected from an approved source. The coarse aggregate retained on the 4.75mm sieve shall consist of hard durable particles or fragments of rock and gravel. Gravel which splits when alternately wetted and dried shall be avoided. The gravel shall be of approximately uniform gradation and must be screened and washed.

Fine aggregate passing 4.75mm (no. 4) sieve shall consist of natural or crushed aggregate and fine mineral particles.

4.2. All aggregate shall be free from vegetable matter, lumps of clay and other deleterious

substances and shall conform to the following requirements as shown on the table as listed below:

SIEVE % PASSING WEIGHT

STANDARD (MM)

ALTERNATIVE (INCH)

CLASS A

CLASS B

50

2”

100

100

25 1” 65 65 – 100 9.25 3/8” 40 – 60 35 – 50 4.75 No. 4 25 – 45 20 – 50 2.00 No. 10 12 – 30 10 – 40

0.425 No. 40 6 – 16 5 – 25 0.075 No. 200 0 – 8 2 – 15

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The fraction passing 0.075mm (No. 200) sieve shall not be greater than 2/3 of the fraction passing the 0.425 (No. 40) sieve. After 4 (four) days soaking, when compacted to 95-100% maximum dry density as determined by AASHTO Test T180 Method D, class A aggregate shall have a CBR of not less than 80 and class B aggregate shall possess a CBR of not less than 60.

5.0 CONSTRUCTION REQUIREMENTS.

5.1. Preparation of Base Formation.

5.1.1. Where aggregate is required to be laid on a prepared formation in either as base course or other construction, such formation shall be completed and accepted for at least 100meters or so many square meters ahead of the placing of the base material. However, any earlier approval of prepared formation and any damaged to or deterioration in the formation shall be made good at the Contractor's expense before aggregate base is placed.

5.1.2. Where aggregate base is required to be laid directly on the existing pavement,

the surface of the pavement shall first be slightly scarified or roughened sufficiently to be made permeable and re-compacted.

5.1.3. Re-compaction shall be performed after the addition of aggregate base,

provided that the total depth of scarified and added material does not exceed the permissible depth of loose layers.

5.1.4. Any lumps larger than 50mm resulting from scarifying shall be picked out or

broken before the addition of aggregate base. Mixing of the existing scarified pavement with the new aggregate base should be avoided.

5.1.5. No separate payment shall be made for scarifying or roughening and

compaction, as this work shall be considered incidentals for the aggregate base preparation.

5.2. Spreading.

Aggregate base shall be evenly spread over the full width of the road bed in layers

with un-compacted thickness not exceeding 250mm and be subject to the Project Manager's approval. The layers, if more than one (1), shall be as nearly equal in thickness as possible. The material maybe spread and shaped by any approved method that shall not cause segregation of the fine and coarse aggregates. Any portion of segregated coarse or fine material shall be corrected or removed and replaced with graded material. Material shall contain the correct moisture content to achieve the specified degree of compaction by sprinkling with the right quantity of water. Mixing shall be by motor grader until moisture content of material is almost uniform throughout.

5.3. Rolling and Compaction.

5.3.1. Immediately after the final mixing and shaping is completed, each layer of

200mm minimum thickness shall be compacted with suitable and approved equipment. Rolling shall start along the sides and then progress towards the road centerline in a controlled speed of 5km/hr.

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5.3.2. The rolling direction shall overlap each other in a longitudinal manner. On super-elevated sections, rolling shall start at the low grade and progress towards the high side. Rolling operation shall continue until the surface is uniformly compacted, hard, and dense and roller marks are no longer visible.

5.3.3. If aggregate base is too wet or too dry to be compacted to the required

density, it shall be dried out or sprinkled with water, prior to or during compaction.

5.3.4. No additional payments shall be made for adding water or drying of the

material.

5.3.5. Any surface irregularities that may develop after the construction shall be corrected by removing the irregular portion and replaced with good material as required. Each layer of aggregate base shall be compacted to at least 95% of the maximum modified dry density as determined by Method D of AASHTO Test T180.

5.4. Surface and Thickness Tolerances.

The completed surface or finished profile shall vary not more than 10mm above or

below the design elevation at any point. Any deviation in excess of 10mm tolerance shall be corrected by loosening, adding or

removal of material, reshaping and re-compaction. Such expenses shall be the Contractor's responsibility.

Where aggregate base is laid in place with variable thickness on the existing pavement, such thickness shall be within the allowable limits shown in the Drawings. Likewise, proper corrections and/or adjustments shall be done to the profile grade upon written approval of the Project Manager, in order to meet the allowable tolerance as stated in this specification.

5.5. Inspection and Testing.

The density of compacted material shall be determined by ASTM D 1557 or AASHTO

T 180. The test shall be executed to the full depth of the layers at location or points determined by the Project Manager, which shall not be more than 200meters apart. Test holes shall be backfilled with the same material and compacted by the Contractor without delay.

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SPECIFICATION

02845

GUARDRAILS 1.0 DESCRIPTION OF WORK. The work shall cover the transportation, furnishing of man power, equipment and materials,

and installation of guardrails at location as shown in the Drawings or as directed by the Project Manager.

2.0 REFERENCE STANDARDS.

2.1. Produk Standar untuk Jalan Perkotaan.

2.2. American Association of State Highway and Transportation Officials (AASHTO).

2.3. American Society for Testing and Materials (ASTM).

2.4. Specification 03300 - Cast-in-Place Concrete. 3.0 GENERAL PROCEDURES.

3.1. Technical Data. Contractor shall submit technical data of the required material to the Project Manager

for review and approval prior to delivery to the site.

3.2. Shop Drawings. Prior to starting the work, Contractor shall prepare and submit Shop Drawings describing

dimensions, lay-outs, connections and other necessary details for installation for Project Manager’s review and approval.

3.3. Delivery.

The Project Manager will inspect the fabrication at the time the materials were to be

delivered at the site designated by the Project Manager. The material shall be considered inspected if there is an acceptance and approval from the Project Manager. The Contractor shall be responsible for the delivery of guardrails, posts and other parts to the agreed delivery place.

3.4. Shipping Instruction.

Prior to the shipment, all materials shall be galvanized in accordance with the

manufacturer's specification and shall be approved by the Project Manager. All loose items such as bolts, nuts, washers, fasteners and connectors shall be

packaged, labeled and properly sealed. Bigger items such as guardrails and posts shall be piece marked and its corresponding weight shall be indicated.

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4.0 MATERIALS.

4.1. Guardrails.

4.1.1. All guardrails and accessories shall be new and made of hot dip galvanized steel beams which are neither too rigid nor too elastic, but which are able to absorb impact.

4.1.2. Guardrails shall have characteristics as follows:

- Rail in ± 4330mm with 2.7mm thick and weight of ± 45kg, - Having maximum tensile strength of 5600kg/m2, - Strength of beam including connection of 680kg and deflection of 50mm if

tested on a clear span along 365cm using load through flat plate of 80mm width at the centre,

- Connections having capability to withstand side pull of 2200kg, - Complying with AASHTO M180, such as manufactured by Bakrie, Bumi Kaya or approved equal by the Project Manager.

4.2. Accessories

Guardrails shall be completed with accessories manufactured by the same manufacturer as the guardrails and consisting of the following: - Supporting post length of ± 1800mm in 6mm thick and weight of 26kg. - Block piece length of ± 350mm in 6mm thick and weight of 5kg. - Terminal end length of ± 725mm in 2.7mm thick and weight of 8kg. - High tensile hexagon bolts and nuts according to ASTM A 325.

4.3. Concrete Concrete for foundation of posts shall comply with the requirements of Specification

03300. 5.0 CONSTRUCTION REQUIREMENTS.

5.1. General.

5.1.1. The guardrails shall be installed in accordance with the manufacturer's installation instructions.

5.1.2. Where shown to use guardrails in curve shape with radius between 2000mm

or more, this curve shape shall be bended at the manufacturer’s factory.

5.2. Installation

5.2.1. Posts

Post shall be set plumb, by hand or mechanically dug holes. Driving of post shall avoid shaterring, battering, brooming or distorting of the top of butt. Post shall be set on steel anchored concrete and shall be as shown in the Drawings.

Concrete work shall be in accordance with Specification 03300.

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5.2.2. Anchorage.

End anchorage if required shall be constructed according to the details shown by the manufacturer.

5.2.3. Bolts.

Post bolt shall be located at the centre corrugation of rail beam as

recommended by the manufacturer.

DIVISION 3 CONCRETE

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SPECIFICATION

03200

CONCRETE REINFORCEMENT 1.0 DESCRIPTION OF WORK. This work shall consist of furnishing concrete reinforcement in conformity with the Drawings. The

work shall include all machinery, equipment, manpower and the required workmanship and performance to the satisfaction of the Project Manager.

This Specification shall govern over the Drawings in the event of any conflicting details that may arise.

2.0 REFERENCE STANDARDS.

2.1. Standar Nasional Indonesia (SNI):

- SNI 07-2052-2002 - Baja Tulangan Beton (Concrete reinforcement steel bars). - SNI 07-0663-1989 - Jaringan Kawat Baja Las untuk Tulangan Beton (Steel wire

netting for concrete reinforcement bars). - SNI 03-2847-2002 - Tata Cara Penghitungan Struktur Beton untuk Bangunan

Gedung (Code for concrete structure calculation of building).

2.2. American Society for Testing and Materials (ASTM):

- ASTM A615/A615M - Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement.

2.3. British Standard (BS):

- BS 4449 - Steel for the reinforcement of concrete. Weldable reinforcing steel. Bar, coil and decoiled product. Specification

2.4. American Concrete Institute (ACI):

- ACI 315 - Details and Detailing of Concrete Reinforcement. - ACI 318 - Building Code Requirements for Reinforced Concrete.

2.5. American Welding Society (AWS):

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

2.6. Related Specification: 03300 - Cast-in-Place Concrete.

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3.0 GENERAL PROCEDURES.

3.1. Sample and Mill Certificate.

3.1.1. The Contractor shall submit to the Project Manager samples and the manufacturer's certificate of compliance with the mild steel reinforcement for approval.

3.1.2. Prior to ordering of material, all the order lists and cutting schedules shall be

properly prepared by the Contractor and submitted to the Project Manager for approval.

However, such approval shall in no way relieve the Contractor of his responsibility for ascertaining the accuracy of such order lists and cutting schedules.

Any revision of the approved material lists and schedules of the concrete reinforcement shall be the full risk and expense of the Contractor.

3.2. Shop Drawings.

3.2.1. Shop Drawings shall be submitted by Contractor for Project Manager's approval

and shall include of the following:

- Reinforcing steel cutting schedule showing dimensions, locations, bends, hooks sizes, anchor and laps, and others which shall conform to ACI 315 and SNI 03-2847-2002.

- Bar spacing, concrete cover allowances and spacers, dowels and metal chairs.

3.2.2. The Contractor may be permitted to substitute the designed sizes of the mild steel reinforcement as shown in the Drawings provided that the substitution is carefully analyzed and he has checked that the required strength is still maintained. Such substitution shall be approved by the Project Manager prior to work execution.

3.2.3. Details of concrete reinforcement and accessories not shown in the Drawings shall be in accordance with the Project Manager requirements.

3.3. Handling and Storage.

Reinforcing steel be protected at all times from damage and shall be stored in a location (and on blocks) where the potential for rusting is minimized and is not in contact with oil, grease, mud and other objectionable materials.

4.0 MATERIALS.

4.1. Reinforcing Steel.

4.1.1. Reinforcing steel of plain type with diameter of < 13mm shall be of grade BjTP-24 material with yield strength of 2400kg/cm² and shall comply with SNI 07-2052-2002, BS-4449 or ASTM A 615. Diameter to be used shall be as indicated in the Drawings.

4.1.2. Reinforcing steel of deformed type with diameter of 13mm shall be of grade BjTS-40 material with yield strength of 4000kg/cm² and shall comply with SNI 07-2052-2002, BS-4449 or ASTM A 615. Diameter to be used shall be as indicated in the Drawings.

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4.2. Prefabricated Steel Reinforcing (Reinforcing Steel Wire Mesh).

Prefabricated steel reinforcing (reinforcing steel wire mesh) shall be manufactured from plain or deformed steel wires of grade Bj-50 material with tensile strength of 5000kg/cm² conforming to SNI 07-0663-1989, welded together by an automatic welding machine, such as BRC, Union Mesh, Lionmesh, Adhi Mesh or approved equal.

4.3. Accessories.

4.3.1. Metal chairs, spacers and other shall be sized and shaped to adequately support

reinforcing.

4.3.2. Accessories in exposed concrete shall be galvanized steel material. Steel material shall conform to the requirements of Specification 05500.

5.0 CONSTRUCTION REQUIREMENTS.

5.1. Hooks/Bends.

Reinforcing steel shall be provided with hook/bend minimum as in indicated in the Drawings

or as specified in SNI 03-2847-2002 or as determined by the Project Manager.

5.2. Cutting.

Length in excess required in the Drawings (apart from overlaps), shall be done by steel cutting or any cutting tools approved by the Project Manager.

In areas where block outs are made for machineries, equipment and other utilities, the reinforcing steels shall be cut to suit the opening or size of the block out.

5.3. Dowel Bars.

Unless otherwise specified in the Drawings, for the designed slabs up to 130mm thickness,

use 12mm diameter mild steel round dowel bars 600mm long spaced at 250mm on centers.

For slabs 150mm to 200mm thickness, use 12mm diameter mild steel round dowel bars 800mm long, spaced at 200mm on centers.

5.4. Placing and Fastening of Reinforcing Steel.

5.4.1. Before placing, the reinforcing steel shall be free from loose, rust, loose scales, oil,

paint and any other objectionable substances.

5.4.2. All reinforcing steel shall be accurately placed in conformance with the grade, dimension and location as shown in the Drawings. Metal chairs or inserts shall be spaced at one meter square or as determined by the Project Manager. Stones, bricks or wood blocks are not allowed as chairs or insert. All laps shall be tied with no. 16 AWG or 1.62mm diameter tie wire or equal. Spot welding may be applicable in mild steel reinforcement only in lap work as approved by the Project Manager.

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5.5. Concrete Pouring.

Concrete pouring shall be carried out in accordance with Specification 03300.

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SPECIFICATION

03300

CAST- IN- PLACE CONCRETE 1.0 DESCRIPTION OF WORK This work shall include cast-in-place concrete structures, constructed in close conformity with the

lines, grade and dimensions shown in the Drawings. All work, material and performance related to cast-in-place concrete shall conform to this

Specification and related Specifications and standards. 2.0 REFERENCE STANDARDS

2.1. Standar Nasional Indonesia (SNI):

- SNI 03-2847-2002 - Tata Cara Penghitungan Struktur Beton untuk Bangunan Gedung.

- SNI 15-2049-2004 - Semen Portland

2.2. American Concrete Institute (ACI):

- ACI 318 - Building Code Requirements for Reinforced Concrete - ACI 347 - Formwork for Concrete.

2.3. American Association of State Highway and Transportation Officials (AASHTO):

- AASHTO M6 - Standard Specification for Concrete Aggregates. - AASHTO T11 - Amount of Material Finer than 0.075 mm (No. 200) Sieve in

Aggregate. - AASHTO T27 - Sieve Analysis of Fine and Coarse Aggregate. - AASHTO T112 - Clay Lumps and Friable Particles in Aggregate. - AASHTO T113 - Lightweight Pieces in Aggregate.

2.4. American Society for Testing and Materials (ASTM):

- ASTM C33 - Specification for Concrete Aggregate. - ASTM C150 - Specification for Portland Cement. - ASTM C260 - Standard Specification for Air-Entraining Admixtures for Concrete. - ASTM C494 - Standard Specification for Chemical Admixtures for Concrete. - ASTM C685 - Specification for Concrete Made by Volumetric Batching and

Continuous Mixing.

2.5. Related Specifications:

- 01400 - Concrete Test. - 03200 - Concrete Reinforcement.

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3.0 GENERAL PROCEDURES

3.1. Shop Drawings.

The following Shop Drawings shall be submitted by Contractor for Project Manager's approval:

- Reinforcing steel cutting schedule showing bends, hooks sizes, laps, anchors and

others as specified in Specification 03200. - Shop Drawings of form works shall show structural members, spacing, sizes, joints,

inserts and other related work in form works, and shall be approved by the Project Manager.

- Scheme of concrete pouring including mix design, manpower, equipment and tools.

3.2. Field Inspection, Sampling and Testing

3.2.1. Field Inspection.

- Prior to the commencement of the cast-in-place concrete work the following preliminary test shall be performed by the Laboratory at the Contractor's expense. Additional tests shall be performed if necessary.

- The Contractor is obligated to follow the results of the trial mixes and estimates he intends to use in the work described herein.

- The Contractor shall furnish assistance to the Project Manager in sampling and testing works. The preliminary tests shall include the determination of:

· Durability. · Characteristics and distribution of aggregates. · Cement type and quality. · Selection and dosage of admixtures. · Proportioning of aggregates classes in the mix. · Cement strength, type. · Water cement ratio. · Slump test. · Characteristic of different fresh concrete mixes. · Compressive strength. · Water tightness. · Resistance to weathering. · Resistance to adverse chemical reactions.

- These tests shall be carried out until concrete mixes have been obtained in

conformance with this Specification.

3.2.2. Sampling and Testing

All testing and sampling shall be accomplished by the Contractor without additional cost. This work shall continue during actual concrete placing.

Samples and testing shall be taken by the approval of the Project Manager, as described below:

a. Cement.

Cement shall have the certificate obtained from the factory of origin, showing weight per bag of three (3) to six (6) ply rating.

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b. Aggregates.

Aggregate shall conform to and be tested according to ASTM C 33 Specification. Test shall start thirty (30) days prior to the start of the concrete work.

c. Concrete.

At least thirty (30) days before concreting starts, the Contractor will make trial

mixes for testing, materials to be used, and methods which are introduced in the works.

Trial mixes shall be as specified in section 3.3 of this Specification.

d. Admixtures.

All admixtures for concrete shall be tested according to the relevant ASTM C 260 and ASTM C 494 at least thirty (30) days prior to the start of the concrete works. Admixtures shall not be used without approval of the Project Manager.

3.2.3. Test Mixing/Trial Mixes. - The Contractor shall conduct test mixing of concrete, each types and

strength applied, prior to placement of concrete. - Mixing design shall indicate water-cement ratio, water content, admixture

content, cement content, aggregate content, aggregate gradations, slump, air content and strength.

- Minimum cement content shall be 360kg per cubic meter of concrete. Maximum water content shall be 170kg per cubic meter of concrete. The design slump shall be in the range 60mm to 100mm. - The aggregates shall be batched from no less than two size grading, coarse

and fine (sand). Coral sand shall not be used for works under this Contract. - Fly ash may be added to increase the durability of concrete. - The Contractor shall submit the grading curves to the Project Manager for

approval. The aggregate sources and the size grading shall not then be changed from the approved aggregates.

- Trial mixes shall be carried out by the Contractor before the mix design is approved by the Project Manager. Proportions may be determined by weigh batching or volume batching. In the case of volume batching, two (2) volume boxes shall be made, one being for sand and the other for coarse aggregate. The Contractor may use the following batch volumes for his trial concrete mix.

- Cement content shall be assessed by the number of 50kg bags of cement type I used in each cubic meter of concrete, in this case being not less than seven (7). Water content shall be assessed by water meter or the number of buckets of known volume of water. There shall be no casual addition of water to the mix by hose or bucket. The Contractor may include concrete additives to the mix with the Project Manager’s approval.

- Make test mixing to that when test specimens are cured and tested under laboratory conditions, their compressive strength will exceed the adequate strength required. For each test mixing, make four (4) specimens at 7 days and 28 days strength.

The 7 days test strength shall be at least 65% of the 28 days strength required for the test mixing.

Concrete test shall be as stipulated in Specification 01400. - The test result report shall be submitted to the Project Manager for approval.

The Contractor shall not commence construction of concrete works until the

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Project Manager has approved the Contractor’s Concrete Mix Design. Once approved, the Contractor shall not vary the trial mix proportions or component materials without the written approval of the Project Manager.

- Prior to using any water reducing agents or high early strength promoting admixtures, the Contractor shall submit details of the products technical data to the Project Manager for review. The Contractor shall prepare a series of four (4) concrete test cubes specimens trial mix using the approved Concrete Mix Design with the proposed concrete admixture. Testing of the specimens shall be carried out by a test laboratory approved by the Project Manager. Two (2) of the specimens shall be tested at 7 days and the remaining two (2) tested at 28 days. The results of the trial mix testing (incorporating the admixture) shall be submitted to the Project Manager for review and approval following each series of testing.

4.0 MATERIALS

4.1. Concrete

4.1.1. Composition of concrete, either by weight or by volume, shall be as determined by the Project Manager and shall comply with the following conditions:

- Slump shall be as specified herein. - Alternative mixes shall be used prior to the approval of the Project Manager. - Excluding surface water aggregates.

4.1.2. Concrete are grouped in different classes, according to the following

requirements:

- f’c= 29MPa (K-350) concrete for abutment, beams, floor slabs and pile caps as shown in the Drawings.

- f’’c= 10.4MPa (K-125) concrete for lean concrete bedding and filling.

4.1.3. All ready mixed concrete shall comply with the requirements of ASTM C 94.

4.2. Cement

Cement shall be portland cement type I complying with SNI 15-2049-2004. Cement shall come from one brand, such as Semen Gresik, Tiga Roda, Holcim or

approved equal. 4.3. Water

Water for mixing, curing or other designated applications shall be clean and free from harmful and deleterious substances such as alkali, acids, salt and other inorganic matters.

However, as the case may happen, all water except what as mentioned herein shall be tested and shall meet the requirement of AASHTO T26 and/or approved by the Project Manager.

4.4. Fine Aggregates

4.4.1. The fine aggregate for concrete consisting of natural hard sand shall meet ASTM C33 requirements, and shall be approved by the Project Manager for concreting works.

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Fine aggregate shall also meet the requirements of the following:

DESCRIPTION AASHTO TEST METHOD % BY WEIGHT

Clay Lump T 112 0.5%

Coal and Ignite T 113 0.5%

Material Passing No. 200 Sieve T 11 3 %

4.4.2. Fine aggregate shall not contain inorganic materials, acids, alkalis and other

substances. Fine aggregates shall be uniformly graded and shall meet the following grading requirements:

SIEVE DESIGNATION % WEIGHT PASSING SIEVE (AASHTO T 27)

3/8” (9,5mm)

100

No. 4 (4,75mm) 95 – 100

No. 16 (1,18mm) 45 – 80

No. 50 (0,300mm) 10 – 30

No. 100 (0,150mm) 2 – 10

4.5. Coarse Aggregates.

4.5.1. The coarse aggregates for construction shall consist of crushed granular stones, crushed stone, blast furnace slag or other approved inert material of similar characteristics which are hard, durable and free from deleterious substances.

4.5.2. Coarse aggregates shall not contain deleterious substances in excess of the

percentages:

DESCRIPTION

AASHTO TEST METHOD

% BY WEIGHT

Clay Lumps

T 112

0.25%

Materials passing No.200 sieve T 11 1%

Thin or elongated pieces

(length greater than 5 x max.

thickness

- 10%

Other deleterious substances shall not exceed the percentage limits set forth-

in this Specification and/or approved by the Project Manager.

4.5.3. Coarse aggregate grading requirements shall be as specified in ASTM A33:

MAXIMUM SIZE

OF COARSE % BY WEIGHT PASSING SIEVES

AGGREGATE SIEVE DESIGNATION

(CM) 5.08 2.54 1.905 1.27 0.952 4 8 16

3.81 95-100 - - - 10-13 0-5 - -

1.905 - 100 90-100 - 20-55 0-10 0-5 -

0.952 - - - 100 85-100 10-30 0-10 0-5

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4.5.4. Separate sizes of coarse aggregate shall be combined with other sizes at the proportions by weight or by volume to produce an aggregate that meets the grading requirements specified.

4.5.5. A sample of approved coarse aggregate material shall be retained on-site in a

sealed clear plastic container for comparison purposes. Any material brought to site that differs substantially from the approved sample shall be rejected.

4.6. Curing Materials

Curing materials shall conform to the following requirements:

DESCRIPTION

TEST METHOD Burlap cloth made from jute or kenaf

AASHTO M 182

Liquid membrane-forming compounds for curing concrete

AASHTO M 148

White polyethylene sheeting (film) for concrete curing

AASHTO M 171

Other applicable method of curing concrete shall be approved by the Project Manager.

4.7. Admixture

4.7.1. Air entraining admixtures shall conform to ASTM C 260 for all exposed concrete.

4.7.2. Water reducing and retarding admixture for controlling the setting time of

concrete, if required, shall conform to ASTM C 494 type B and D.

4.7.3. Admixture for accelerating the setting time of concrete, if required, shall conform to ASTM C 494 type C.

4.7.4. Admixture for waterproofing substructure concrete, if required or as instructed

by the Project Manager, shall conform to BS 1881: Part 122 for water absorption or ASTM C 494 type A, such as Everdure Caltite by Cementaid, Plastocrete-N by Sika or approved equal.

4.7.5. Superplasticiser shall be of the following types:

- Non-retarding type shall conform to ASTM C494 type F, - Slump-retaining type shall conform to ASTM C494 type G, - Retarding type shall conform to ASTM C494 type G, from Cementaid or approved equal. Type of superplasticiser to be used shall be as recommended by the admixture manufacturer and as approved by the Project Manager.

4.8. Joint Sealant and Water Stop.

4.8.1. Joint sealant shall conform to the requirement of BS 4254 and US Federal

Specification TT-S-00227E, such as Masterflex 700, Thioflex 600, Paraseal or Febseal 2 part Polysulphide.

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4.8.2. Unless otherwise specified, water stop shall be blended polymer hydrophilic type, complying with ASTM D 71, ASTM D 297, ASTM D 6 and ASTM D 217, such as Superswell 47B from Corkjoint or Supercast SW10 from Fosroc.

4.9. Reinforcing Steel

Reinforcing steel shall be as specified in Specification 03200.

5.0 CONSTRUCTION REQUIREMENTS

5.1. Falsework and Forms

5.1.1. Falsework shall be built on foundation of sufficient strength to carry the loads without settlement.

5.1.2. Falsework which can not be founded on solid footings must be supported and

reinforced by sufficient additional supporting falsework. Prior to placing of falsework, a representative design to carry the loads for a certain job shall be submitted to the Project Manager for approval.

5.1.3. Forms shall comply with the requirements below:

- All forms shall be provided with adequate clean out openings to permit inspection and easy cleaning after all the reinforcement is in position.

- Form materials shall be of lumber not less than 20mm thick and plywood not less than 12mm, metal not less than 0,6mm, or other acceptable material. All exposed concrete surfaces shall be cast with a smooth “off-form” finish. No plastering shall be undertaken without the approval of the Project Manager. Provide timber or plastic chamfer strips (20mm x 20mm) securely nail fixed on all corners of formwork for exposed concrete members as indicated in the Drawings. Wood material used shall be approved by the Project Manager, sufficiently dry and solid enough to receive load, selected straight, sound and free from loose knot holes, splits and other defects, milled to net shapes and sizes. The samples of materials, dressed on at least 2 edges and one side for tight fit, shall be submitted to the Project Manager for approval.

- Form, shoring and bracing design and construction shall be the Contractor's responsibility. Forms shall be mortar tight and structurally rigid to disallow distortion due to the pressure of the vibrator and the concrete and other loads.

- Forms shall be constructed carefully and inspected for adequacy of construction before concrete pour.

- All corner joints shall be rigid in order to prevent opening during construction progress. The Contractor shall be responsible for the adequacy of forms and supports.

- Metal ties, struts, bolts and rods shall be arranged so that when the forms are removed, all metal shall not be less than 50mm from the exposed concrete surface.

- For all weather exposed concrete, metal ties if permitted shall be removed to a depth of at least 25mm from the concrete face without resulting injury of the concrete surface.

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- Suitable cones shall be provided. The cavities shall be filled with mortar and the surface left smooth, even and uniform in colour.

5.1.4. Where the bottom of the forms is inaccessible, the lower form boards shall be

left loose, or other provisions made so that extraneous materials may be removed from the forms easily before concrete placing.

5.2. Form Surface Treatment

All form surfaces shall be-treated with approved form release oil prior to placing of reinforcing steel, and, wood forms shall be wetted with water before concrete placing. No treatment compound shall be used which may discolour the finished concrete.

5.3. Placing of Weep Holes

5.3.1. Weep holes shall be provided and placed on all retaining walls or according to

the Drawings. Unless otherwise specified, weep holes shall be located at 2000mm spacing.

5.3.2. Weep holes, utility pipes and conduits shall be from PVC pipe having working pressure of 8kg/cm² complying with SNI 06-0084-2002, such as from Wavin, Invilon, Poly Unggul, Unilon. Diameter of PVC pipe shall be as shown in the Drawings.

5.4. Tolerances

The Contractor shall maintain and set the concrete forms to ensure that, after form removal and prior to patching and finishing work, no portion of the concrete work shall exceed any of the tolerances specification in the Drawings. Variations of deck levels shall be measured before removal of shoring and supports. Tolerances shall conform to ACI 347 and/or be approved by the Project Manager.

5.5. Concrete Cover

Unless otherwise specified, minimum thickness of concrete cover shall be made according to the usage, such as for foundation, columns and beams (excluding mortar finish), as shown in the Drawings.

5.6. Proportioning and Mixing of Concrete.

5.6.1. Proportioning of materials shall be accomplished by weighing or by volume batching.

5.6.2. The Contractor shall submit his proposed mixing plant to the Project Manager for

approval before use. The plant must be robust and reliable, and be capable of mixing 10 cubic meters of concrete in not more than two hours. The mix volume boxes shall be so sized that they suit the capacity of the mixing bowl of the plant.

5.6.3. Mixing of concrete shall not commence without ensuring that the stocks of

components are adequate, with a reasonable safety margin, for the completion of the particular pour of concrete.

5.6.4. In case of pours which can not be interrupted, the Contractor shall make

provision for adequate standby equipment as approved by the Project Manager.

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5.6.5. Ready-mixed concrete shall be mixed and delivered in accordance with requirements of ASTM C685.

5.7. Placing of Concrete

5.7.1. Concrete shall not be placed until forms, reinforcements, insert, block outs and

others have been approved by the Project Manager. The forms shall be cleaned, free of shakes, splits, notches, debris, and warps before concrete is poured.

5.7.2. The prepared and approved area for pouring the concrete shall be no larger

than 16.83m2 per block. In every concrete run, pouring shall be done one (1) block after the other. The external surface of concrete shall be properly worked out during the placing.

5.7.3. Ambient temperature when placing of concrete shall be 30ºC ± 2ºC. Temperature of concrete shall not exceed than 35ºC.

5.7.4. The difference between temperature of inside of the concrete and its surface

shall not be more than 20ºC.

5.7.5. Thorough vibration of 380-500mm distances shall be maintained in order to avoid honeycombing and to obtain smooth surfaces. During the vibration of concrete, the vibrator stick shall be held plumb or perpendicular to the horizontal surface of the fresh concrete.

5.8. Chutes Pipes and Troughs

5.8.1. Concrete shall be placed so as to prevent segregation of materials and displacement of reinforcing bars. Where steep slopes are required, the chutes shall be equipped with baffle boards which shall be in short lengths that reverse the direction of movement. All chutes, troughs and pipes shall be maintained and kept free from a hardened coating of concrete by properly flushing with water after each run.

The flushed water shall be discharged clear of the concrete already in place.

5.8.2. Concrete shall not be dropped in the forms from a height more than 150cm unless confined by closed chutes or pipes or tremie. After initial setting of concrete, forms shall not be jarred and no strain shall be placed on the ends of the reinforcement. Concrete shall be discharged from the mixer and transported within 1 (one) hour to final positions as approved by the Project Manager.

This shall guarantee that the concrete is of the required workability at the point and time of placing and the Contractor shall maintain a continuous delivery of concrete.

5.8.3. All the equipment, machinery and tools used for this work shall be clean, and

in good operating condition. If possible a standby unit or spare parts shall be available in site.

5.8.4. If used, pump lines must be laid so that the flow of concrete is not interrupted.

Sharp bends shall be avoided.

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5.8.5. Water content and particle size of aggregates shall be carefully watched when concrete is being pumped to avoid clogging. The slopes of troughs for conveying the fresh concrete shall be well chosen so that the concrete with minimum water content flows in a uniform stream without segregation of cement and aggregate.

5.8.6. When concrete is placed directly on earth or plastic membrane placed on

earth, the bed or base shall be clean and compacted, and free from standing or running water, and shall be in accordance with the Specified Drawings. Form surfaces upon where concrete are to be placed shall be properly cleaned of mud, loose rock, debris and other objectionable materials of coatings. These procedures shall be subject to the Project Manager for the approval. To prevent surface water entering the concrete, place moisture barrier made of plastic membrane on the prepared surface. This procedure shall be approved by the Project Manager.

5.9. Construction Joints

All construction joints shall be located where shown in the Drawings or determined by the Project Manager.

Construction joints shall be perpendicular to the principal lines of stress and in general shall be located at points of minimum shear at horizontal construction joints.

Necessary dowels, load transfer devices and bonding devices shall be placed as shown.

5.10. Open Joints

Open joints shall be constructed where shown by insertion and subsequent removal of

wooden strip, metal plate or other approved material. The insertion and removal of the template shall be accomplished without chipping on

breakage of edges or corners of the concrete. Reinforcement shall not extend across an open joint unless otherwise specified.

5.11. Steel Joints and Water Stop

Steel joints and water stop shall be placed as locate at all construction joints which

contact with soil or under ground water and elsewhere as indicated in the Drawings and as directed by the Project Manager. Water stop shall be continuously and shall be accurately placed, and securely supported to prevent displacement in exact positions indicated. Joint at intersections and ends of pieces shall be butt spliced and/or heat sealed as per manufacturer's instructions.

5.12. Removal of Forms

Forms and falsework shall not be removed without the approval of the Project

Manager. The Project Manager's approval shall not relieve the Contractor for the safety of the work. The schedule for removal shall be approved in advance by the Project Manager.

5.13. Patching of Concrete

5.13.1. The Contractor shall request to the Project Manager to inspect concrete

surfaces immediately upon removal of forms. 5.13.2. The Contractor shall (at his own expense) replace concrete not conforming to

required lines, details and elevations or having excessive defects. Do not patch, fill, touch-up, repair, or replace exposed architectural concrete except upon the express direction of the Project Manager.

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5.13.3. All general concrete formed surfaces shall have "as-cast" finish using specified forms.

Tie holes shall be plugged. Exposed surfaces and surfaces to receive paint shall have repairable defects patched, have joints pointed, have fins and mortar drippings rubbed smooth, and have form coating films and surface dirt removed.

5.13.4. Honeycombs, hollows or cold joints shall be repaired only upon the express

direction of the Project Manager. Patching materials shall be cohesive, un-shrinkable and surpass the concrete

in strength.

5.13.5. Remove blemishes, rust, stains or discolouration exposed concrete or concrete to be painted by:

- Light sand blasting. - A clean down with a mild solution of detergent and water applied by

scrubbing vigorously with soft bristle brushes, then flushing out with water. Remove rust stains by applying a paste of oxalic acid, allow to stand and to remove by rubbing with an approved hone.

- A clean down with a solution of muriatic acid containing not less than 2% or more than 5% acid by volume, applied to surface previously saturated with clean water. Remove acid. Protect metal and other materials that would be damaged by acid.

- Lime poultice. - Honing or grinding.

5.14. Concrete Finishing

Unless otherwise specified, the surface of the concrete shall be finished immediately after removal and shall be finished to the grades and dimension as shown.

5.15. Backfilling

Backfill shall be placed in layers of 150mm maximum loose fill thickness and tamped thoroughly as soon as concrete is twenty eight (28) days old or until the cylindrical test indicates the twenty eight (28) days strength has been achieved.

All backfill material shall be approved by the Project Manager prior to the backfilling work, as specified in Specification 02315.

5.16. Curing and Protection

The following measures shall be taken to protect freshly deposited concrete from the

sun, wind and rain until it has set properly, and to prevent quick drying:

- All forms containing concrete shall be kept moist until they are removed. - All exposed surfaces of concrete shall be moistened continuously for 7

consecutive days after pouring. - Special care shall be taken of surfaces of roof-slabs which shall either be covered

with moistened hessian or be protected from drying out by other suitable means. - It shall not be allowed to store materials on or to transport them over construction,

which, in the opinion of the Project Manager, has not been sufficiently hardened.

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SPECIFICATION

03400

PRECAST CONCRETE 1.0 DESCRIPTION OF WORK The work shall consist of the supply of material, labour, equipment and tools and constructing

and placing of precast concrete units of dimension and shape in accordance with the details as shown in the Drawings.

2.0 REFERENCE STANDARDS

2.1. Standard of the Precast Concrete Manufacturer.

2.2. Related Specifications:

- 01400 - Concrete Test. - 02315 - Excavation, Backfilling and Compaction. - 03200 - Concrete Reinforcement. - 03300 - Cast-in-Place Concrete.

3.0 GENERAL PROCEDURES

3.1. Technical Data. Technical data of specified materials shall be submitted to the Project Manager for

approval, prior to delivery and installation. Technical data shall show type/shape, dimension, manufacturer's installation

instruction and all information required for installation and erection.

3.2. Shop Drawings

3.2.1. The Contractor shall submit Shop Drawings which shall show details, placing diagrams, instructions and notes on materials, finish and others in accordance to the lines, elevations of the Drawings and shall be approved by the Project Manager.

3.2.2. The content of the Shop Drawings shall be as follows:

- Unit shapes (elevations and sections) and dimensions. - Finishes - Joint and connection details. - Lifting and erection inserts. - Location, dimensional tolerances and details of anchorage devices that

are embedded in or attached to structure or other construction. - Other items cast into panels. - Handling procedures, plans and/or elevations showing panel location and

sequence of erection for special conditions.

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- Relationship to adjacent material.

3.2.3. Show location of unit by same identification mark placed on panel. 3.2.4. Individual panel details may be submitted at the request of the Project

Manager. It is recognized that a review of the panel details prior to actual release for production will greatly impact the construction schedule.

3.3. Test Reports

Submit, upon request, reports on materials, and compressive strength tests on concrete and water absorption test on units.

3.4. Design Calculations

Submit upon request structural design calculations.

3.5. Handling, Storage and Delivery

3.5.1. Handling

Precast concrete units shall be handled and transported in a manner to minimize damage. Lifting devices or holes shall be consistent with industry standards. Lifting shall be accomplished with methods or devices intended for this purpose as indicated on shop drawings. Upon request, the precast concrete manufacturer shall provide documentation on acceptable handling methods for the product.

3.5.2. Storage

Precast concrete units shall be stored in a manner that will minimize potential damage.

3.5.3. Delivery

Precast concrete units shall be delivered to the site in accordance with the delivery schedule to avoid excessive build-up of units in storage at the site. Upon delivery to the jobsite all precast concrete units shall be inspected by the customer or customer’s agent for quality and final acceptance.

4.0 MATERIALS

4.1. General

All precast concrete materials shall be made of concrete with minimum quality of f'c= 21MPa, unless otherwise specified and determined by the Project Manager.

4.2. Culverts

All box culverts shall be of precast concrete product according to the standard of the manufacturer, all in shape, size or type as shown in the Drawings, such as manufactured by PT Rocla Persada Indonesia, PT Dantosan Precon Perkasa atau PT Duta Sarana Perkasa.

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4.3. Anchorage, Lifting Inserts and Devices

For anchors, lifting inserts and other devices, the precast concrete manufacturer shall provide product data sheets and proper installation instructions upon request. The precast concrete unit dimensions and safe working load shall be clearly indicated.

5.0 CONSTRUCTION REQUIREMENTS

5.1. Jobsite Conditions

5.1.1. Before starting to erect the precast concrete panels, the Contractor shall verify that the structure and anchorage inserts not within the tolerances required to the units have been corrected.

5.1.2. Determine field conditions before commencing erection.

5.1.3. All excavation shall be made to the required depth and dimensions as shown

by the Drawings.

5.1.4. The foundation where the precast concrete materials will be set or located shall be properly tamped and layered with sand blinding layer.

5.1.5. Compaction procedures shall be in accordance with Specification 02315.

5.2. Identification

5.3.1. Mark each precast concrete unit to correspond to the code markings appearing in the Shop Drawings for panel location. Do not mark on the finish surfaces.

5.3.2. Maintain a record of casting date.

5.3. Installation

5.4.1. Clear, well-drained unloading areas and road access around and in the

structure shall be provided and maintained by the Contractor, to include providing and maintaining accessible roadways in which cranes and trucks can maneuver under their own power.

5.4.2. Contractor shall install adequate barricades, warning lights or signs to

safeguard traffic in the immediate area of hoisting and handling operations. Any overhead obstructions interfering with the erection must be removed by others and any underground equipment installed where cranes and trucks must maneuver is installed at the risk of the trade requiring them and be protected by that contractor.

5.4.3. The forms shall be set so that the top of unit shall conform to the desired lines

and grades.

5.4.4. All precast concrete units shall be placed at designated interval as shown or as directed by the Project Manager.

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5.4.5. Set precast concrete unit’s level, plumb, square and true within the allowable tolerances. The Contractor shall provide true, level bearing surfaces on all fields placed concrete which are to receive precast concrete units. The Contractor shall be responsible for providing offset lines and elevations in sufficient detail to allow installation.

5.4.6. Fasten precast concrete units in place by bolting and/or welding, completing

dry packed joints, grouting sleeves and pockets and/or placing cast-in-place concrete joints, as indicated in the approved Shop Drawings.

5.4.7. Temporary lifting and handling devices cast into the precast concrete units

shall be completely removed, or if protectively treated remove only where they interfere with the work of any other trade.

5.4.8. All joints shall be 20mm spaced and sealed tightly with 1 : 3 mix of cement

mortar as directed by the Project Manager.

5.4.9. Backfill shall be immediately placed after the placing of precast concrete unit and shall be tamped to the level of the top as shown in the Drawings. The distance of the backfill from the edge of the unit shall be in accordance to the direction of the Project Manager.

5.4. Protection

All work and materials of other trades shall be adequately protected by the Contractor at all times.

5.5. Warranty

The Precast Concrete Manufacturer shall guarantee the precast concrete products against defects in material and workmanship, for a period of one (1) year, after acceptance of the units by the Owner.

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SPECIFICATION

03600

GROUT 1.0 DESCRIPTION OF WORK

The work shall include furnishing of equipment, materials, labour and application of grout at places as directed by the Project Manager.

The work shall include, but not be limited to the following:

- Grouting of anchor bolts and base plates. - Grouting of posts and structural steel members.

2.0 REFERENCE STANDARDS

2.1. American Society for Testing and Materials (ASTM).

2.2. British Standard (BS).

2.3. Standar Nasional Indonesia (SNI):

- SNI 03-2847-2002 - Tata Cara Penghitungan Struktur Beton untuk Bangunan Gedung.

2.4. Related Specifications:

- 03300 - Cast-in Place Concrete. - 05120 - Structural Steel. - 05500 - Miscellaneous Metals.

3.0 GENERAL PROCEDURES

3.1. Samples and Technical Data

Sample, brochure and/or technical data of the specified material shall be submitted to the Project Manager for approval, prior to delivery to location.

3.2. Handling and Storage

Original pack/bag from the factory shall be tightly closed and shall be kept in storage with

enough ventilation, free from humidity and water, and shall be placed at 30cm above floor.

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4.0 MATERIALS

4.1. Grout

Grout shall be made of cement material and shall have minimum characteristics as follows:

- Premixed product ready to use, - Impact and vibration resistant, - Non-shrinkage and non-metallic type, - Complying with ASTM C 1107, - Having minimum compressive strength of 610kg/cm² at 7days of age, according to

ASTM C 109 or 650kg/cm² according to BS 1881 part 116,

such as Sika Grout 214-11, Conbextra GPXtra by Fosroc, Masterflow 830 by BASF or approved equal.

4.2. Water

Water for mixing shall be clean water complying with the requirements of Specification

03300.

4.3. Moulds/Formworks

Moulds/formworks shall be made of steel plate or plywood from suitable thickness, which shall be formed in sizes and forms as specified in the Drawings.

Moulds/formworks shall be made in same size for places which shall have same size and form.

5.0 CONSTRUCTION REQUIREMENTS

5.1. Preparation

5.1.1. Moulds/formworks shall be designed so that the grout is surcharged throughout the grouting operation. Good access should be provided.

5.1.2. Moulds/formworks shall have been prepared and surfaces/parts to be grouted are

clean, dry and free from oil, grease and other contaminants likely to impair bond. Dust has to be blown from pockets.

5.1.3. Anchors, fixing bolts and base plates shall have been elevated prior to grouting.

5.2. Weather

The weather at the time of grout application being held shall be in accordance with the

requirements of the grout manufacturer.

5.3. Mixing

The mixing comparison between grout and water shall be in accordance with the manufacturer instruction.

Mixing is carried out mechanically, by force action mixer or a suitable mixing paddle attachment to a slow speed drill.

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5.4. Application

5.4.1. Grout might be poured or pumped into the mould, or as specified by the manufacturer's instruction.

Gentle vibration will aid flow.

5.4.2. Use of straps or chains will aid flow where distances of over 100cm are involved (sawing action of the strap or chain promotes sympathetic flow of the grout-the technique shall be used with discretion to avoid the creation of voids).

5.4.3. Flow of grout shall be maintained until the grout has completely filled the void and

has risen for the full length of the form on the opposite side. Grouting shall take place from one side only.

DIVISION 5 METALS

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SPECIFICATION

05120

STRUCTURAL STEEL 1.0 DESCRIPTION OF WORK. This work shall include the transportation, furnishing, fabrication, inspection and installation of

structural steel in field, as indicated and as described in this Specification or as directed by the Project Manager.

2.0 REFERENCE STANDARDS.

2.1. Standar Nasional Indonesia (SNI):

- SNI 03-1729-2002 - Tata Cara Perencanaan Bangunan Baja untuk Gedung.

2.2. American Institute of Steel Construction (AISC).

2.3. American Welding Society (AWS):

- D1.1 - Structural Welding Code- Steel.

2.4. American Society for Testing and Materials (ASTM):

- ASTM A36/A36M - Specification for Structural Steel. - ASTM A123 - Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and

Steel Products. - ASTM A307 - Specification for Carbon Steel Externally Threaded Standard

Fasteners. - ASTM A325/A325M - Specification for High-Strength Bolts for Structural Steel

Joints. - ASTM A525 - General Requirements for Steel Sheet, Zinc-Coated (Galvanized)

by the Hot-Dip Process

2.5. Japanese Industrial Standard (JIS):

- JIS G 3101 - Rolled Steel for General Structure (SS 400).

2.6. Related Specification 03600 - Grout. 3.0 GENERAL PROCEDURES.

3.1. Mill Certificates and Other Information.

3.1.1. Mill certificates covering the dimension, microstructure and chemical, physical, charpy V-notch properties, the heat treatment data (as applicable) and dimension of all steel to be used shall be submitted to the Project Manager for approval prior to fabrication.

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3.1.2. Prior to ordering of material, all the order lists shall be properly prepared by the Contractor and submitted to the Project Manager for approval.

3.1.3. Prior to starting shop work, the Contractor shall furnish the Project Manager

with the following information:

- Fabricator's facilities. - Materials intended for use and material manufacturers and suppliers. - Mill certificate and test report. - Shop Drawings procedures and schedule. - Measuring tapes intended for use. - Quality control methods and procedures. - Product procedures and schedule such as marking, cutting, bending,

drilling, milling and treating of frictional surface for bolt connection, etc. - Shop assembly facilities and procedure. - Proposed manufacturer welding details for:

· flux, gas, welding rod and wire together with manufacturers recommendations for storage.

· Temporary welding, welding sequence and procedure, preheating, welding equipment and accessories, arcair gausing/chipping.

- Method of embedding anchor bolts and setting base plates. Installation procedures and allowable tolerance of anchor bolt location.

- Inspection including full-size drawing inspection, marking drawing inspection, assembly inspection, welding inspection, material inspection, product inspection.

A copy of the Contractors inspection record form shall be submitted. The proposed inspection record form shall be attached.

- Proposed method of correction of faulty work. - Method of paint application. - Storage at plant yard and at site. - Transporting facilities and route from shop to site. - Qualifications of welders and other specialists.

3.2. Shop Drawings.

3.2.1. Contractor shall submit Shop Drawings to the Project Manager for approval

prior to fabrication. The following items shall be included in the Shop Drawings as applicable:

- Material specification. - Piece mark numbers/installation drawings. - List of material parts. - Fabrication details. - Welding details. - Painting requirements. - Shop splices details and locations.

3.2.2. The approval of Shop Drawings by the Project Manager does not relieve the

Contractor of his responsibility for errors and omissions.

3.2.3. No alterations shall be made in the finally accepted Shop Drawings by the Contractor without written consent of the Project Manager.

3.2.4. Changes initiated by Contractor for his convenience shall be subject to the

Project Manager's approval and made at Contractor's expense.

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3.3. Inspection and Testing.

3.3.1. Materials, connections and workmanship generally shall be subject to tests or inspection in the mill, shop and field.

3.3.2. Tests and inspections shall be conducted by a qualified person or testing

laboratory retained by the Contractor and approved by the Project Manager. The Contractor shall furnish all materials for testing and any access to, or

handling of required materials to perform material tests.

3.3.3. Inspect shop assemblies and welding for conformance with the specified requirements.

3.3.4. Clean, grind and prepare all areas as required for ultrasonic and radiographic

tests.

3.3.5. The Project Manager shall have the right to carry out and/or order the carrying out of test and inspections at any time.

The Project Manager shall have the right, at all reasonable times, to enter the Contractor's fabrication plant for the purpose of testing and inspecting the work. All labour and tools required for testing and inspecting in the fabricator shop shall be provided by the Contractor.

3.3.6. The Project Manager reserves the right to reject materials and/or workmanship

not conforming to the design drawings at any time before final acceptance. The Project Manager's acceptance of material of workmanship shall not prevent its subsequent rejection if defects are discovered later. The Contractor shall remove installed materials which are rejected by the Project Manager and replace them at no additional cost to the Employer.

3.3.7. All welders shall have valid current licenses. If required by the Project

Manager, the Contractor shall perform tests of welder's skill. Tests, when required, shall be conducted at no additional expense to the

Owner.

3.4. Steel Measuring Tape. The Contractor shall provide the number of precise tapes required for the carrying out

of the work (minimum of 3 tapes). At all times, the ambient temperature shall be recorded and thermal adjustments made

to all measurements. Measuring tape used in the fabricator shop of the steel work shall be compatible with those used for site erection of the steel work.

The Contractor shall arrange such test as necessary to allow the Project Manager to approve the tolerance between the tapes used on either location as negligible. All measurements shall be the Contractor's responsibility.

3.5. Handling and Storage.

3.5.1. All steel materials shall be delivered complete with original mill certificates.

3.5.2. All steel materials shall be handled with extreme care, in such a manner so as

not to cause excessive scratches or dents, as determined by the Project Manager.

3.5.3. Material shall be stored out of contact with the ground in such manner and

location as will minimize rusting and corrosion.

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4.0 MATERIALS.

4.1. General Requirements.

4.1.1. All material values shall be in accordance with and as stated in this Specification, unless otherwise noted.

4.1.2. Chemical composition, mechanical properties, dimensions and other qualities

of materials are specified in each standard. These material qualities shall be confirmed by a testing prior to shop works whether it is equivalent with the manufacture certificates.

4.2. Structural Steel

4.2.1. All steel material shall be new and be free from defects impairing strength,

durability or appearance and shall be of the best commercial quality, and shall comply with the relative standard.

4.2.2. Structural steel shall be standardized products as listed below or their

equivalents approved by the Project Manager:

- Steel grade Bj.37 (St. 37) having yield strength of 24kg/mm2 and tensile strength of 37kg/mm2 complying with SNI 03-1729-2002 or ASTM A36/A36M.

- Steel grade SS 400 having yield strength of 24kg/mm² and tensile strength of 41kg/mm² complying with JIS G 3101.

4.2.3. The steel to be used shall not have any structural defects and not be

obtrusively corroded. The shape and dimensions of steel profile and other related items shall be according to the relative SNI, JIS and ASTM, or equivalent.

4.2.4. Bolts, nuts, washers, anchor bolt and plates shall be as follows:

- Ordinary bolts, nuts and washers shall meet the requirements of the

following standards or their equivalents: · SNI 03-1729-2002 (Bj.37/St 37). · ASTM A307.

- High strength bolt, nuts and washers shall meet the requirements ASTM A325/A325M.

- Anchor bolts shall meet the requirements of the following standards or their equivalents: · SNI 03-1729-2002 (Bj.37/St 37). · JIS G 3101 (SS 400). · ASTM A36/A36M.

- Nuts, washers and screw threads shall be according to standards of ordinary bolt listed above.

4.2.5. For standardized items the certificates proving the conformity of the products

to the approved standards may be submitted in lieu of tests. However the Project Manager may, when necessary, request the Contractor to carry out mechanical tests of the materials at the Contractor's expense.

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4.3. Bridge Deck

Bridge deck or steel deck for bridge floor shall have minimum specification as follows: - Steel material : Complying with ASTM A 572, JIS G 3101, JIS 3131 and JIS G

3352, - Size of profile : 6mm x 100mm x 455mm with standard length of 7000mm or

9000mm, - Finishing : Hot dip galvanizing of 90 micron according to ASTM A 525-86,

Such as manufactured by Gunung Garuda or Gunung Raja Paksi or approved equal.

4.4. Welding Materials.

4.3.1. Electrodes to be used for welding shall be standard products from the type

conforming to AWS A5.1-E70xx or equivalent. The appropriate electrodes shall be selected best fitting the type of steel to be welded.

4.3.2. Welding materials other than those stipulated above shall be selected

according to the method of welding to be employed.

4.3.3. When base metals of two different yield stresses are welded together, filler metal shall be selected based on the base metal that has the higher yield stress.

4.5. Galvanizing

Galvanising shall conform to ASTM A 123 specification for Zinc (Hot-Dip Galvanized) Coating on Iron and Steel Product, and the thickness of zinc coating shall be in the range between 19 to 21microns.

4.6. Grout.

Grout for filling anchor's holes, base-plate’s pad and others as indicated in the

Drawings shall be made of cement material, of non-shrinkage and non-metallic type as specified in Specification 03600.

5.0 CONSTRUCTION REQUIREMENTS.

5.1. Fabrication.

5.1.1. General.

- The Contractor shall give the Project Manager one (1) week's notice before commencing any major fabrication segment, such as enclosing the sides of any major structure.

- Steel items shall be of the sizes, shapes and construction as indicated or specified.

- Prior to the fabrication, all the necessary measurements shall be verified and checked in accordance with the quality control procedures of the AISC requirements.

Unless otherwise specified, the items shall be fabricated in accordance with an efficient shop method.

- The Contractor shall be responsible for correction of all errors and omissions in detailing, layout and fabrication at his own cost.

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5.1.2. Location of Fabrication. Structural steel shall be fabricated and assembled in the Contractor's shop or

yard or in location as approved by the Project Manager. Basically welding at the field shall not be permitted.

5.1.3. Welding.

a. Welder.

- The qualification of welder shall, in principle, conform to the respective stipulations of AWS D1.1 of the latest edition according to a type of welding to be carried out.

The welder shall have more than recent one year of continuous experience in structural welding and shall receive the approval of the Project Manager.

- If the Project Manager has any doubts of the welder qualification although an approval has been given, the Project Manager may direct to carry out examination tests in accordance with relevant AWS or other equivalent standards or may cancel the approval.

b. Preparation of Materials.

- Edge Preparation

· Groove angle shall be in accordance with the design and Shop Drawings. However it may be modified according to a type of welding to be carried out with the approval of the Project Manager.

· Grooves shall be made to the shape as stipulated above by automatic gas cutting or other mechanical methods. Manual gas cutting may be allowed under inevitable situations with the approval of the Project Manager.

- Welding Material · Electrodes shall be carefully handled and due precaution shall be

taken so as not to use electrodes which have their covering materials peeled, contaminated, deteriorated and exposed to moisture.

· Welding materials shall be stored dry, and shall be sufficiently dried before their use in case they have been exposed to moisture.

c. Assembly of Elements.

- Accurate assembly of elements shall be achieved by using proper jigs. - Where fillet welding shall be carried out the element shall be closely

adhered to the base metal as possible. - Temporary welding shall be held at a minimum and shall avoid areas

where it is structurally or erection wise impeding. Where it becomes part of the permanent welding the welding shall be without faults.

d. Welding Equipment and Ancillary Equipment.

- Welding equipment shall be of a type best meeting the requirements

for a material and dimension of joints to be welded and be able to achieve and even welding.

- Ancillary equipment shall have the required performance characteristics and shall be well maintained.

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e. Cleaning of Base Metal. Welding surface of the base metal shall be sufficiently cleaned of slag,

moisture, dirt, corrosion, oils, paints or other contaminants before welding.

f. Welding Works.

- Welding shall be done at proper speed, correct current and voltage according to a type and position of welding.

- Shop welding shall, whenever possible, be done facing downwards using a rotating jig positioner.

- Steel elements shall be pre-heated as required according to plate thickness and type of materials.

- Fabrication of built-up beams and girders shall be submerged arc welding where possible.

- Welding: · Method and sequence of welding shall be planned so as not to

cause any strain or to leave residual stress. · Before or during the permanent welding, temporary welding shall

be removed, if the temporary welding has any damage. - Finished state:

· The surface of welding shall have a uniform wave pattern, and size and length of welding shall not be less than a dimensions shown in the Drawings. The size of welding may be larger than specified but shall not be overly large or be irregular in pattern.

· The welded part shall not have cracks, incomplete, fusion, lack of penetration, slag inclusion, pits, blowholes, undercutting, overlapping unevenness of legs or other faults.

- Fillet welding: · In case of equal leg fillet welding, it shall not be overt difference

between the two legs. · A depth of reinforcement of weld shall be less than 0.1S+1 mm

(S: the specified fillet size). - Arc:

· Special care shall be taken to prevent lack of penetration and slag inclusion at the starting point of arc. An arc shall be moved along the base metal or the element to be welded whether it is the beginning of a weld or a continuation of a bead.

· Care shall be taken so as not to cause cracks in the bead of the arc end. Slag and spatters shall be removed from the welded surfaces and around surface of the welding.

g. Weather Conditions.

Welding shall not be done when a welding surface is wet due to rain or

other reasons or when strong winds are blowing. However if the position of weld and the welder is adequately protected and proper curing of the base metal is carried out, welding may be carried out after confirmation of no remained moisture on the surface, and with the Project Manager's approval.

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h. Correction of Materials. Warping caused in the materials shall be corrected by mechanical means

or by heating in such a way as not to cause any pernicious affect to the materials.

i. Inspection of Welding.

- During and after welding proper in-shop inspection shall be performed.

Defective portions shall be corrected repeatedly to the satisfaction of Project Manager. The charge shall be counted as Contractor’s cost.

- The minimum welding inspection to be performed by Contractor and/or fabricator shall be by visual examination, liquid penetration test and radiographic test.

All welds shall present a uniform appearance and excessive undercut shall be held at a minimum.

- After welding and after the above in-shop inspection, welds shall be inspected by the Project Manager. However the above may be abbreviated with the Project Manager's approval by submission of the result of the in-shop inspection.

5.1.4. Bolt Connections.

a. Holes Diameter.

All holes for bolted connections shall be of a diameter 2mm larger than

bolts used, unless otherwise indicated.

b. Holes Fabrication. All holes shall be drilled at right angles to the surface of the metal and

shall not be enlarged by burning. Enlarging of holes shall be by reaming only with the approval of the Project Manager.

Holes shall be clean-cut without torn or roughed edges. Outside burs resulting from drilling or reaming operations shall be

removed with a tool making a 1,5875mm bevel. All holes shall be drilled and reamed as necessary prior to application of protective coating.

c. Holes Reinforcement.

Where holes are provided for the connection of equipment or for cable

and piping access, and affect any major structural members, said members shall be reinforced adequately as designated by the Project Manager.

5.1.5. Cutting, Shearing and Clipping.

Shearing, flame cutting and clipping shall be done carefully and accurately by

a mechanically guided tool. All edges shall be left free of slag. Any bevelled edge that has been damaged shall be restored to the minimum tolerances.

5.1.6. Fabrication Tolerances.

The location of each member is essential to the design of the structure. Each

member shall be accurately located as shown in the Drawings, within the fabrication tolerances given in AISC.

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5.1.7. Product Inspection.

- In-shop inspection report of finished products shall be submitted to the Project Manager for approval.

- After the in-shop inspection, the products shall be inspected by the Project Manager. The product shall be laid in a way not to hinder inspection and instruments necessary for inspection.

- Faulty portions shall be promptly rectified.

5.1.8. Protective Coating/Galvanizing.

- Provide as indicated or specified. Galvanize after fabrication where practicable.

- Method of galvanizing shall conform to ASTM A 123 specification for Zinc (Hot-Dip Galvanized) Coating on Iron and Steel Product, and the thickness of zinc coating shall be in the range between 19 to 21microns.

5.2. Installation.

5.2.1. Procedures and Sequence.

- Prior to scheduled erection of the structure, the Contractor shall submit to

the Project Manager an installation procedure and sequence with supporting calculations to verify that sufficient engineering has been done to ensure a successful erection, for approval.

- Prior to starting field erection, the Contractor shall furnish the Project Manager with the following information: · Roof structure erection.

* Plant of erection equipment and scaffolding. * Details of crane foundation, erection and removal. * Temporary staying and bracing. * Required erection accessories. * Shipping and delivery (including schedule). * Temporary storage yard and handling methods. * Temporary electric supply. * Erection sequence, procedures and methods. * Erection tolerances and methods for maintaining. * Equipment and procedures for tightening erection bolts.

· Setting anchor bolts and base plates. · Painting. · Field inspection. · Safety measures proposed.

- Installation and erection equipment shall be provided in sufficient quantity,

quality and capacity to perform the operation without failure or shutdown. The schedule shall provide for an expeditious completion of erection and

installation. Erection procedures shall delineate actions to be taken in the event of rough weather at any point of the operation.

5.2.2. Pick-Up.

- Contractor shall be responsible for the structural adequacy of any structure or portion of structure which he lifts or moves. Contractor shall perform the structural analysis necessary to ensure that installation will be made without damage to the structure.

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- Contractor may submit pickup method for erection work for Project Manager's approval. Any additional materials and fabrication cost required to withstand the loading introduced by the alternate pickup method shall be furnished by Contractor at no additional cost to the Project Manager.

5.2.3. Environmental Conditions.

Do not erect roof structure during heavy or gusty wind conditions.

5.2.4. Installation Tolerances.

- The Contractor shall install the structure on the designated erection site. Contractor shall verify condition of existing site prior to commencing installation procedures and shall report to the Project Manager any conditions which would preclude installation of structure to the AISC tolerances.

- All structures shall be erected within tolerances set forth in the AISC specifications unless otherwise stated. Any erected member of structure shall be self supporting to any external forces likely to be exerted while erection is in progress.

- Any temporary bracing added to the structure for self support and alignment shall be designed to withstand all conditions of loading, at his cost, during any phase of the work.

5.2.5. Bolt Tightening.

- Prior to the erection, all bolts, connections, alignments, grades, materials

and facilities shall be thoroughly worked out. - Bolt tightening shall be done by calibrated torque wrench in order to

determine the necessary bolt tension. - Bolt holes shall be aligned so that bolts can be placed without damaging

threads. Bolt heads and nuts shall rest squarely against the metal. Unfinished bolts transmitting shear shall be threaded to such a length that

no more than one thread will be within the grip of the structural members. The bolts shall be of length that will extend entirely through but no more

than 6.35mm beyond the nuts. Bolts heads and nuts shall be drawn tight against the work surface with a suitable wrench not less than 381mm.

Bolt heads shall not be tapped with a hammer while the nut is being tightened. After having been finally tightened, the nuts shall be brushed and painted.

5.2.6. Grouting.

Grouting shall be carried out in accordance with the requirements of

Specification 03600.

5.2.7. In-Site Painting.

- Damage to the coat surface erection shall be mended immediately after completion of erection.

- Use galvanizing repair paint for galvanizing damaged part caused by handling, transporting, cutting, welding or bolting. Do not heat surfaces where repair paint has been applied on.

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SPECIFICATION

05500

MISCELLANEOUS METALS 1.0 DESCRIPTION OF WORK. The work under this specification shall comprise transportation, the supply of labour, materials,

and the performance of all work necessary to install metal works in relation to non-structural works as indicated in the Drawings.

It shall include but is not limited to the following:

- Handrails and railings, - Bollards or post guards, - Anchor bolts, - Bolts, nuts and washers, - And others as indicated in the Drawings.

2.0 REFERENCE STANDARDS.

2.1. American Society for Testing and Materials (ASTM).

2.2. American Welding Society (AWS).

2.3. American Institute of Steel Construction (AISC).

2.4. American National Standard Institute (ANSI).

2.5. Standar Nasional Indonesia (SNI):

- SNI 03-1729-2002 - Tata Cara Perencanaan Struktur Baja untuk Bangunan Gedung.

2.6. Related Specifications:

- 03600 - Grout. - 05120 - Structural Steel.

3.0 GENERAL PROCEDURES.

3.1. Samples and Mill Testing. Samples completed with mill certificates covering the chemical, physical, charpy

V-notch properties and the heat treatment data of all steel or metal to be used shall be submitted to the Project Manager for approval prior to fabrication.

All testing shall be performed on a sample of the finished product.

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3.2. Shop Drawings. A Shop Drawing and list of materials of pre-fabricated items falling into this category

shall be submitted to the Project Manager for approval prior to fabrication. After the approval, no deviations or alterations shall be made in the finally accepted shop drawings by the Contractor without written consent from the Project Manager.

The following items shall be included in the Shop Drawings as applicable:

- Materials specification, - Piece mark numbers, - List of material parts, - Dimensions (exact length and shape) and weight, - Fabrication details, - Connection and welding details, - Installation details, - Painting requirements. - Shop splice details and locations,

3.3. Inspection and Testing.

3.3.1. The material to be furnished under this Specification shall be subject to

inspections and tests in the mill, shop and field by the Project Manager. However, inspection in the mill or shop will not relieve the Contractor of the responsibility to furnish new and first quality of materials and workmanship.

3.3.2. The Contractor shall perform and pay the cost of all sampling and testing of

materials and work as required, including any product demonstration proposed by the Project Manager.

3.3.3. The Project Manager reserves the right to reject any material or fabricated

item if at any time before final acceptance of the structure, the following condition occurs:

- The materials supplied do not conform to this Specification. - The fabricated items do not conform to the Drawings or Specification. - Modification has been made without the written approval from the Project

Manager.

3.4. Handling and Storage of Material.

3.4.1. Materials shall be stored out of contact with the ground in such manner and location as will minimize rusting and corrosion.

3.4.2. All metals shall be handled with extreme care, in such a manner as not to

cause excessive scratches or dents, as determined by the Project Manager.

3.4.3. All imperfections must be thoroughly inspected and any deep cuts or serious abrasions shall be repaired and ground smooth. Plate repair procedure shall be submitted to the Project Manager for approval. No other grinding shall be permitted on base material to remove surface imperfections except as to prepare surface for welding.

Burning shall not be used to straighten or to bend material, except by written consent of the Project Manager.

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4.0 MATERIALS.

4.1. General.

4.1.1. All metals shall be new and free from defects impairing strength, durability or appearance, and shall be of the best commercial quality.

4.1.2. Unless otherwise specified, steel for light structural shapes, hollow and plates

shall be made of steel grade Bj.37 having minimum yield strength of 2400kg/cm², conforming to the requirements of SNI 03-1729-2002 and/or ASTM A36, finished in hot dip galvanizing coat of minimum 90microns, unless otherwise specified.

Items to be substituted shall be approved by the Project Manager.

4.2. Steel Pipe.

Steel pipe for bollards or post guards, handrails and railings shall be galvanized type of medium class complying with SNI 07-0039-2010 and of diameter as required and as specified in the Drawings, finished in yellow colour, unless otherwise specified.

4.3. Anchor Bolts, Bolts and Nuts.

4.3.1. Anchor bolts shall be made of steel round bar having minimum yield strength of 2400kg/cm², complying with SNI 03-1729-2002 and/or ASTM A 36/A 36M, and in diameter and length as indicated in the Drawings.

4.3.2. Bolts and nuts shall conform to ASTM A-307, and shall be cadmium plated,

except where high strength bolts are shown or specified. All washers shall be cadmium plated.

4.3.3. Chemical and or expansion anchor bolts shall be similar or equal to Ramset,

Fischer or Hilti product. Diameter and length of chemical and or expansion anchor bolts shall as indicated in the Drawings and as recommended by the manufacturer.

4.4. Welding Materials.

4.6.1. Electrodes to be used for welding shall be standard products conforming to

AWS D1.1 of latest edition. The appropriate electrodes shall be selected best fitting the type of steel to be welded, such as E70XX electrodes.

4.6.2. Welding materials other than those stipulated above shall be selected

according to the method of welding to be employed.

4.6.3. When base metals of two different yield stress are welded together, filler metal shall be selected according to the base metal which has the higher yield stress.

4.5. Grout.

Grout for filling anchor's holes, baseplate's pad and others as indicated in the

Drawings shall be made of cement material, of non-shrinkage and non-metallic type as specified in Specification 03600.

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5.0 CONSTRUCTION REQUIREMENTS.

5.1. General.

5.1.1. Miscellaneous metal items shall be of the sizes, shapes and constructed of materials as indicated or specified in Drawings.

Unless otherwise specified, the items furnished shall be an approved product, fabricated in accordance with an efficient shop method.

Prior to the fabrication, all the necessary measurements shall be verified and checked in accordance with the quality control procedures of the AISC requirements.

5.1.2. Design and members and connections for any portion of the structures not

indicated in the Drawings shall be completed by the Contractor and indicated on the Shop Drawings.

5.1.3. The Contractor shall be responsible for correction of all errors and omissions

in detailing, layout and fabrication at his own cost.

5.2. Fabrication and Installation.

5.2.1. General.

- Fabrication of miscellaneous metals shall be carried out in accordance with the Drawings and this Specification.

Welding work shall be carried out in accordance with AWS D1.1 of latest edition.

- Unless otherwise indicated in the Drawings, minimum thickness of welding shall be 3mm by using E70XX electrodes.

- For fabrication of work exposed-to-view, use only materials that are smooth and free of surface blemishes including pitting, seam marks, roller marks, rolled trade names and roughness. Remove blemishes by grinding, or by welding and grinding, prior to cleaning, treating and application of surfaces finishes.

- Exposed connections with hairline joints which are flush smooth shall be formed using concealed fasteners wherever possible. Use exposed fasteners of the type indicated or, if not indicated, use cross-recessed flat head (countersunk) screws or bolts.

- Installation of miscellaneous metal in types, sizes and distances as shown in the Drawings, shall be carried out according to the Drawings, Specification of the related works and the approved Shop Drawings.

- Anchor bolts, anchor bolt assemblies and hook bolts shall be furnished and installed in conformity with the Drawings and as directed by the Project Manager. All steel anchorage embedded to concrete shall be properly cleaned of rust, loose scales, oil and other objectionable matter in order to have a good bond to the concrete.

Grouting shall be in accordance with Specification 03600. - Provide and coordinate anchorage of the type indicated with the

supporting structure. Fabricate and space anchoring devices to provide adequate support for the intended use of the work.

5.2.2. Handrails and/or Railings.

- Adjust railings prior to securing in place to assure proper matching at butting

joints and correct alignment throughout their length. Plumb post in each direction. Secure posts and rail ends to building construction.

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- Post shall be welded to base with flange, angle types or floor types as required by conditions or by the Drawings. Then post with its base shall be bolted to the supporting members as described or as directed by the Project Manager.

5.2.3. Bollards or Guard Posts

Bollards or guard posts shall be fabricated from steel pipe of 100mm in diameter, unless otherwise indicated in the Drawings.

Bollards or guard posts shall be securely embedded 500mm deep, and filled with concrete to give necessary impact resistance, with the height of 1200mm from the floor surface, unless otherwise indicated in the Drawings.

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SPECIFICATION

05800

EXPANSION CONTROL 1.0 DESCRIPTION OF WORK.

The work shall consist of furnishing and installing elastomeric bridge joint control in accordance with the details shown in the Drawings and the requirements of the Specifications.

2.0 REFERENCE STANDARDS.

2.1. Australian Standard (AS).

2.2. British Standard (BS). 3.0 GENERAL PROCEDURES.

3.1. Samples and Product Data. Sample and product data of material to be used shall be submitted to the Project

Manager for approval. Sample of expansion joint shall be at least 150mm long for each type.

3.2. Shop Drawings. The Contractor shall prepare and submit Shop Drawing to the Project Manager for

approval. Shop Drawing shall cover typical expansion joint cross section indicating pertinent

dimensioning, general construction, component connections, anchorage methods and hardware locations.

3.3. Handling and Storage

All material shall be delivered in each manufacturer's original intact labeled containers

and stored under cover in a dry location until installed. Store off the ground, protected from the weather and construction activities.

3.4. Quality Control

Manufacturer shall be ISO-9001:2000 certified and shall provide written confirmation that a formal Quality management System and Quality Processes have been adopted in the areas of, (but not limited to) Engineering, Manufacturing, Quality Control and Customer Service for all processes, products and their components. Alternate manufacturers will be considered provided they submit written proof that they are ISO 9001:2000 certified prior to the project bid date.

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3.5. Job Conditions The installation of work in this section shall be coordinated with related work. Protect

installed units until completion of the entire work. 4.0 MATERIALS

4.1. Manufacturers.

Manufacturer shall a minimum ten (10) years experience specializing in the design and manufacture of expansion control systems

4.2. Elastomeric Bearing

- Elastomeric bearing of laminated type shall consist of natural rubber of hardness

shore A 60+/-5 with minimum tensile strength of 176kg/cm2 and ultimate elongation of 400%, with layers and thickness according to the standard of the manufacturer, reinforced by thin steel plate of thickness according to the standard of the manufacturer of minimum tensile strength 3,700kg/cm2.

- Dimension shall be according to the requirements as shown in the Drawings, B y BS (rectangular reinforced bearings) type, made by VSL or approved equal.

- Elastomeric bearing shall comply with the requirements of BS 5400 Part 9, Memorandum BE 1/76 Department of Environment UK and AS 1532.

- Elastomeric bearing shall be highly resistant to deterioration from exposure to weather, sunlight, oils, chemicals, heat, abrasion and impact.

4.3. Expansion Joint.

Expansion joint shall consist of chloroprene rubber that is fabricated, connected to the

edge of the joint using waterproofed bond, anchored with Carbon Fiber Reinforced Plastic (CFRP) to SBR mortar filler such as A-3 new cut off joint type from Sho-Bond or approved equal. Maximum expansion width shall be 50mm, unless otherwise shown in the Drawings.

SBR mortar shall comply with JIS R 5201; bonding agent and joint seal rubber shall comply with JIS K 6301.

5.0 CONSTRUCTION REQUIREMENTS.

5.1. Preparation.

5.1.1. Manufacturer's Instructions: In addition to requirements of this Specification, comply with manufacturer's instructions and recommendations for phases of Work, including preparing substrate, applying materials, and protecting installed units.

5.1.2. Coordinate and furnish anchorage, setting drawings, templates, and instruction for

installation of expansion joint cover assemblies to be embedded in or anchorage or to have recesses formed into edges of concrete slab for later placement and grouting-in frames.

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5.2. Installation

5.2.1. Install seals complying with manufacturer's instructions and with minimum number of end joints. For straight sections provide preformed seals in continual lengths. Vulcanize or heat-weld field splice joint in preformed seal material to provide watertight joints using procedures recommended by manufacturer. Apply adhesive, epoxy, or lubricant-adhesive approved by manufacturer to both frame interfaces before installing preformed seal. Seal transitions according to manufacturer's instructions.

5.2.2. Seal end joints within continuous runs and joints at transitions according to

manufacturer's directions to provide a watertight installation.

5.3. Cleaning and Protection. Do not remove protective covering until finish work in adjacent areas is complete. When

protective covering is removed, clean exposed surfaces to comply with manufacturer's instructions.

PT BITA ENARCON ENGINEERING

Head Office :Jl. Pahlawan No. 74, Bandung - 40124

West Java, Indonesia

Ph : +62.22.7202748 (Hunt)

Fax : +62.22.7202749

E-mail : bita@bita.co.id

Jakarta Office :Jl. Prof. DR. Satrio No. 289, 3rd Floor,

Karet Kuningan,

Jakarta -12930, Indonesia

Ph : +62.21.5790 1030, 7093 1291

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E-mail : bita-eng@indo.net.id

Balikpapan Office :Ruko Fantasy Junction Block. FJ-1 No.3, Ruko Fantasy Junction Block. FJ-1 No.3,

Balikpapan Baru, Balikpapan - 76114

East Kalimantan, Indonesia

Ph : +62.542.7070514 / 7070515 / 7034580

Fax : +62.542.7212358

E-mail : bita-bpn@indo.net.id

Yogyakarta Office :Jl. Palagan Tentara Pelajar No. 27

Yogyakarta 55581, Indonesia

Phone/ Fax : +62 274 885370

E-mail : bita_yogya@bdg.bita.co.id