Gmws Iss.5 Vol1 C&s

GENERAL
MATERIALS AND WORKMANSHIP

SPECIFICATION
VOLUME 1
CIVIL AND STRUCTURAL WORKS
ISSUE NO. 5
JANUARY 2011
[this page not used]
GENERAL MATERIALS AND WORKMANSHIP SPECIFICATION

TABLE OF CONTENTS
VOLUME
CIVIL AND STRUCTURAL WORKS
Section
General Civil and Structural Works
Temporary Works
Site Clearance
Landscaping Works
Fencing
Drainage Works
Earthworks
Geotechnical Works
Carriageways: Sub-base Material and Bituminous Materials
10
Concrete Carriageways
11
Miscellaneous Roadworks
12
Traffic Signs, Road Markings and Road Studs
13
Work for Electrical and Mechanical Installations
14
Water Supply Pipeworks
15
Not Used
16
Not Used
17
Piling Works
18
Formwork and Finishes to Concrete
19
Steel Reinforcement
20
Concrete and Joints in Concrete
21
Prestressing
22
Steelwork
23
Bridgeworks
24
Water Retaining Structures
VOLUME
ARCHITECTURAL WORKS
Section
25
General Architectural Works
26
Masonry and Blockwork
27
Waterproofing and Tanking
28
Roofing and Wall Cladding
29
Curtain Walling
General Materials & Workmanship Specification

Issue No. 5 Table of Contents
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January 2011

TABLE OF CONTENTS (CONTD)
VOLUME
ARCHITECTURAL WORKS (CONTD)
Section
30
Internal Cladding Systems
31
Carpentry and Joinery
32
Internal Cladding Systems
33
Linings, Sheathings, Drywall Partitions and Toilet Cubicles
34
Suspender Ceilings
35
Architectural Metalwork (Including Metal Doors and Shutters)
36
Ironmongery
37
Hard Floor Finishes
38
Flexible Floor Finishes
39
Wall Finishes
40
Painting and Decoration
41
Fire Protection and Fire Stopping Systems
42
Signage
43
Not Used
VOLUME
ELECTRICAL AND MECHANICAL WORKS
Section
44
General Electrical and Mechanical Works
45
Electrical Supply
46
Low Voltage Switchboards
47
Sub-Mains Electrical Distribution Equipment
48
Wiring and Cables
49
Cable Management Systems
50
Wiring Accessories and Miscellaneous Electrical Equipment
51
General Lighting Systems
52
Uninterruptible Power Supply System (UPS)
53
Motors
54
High Voltage Electrical Services
57
Earthing and Bonding System
58
Lighting Protection System
59
Electromagnetic Compatibility
60
Inspection, Testing and Commissioning - Electrical Services

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January 2011

VOLUME
ELECTRICAL AND MECHANICAL WORKS (CONTD)
Section
61
Air Handling units
62
Fan Coil Units
63
Fans
64
Split Type Air Conditioning Unit
65
Window Type Air Conditioning Unit
66
Air Cooling Coils
67
Dampers and Air Volume Control Devices
68
Registers, Diffusers and Grilles
69
Air Filters
70
Ductwork and Fittings
71
Water Handling Equipment
72
Pipeworks, Fittings and Valves
73
Thermal Insulation
74
Sound Attentuator
75
Noise and Vibration Control
76
Electrical Equipment and Installation
77
Automatic Controls
78
Instruments
79
Testing, Inspection and Commissioning Mechanical Services
80
Automatic Sprinkler System
81
Hydrant and Hose Reel System
82
Gaseous Fire Extinguishing System (FM200)
83
Fire Alarm and Detection System
84
Portable Hand Equipment
85
Visual Fire Alarm
86
Exist Sign and Directional Sign
87
Pipework, Valves and Fittings
88
Pumps and Tanks
89
Automatic Sprinkler System
90
Inspection, Testing and Commissioning Fire Services

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January 2011

VOLUME
ELECTRICAL AND MECHANICAL WORKS (CONTD)
Section
91
Foul Water Disposal
92
Storm Water Disposal
93
Water Supply
94
Hot Water Supply System
95
Pipework, Fittings and Valves
96
Town Gas Reticulation
97
Pumps and Tank Level Controls
98
Electrical Equipment and Installation
99
Inspection, Testing and Commissioning Hydraulic Services
100 General Building Management System

101 Mechanical Building Management System
102 Voice and Data
103 Public Address System
104 Access Control System
105 Trunked Mobile Radio System
106 Closed Circuit Television System
107 Master Antenna Television (MATV)
108 Inspection, Testing and Commissioning Airport Systems
109 Not Used
110 Not Used
111 Not Used
112 Not Used
113 Not Used
114 Not Used
115 Not Used
116 Not Used
117 Not Used
118 Not Used
119 Not Used

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January 2011

VOLUME
AIRFIELD WORKS
Section
120 General - Airfield Works

121 Airfield Ground Lighting System
122 Airport Lightning Warning System
123 Fixed Ground Power System
124 High Mast Lighting system
125 Pre-conditioned Air Supply Units
126 Aircraft Parking Aid System
127 Airfield Supervisory Control and Data Acquisition System
128 Aircraft Loading Bridges
129 Perimeter Fence Lighting System
130 Jet Blast Screens

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January 2011

VOLUME 1 CIVIL AND STRUCTURAL WORKS
SECTION 1
GENERAL CIVIL AND STRUCTURAL WORKS
1.1
1.2
Definitions and Abbreviations

Relevant Codes and Standards
SECTION 2
TEMPORARY WORKS
2.1
2.2
Introduction
Design and Performance Criteria
APPENDIX A2.1
Temporary Works Design Criteria
A2.1.1
A2.1.2
A2.1.3
A2.1.4
A2.1.5
A2.1.6
A2.1.7
A2.1.8
A2.1.9
A2.1.10
A2.1.11
A2.1.12
Preamble
Ground Movement
Ground Water
Construction Method
Loads and Forces
Excavation
Design Life
Cofferdams and Temporary Retaining Walls
Temporary Decks and Pedestrian Bridges
Falsework
Formwork
Earthworks
APPENDIX A2.2
Certification of the Design of Temporary Works
APPENDIX A2.3
Certification of Loading, Dismantling or Removal of Temporary Works
SECTION 3
SITE CLEARANCE AND DEMOLITION
3.1
3.2
3.3
3.4
3.5
General
Submissions
Workmanship
Inspection

Issue No. 5, Volume 1 Civil & Structural Works
Table of Contents
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SECTION 4
LANDSCAPING WORKS
4.1
4.2
4.3
4.4
4.5
4.6
4.7
General
Materials
Submissions
Workmanship
Inspection, Testing and Commissioning
APPENDIX A4.1
British Standards Publications
SECTION 5
FENCING
5.1
5.2
5.3
5.4
5.5
General
Materials
Submissions
Workmanship
SECTION 6
DRAINAGE WORKS
6.1
6.2
6.3
6.4
6.5
6.6
General
Glossary of Terms
Materials
Submissions
Workmanship
APPENDIX A6.1
CCTV Inspection of Pipelines
A6.1.1
A6.1.2
A6.1.3
A6.1.4
Scope
Equipment
Procedure
Recording of Results
APPENDIX A6.2
Determination of the Compaction Fraction Value of Aggregates for

Granular Bed
A6.2.1
A6.2.2
A6.2.3
A6.2.4
A6.2.5
Scope
Apparatus
Procedure
Calculation
Reporting of Results
APPENDIX A6.3
Determination of the Resistance to Fracture of Manhole Covers and

Gully Gratings
A6.3.1
A6.3.2
A6.3.3
A6.3.4
Scope
Equipment
Procedure

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APPENDIX A6.4
Tests on Gravity Pipelines for Drainage Works
A6.4.1
A6.4.2
A6.4.3
A6.4.4
A6.4.5
A6.4.6
A6.4.7
A6.4.8
A6.4.9
Scope
Equipment
Procedure: Before Tests and Inspections
Procedure: Water Test
Procedure: Air Test
Procedure: Visual Inspection
Procedure: Infiltration Test
Calculation
APPENDIX A6.5
Tests On Pressure Pipelines For Drainage Works
A6.5.1
A6.5.2
A6.5.3
A6.5.4
A6.5.5
Scope
Equipment
Procedure
Calculation
SECTION 7
EARTHWORKS
7.1
7.2
7.3
7.4
7.5

Materials
Submissions
Workmanship
APPENDIX A7.1
Test Methods for Fill Material
A7.1.1
A7.1.2
A7.1.3
General
Terms and Symbols
Grouping of Material
APPENDIX A7.2
Determination of the Moisture Content of Fine Grained and Medium

Grained Material by the Microwave Oven Drying Method
A7.2.1
A7.2.2
A7.2.3
A7.2.4
A7.2.5
Scope
Apparatus
Procedure
Calculation
APPENDIX A7.3
Determination of the In-Situ Bulk Density and the In-Situ Dry Density
of Fine Grained And Medium Grained Material by the Nuclear
Densometer Method
A7.3.1
A7.3.2
A7.3.3
A7.3.4
A7.3.5
A7.3.6
A7.3.7
Scope
Apparatus
Procedure: Comparability of Test Methods
Procedure: Routine Denosometer Check
Procedure: Determination of In-situ Bulk Density
Calculation

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APPENDIX A7.4
Determination of the Maximum Converted Bulk Density by the HILF

Method
A7.4.1
A7.4.2
A7.4.3
A7.4.4
A7.4.5
Scope
Apparatus
Procedure
Calculation
APPENDIX A7.5
Adjustment of the Maximum Converted Bulk Density for the

Determination of the Relative Compaction
A7.5.1
A7.5.2
A7.5.3
A7.5.4
A7.5.5
Scope
Apparatus
Procedure
Calculation
SECTION 8
GEOTECHNICAL WORKS
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
General Requirements
Trials for Geotechnical Works
Definitions and Abbreviations Ground Investigation
Submissions Ground Investigation
Workmanship Ground Investigation
Inspection, Testing and Commissioning Ground Investigation
Materials Slope Treatment Works
Submissions Slope Treatment Works
Workmanship Slope Treatment Works
Inspection, Testing and Commissioning Slope Treatment Works
Definitions and Abbreviations Grouting for Geotechnical Works
Materials Grouting for Geotechnical Works
Submissions Grouting for Geotechnical Works
Workmanship Grouting for Geotechnical Works
Inspection, Testing and Commissioning Grouting for Geotechnical
Works
Definitions and Abbreviations Groundwater Drainage and Control
Materials Groundwater Drainage and Control
Submissions Groundwater Drainage and Control
Workmanship Groundwater Drainage and Control
Inspection, Testing and Commissioning Groundwater Drainage and
Control
Definitions and Abbreviations Geotechnical Instrumentation
Materials Geotechnical Instrumentation
Submissions Geotechnical Instrumentation
Workmanship Geotechnical Instrumentation
General Laboratory Work
Workmanship Laboratory Work
Inspection, Testing and Commissioning Laboratory Work
8.16
8.17
8.18
8.19
8.20
8.21
8.22
8.23
8.24
8.25
8.26
8.27

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APPENDIX A8.1
GEO Probe Test
A8.1.1
A8.1.2
A8.1.3
A8.1.4
Scope
Apparatus
Procedure
APPENDIX A8.2
Determination of the Flow of Grout
A8.2.1
A8.2.2
A8.2.3
A8.2.4
A8.2.5
A8.2.6
Scope
Apparatus
Procedure: Calibration
Procedure: Flow Test
Calculation
SECTION 9
CARRIAGEWAYS: SUB-BASE MATERIAL AND BITUMINOUS

MATERIALS
9.1
9.2
9.3
9.4
9.5
9.6

Materials
Submissions
Workmanship
APPENDIX A9.1
Determination of the Permeability of Friction Course Material
A9.1.1
A9.1.2
A9.1.3
A9.1.4
Scope
Apparatus
Procedure
SECTION 10
CONCRETE CARRIAGEWAYS
10.1
10.2
10.3
10.4
10.5
General
Materials
Submissions
Workmanship
APPENDIX A10.1
Determination of the Texture Depth Of Carriageways
A10.1.1
A10.1.2
A10.1.3
A10.1.4
A10.1.5
A10.1.6
Scope
Materials
Apparatus
Procedure
Calculation

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SECTION 11
MISCELLANEOUS ROADWORKS
11.1
11.2
11.3
11.4
11.5
11.6
General
Materials
Submissions
Workmanship
APPENDIX A11.1
Determination of Characteristic Compressive Strength of Interlocking

Blocks
A11.1.1
A11.1.2
A11.1.3
A11.1.4
A11.1.5
Scope
Apparatus
Procedure
Calculation
SECTION 12
TRAFFIC SIGNS, ROAD MARKINGS AND ROAD STUDS
12.1
12.2
12.3
12.4
12.5
12.6
12.7
General
Materials
Submissions
Workmanship
SECTION 13
WORK FOR ELECTRICAL AND MECHANICAL INSTALLATIONS
13.1
13.2
13.3
13.4
General
Materials
Workmanship
SECTION 14
WATER SUPPLY PIPEWORKS
14.1
14.2
14.3
14.4
14.5
14.6
General
Materials
Submissions
Workmanship
APPENDIX A14.1
A14.1.1
A14.1.2
A14.1.3
A14.1.4
A14.1.5
Pressure Tests on Pipelines

Scope
Equipment
Procedure
Calculation

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SECTION 15
NOT USED
SECTION 16
NOT USED
SECTION 17
PILING WORKS
17.1
17.2
17.3
17.4
17.5
17.6
17.7
General
Materials
Submissions
Workmanship
Inspection Testing and Commissioning
APPENDIX A17.1
Determination of the Load Defection Characteristics of Piles by Load

Test
A17.1.1
A17.1.2
A17.1.3
A17.1.4
A17.1.5
A17.1.6
Scope
Equipment
Procedure: Before Testing
Procedure: Load Test
Procedure: After Testing
APPENDIX A17.2
Pile Driving Record (Prefabricated Steel and Driven Cast-in-place

Piles)
APPENDIX A17.3
Pile Records (Bored Cast-in-place Piles)
APPENDIX A17.4
Pile Records (Barrettes)
APPENDIX A17.5
Bentonite Slurry Records
APPENDIX A17.6
Pile Load Test Records (Test Result)
SECTION 18
FORMWORK AND FINISHES TO CONCRETE
18.1
18.2
18.3
18.4
18.5
18.6
18.7
General
Materials
Submissions
Workmanship
SECTION 19
STEEL REINFORCMENT
19.1
19.2
19.3
19.4
19.5

Materials
Submissions
Workmanship

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SECTION 20
CONCRETE AND JOINTS IN CONCRETE
20.1
20.2
20.3
20.4
20.5
20.6
20.7
20.8
General
Materials
Submissions
Workmanship
APPENDIX A20.1
Determination of the Efficiency Index of Curing Compounds
A20.1.1.
A20.1.2.
A20.1.3.
A20.1.4.
A20.1.5.
A20.1.6.
A20.1.7.
Scope
Materials
Apparatus
Procedure: Preparation of Specimens
Procedure: Determination of Efficiency Index
Calculation
APPENDIX A20.2
Determination of the Deflection, Recovery and Resistance to Cracking

of Precast Units
A20.2.1
A20.2.2
A20.2.3
A20.2.4
Scope
Equipment
Procedure
APPENDIX A20.3
Determination of the Disintegration and Shrinkage, the Recovery

Value and Reduction in Mass, and the Extrusion of Joint Filler
A20.3.1
A20.3.2
A20.3.3
A20.3.4
A20.3.5
A20.3.6
A20.3.7
Scope
Apparatus
Procedure: Weathering Test
Procedure: Compression and Recovery Test
Procedure: Extrusion Test
Calculation
APPENDIX A20.4
Routine Checks for Plant and Equipment
PART 1
A20.4.1
A20.4.2
A20.4.3
A20.4.4
Batching and Mixing Equipment

Daily Routine
Weekly Routine
Monthly Routine
Quarterly Routine
PART 2
A20.4.5
A20.4.6
Transporting Equipment Mixer and Agitator Units

Daily Routine
Monthly Routine

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SECTION 21
PRESTRESSING
21.1
21.2
21.3
21.4
21.5
21.6
General
Materials
Submissions
Workmanship
SECTION 22
STEELWORK
21.7
21.8
21.9
21.10
21.11
21.12
General
Materials
Submissions
Workmanship
SECTION 23
BRIDGEWORKS
23.1
23.2
23.3
23.4
23.5
23.6
23.7
General
Materials
Submissions
Workmanship
APPENDIX A23.1
Friction Test for Bridge Bearings
A23.1.1
A23.1.2
A23.1.3
A23.1.4
A23.1.5
Scope
Equipment
Procedure
Calculation
SECTION 24
WATER RETAINING STRUCTURES
24.1
24.2
24.3
24.4
24.5
24.6
General
Materials
Submissions
Workmanship

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SECTION 1
GENERAL CIVIL AND STRUCTURAL WORKS
1.1
DEFINITIONS & ABBREVIATIONS
1.1.1
Definitions
Words and expressions, to which meanings have been assigned in the General
Conditions and General Specification, shall have the same meanings in this
volume.
1.1.2
Abbreviations
Abbreviations in this volume shall have the following meanings:
AAR
Alkali-Aggregate Reaction
ACI
American Concrete Institution Standard
AOAC
Association of Analytical Chemistry
APHA
American Public Health Authority
ASSHTO
American Association of State Highway and Transportation Officials
AWWA
American Water Works Association
ASTM
American Society for Testing and Material
BS
British Standard
CAPWAP
CASE Pile Wave Analysis Program
CCTV
closed circuit television
CD
chart datum
CI
cast iron
CIRIA
Construction Industry Research and Information Association
CP
British Standard Code of Practice
CS
Construction Standard
C&D
Construction and Demolition
DI
ductile iron
DN
nominal size
Dn
nominal size of tees and tapers
FGL
finished ground level, or finished level of permanent works
GEO
Geotechnical Engineering Office, Civil Engineering Department

(Hong Kong Government)
GGBFS
Ground Granulated Blast Furnace Slag
GI
galvanised iron
GIFW
Ground Investigation Field Work
GRC
glassfibre reinforced concrete
HDPE
high density polyethylene
HOKLAS
Hong Kong Laboratory Accreditation Scheme
HKQAA
Hong Kong Quality Assurance Agency

Section 1 General Civil & Structural Works
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January 2011
HSFG
high strength friction grip
IRHD
International Rubber Hardness Degree
ISO
International Organisation for Standardization
OPC
ordinary Portland cement
PD
Principal Datum
PFA
pulverised-fuel ash
PPFAC
Portland pulverised-fuel ash cement
PNAP
Practice Note for Authorised Persons and Registered Structural

Engineers
Ppm
parts per million
PTFE
polytertrafluroethylene
PVC
polyvinyl chloride
QSPSC
Quality Scheme for the Production and Supply of Concrete
RHPC
rapid hardening Portland cement
RSC
Registered Specialist Contractor
SIL
Standard Inter-departmental Landscape Technical Group
SIS
Swedish Standard
SRPC
sulphate resisting Portland cement
UPVC
Unplasticised polyvinyl chloride
1.2
RELEVANT CODES AND STANDARDS
1.2.1
General
The Standards and Codes of Practice specified in this section are listed below for
information only. The Contractor shall comply with the edition of the Standard or
Code of Practice listed in the text when stated, or the latest edition when no edition
is listed. Where British Standards have been replaced by the new BS EN
documents, the old BS number is retained in the text, with the new BS EN number
listed below.
1.2.2
British Standards
BS 4
Structural steel sections
BS 4 : Part 1 : 1993
Structural steel sections. Specification for hot-rolled

sections
BS 12 : 1989 (1996)_
Specification for Portland cements
(replaced by BS EN 1971:2000)
BS 21 : 1985
Specification for pipe threads for tubes and fittings

where pressure - tight joints are made on the threads
(metric dimensions)
BS 29 : 1987(replaced by
BS EN 10250-2:2000)
Specification for carbon steel forgings above 150

mm ruling section

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January 2011
BS 65 : 1988 (replaced by
BS 65:1991)
Specification for vitrified clay pipes, fittings, joints

and ducts
BS 144 : 1997
Wood preservation using coal tar creosotes
BS 373 :1986
Methods of testing small clear specimens of timber
BS 381C:1996
Specification for colours for identification, coding and

special purposes
BS 410 : 1986
Specification for test sieves
BS 416 : 1990
Discharge and ventilating pipes and fittings, sandcast or spun in cast iron
BS 417 : Part 2 : 1987
Specification for galvanized low carbon steel

cisterns, cistern lids, tanks and cylinders - metric
units
BS 427 : 1990 (replaced

by BS EN ISO 6507-13:1998)
Method for Vickers hardness test and for verification

of Vickers hardness testing machines
BS 434 : 1990
Bitumen road emulsions (anionic and cationic)
BS 434 : Part 1 : 1984
Specification for bitumen road emulsions
BS 434 : Part 2 : 1984
Code of practice for use of bitumen road emulsions
BS 443 :1990 (replaced by

BS EN 10244-2:2001)
Specification for testing zinc coatings on steel wire

and for quality requirements
BS 449 : Part 2 : 1969
Specification for the use of structural steel in building

- metric units
BS 534 : 1990
Specification for steel pipes, joints and specials for

water and sewage
BS 544 : 1969
Specification for linseed oil putty for use in wooden

frames
BS 639: 1986
Specification for covered carbon and carbon

manganese steel electrodes for manual metal-arc
welding

by BS 718 : 1991)
Specification for density hydrometers
BS 729 : 1986(replaced by
BS EN ISO 1461:1999)
Specification for hot dip galvanized coatings on iron

and steel articles

by BS 6398:1983 , BS
6515:1984 and BS
8215:1991)
Specification for materials for damp-proof courses
BS 747 : 2000
Specification for roofing felts
BS 812
Testing aggregates
BS 812 : Part 1 : 1975

Testing aggregates. Methods for determination of

particle size and shape

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BS 812 : Part 2 : 1975

Methods for determination of physical properties
BS 812 : Part 4 : 1976

Chemical properties
BS 812 : Part 4 : 1976
Sampling and testing of mineral aggregates, sands

and fillers
BS 812 : Part 101 : 1984
Guide to sampling and testing aggregates
BS 812 : Part 102 : 1989

Methods for sampling
BS 812 : Part 103: 1985
Methods for determination of particle size distribution
BS 812 : Section 103.1 :

1985
Sieve tests
BS 812 : Section 103.2 :

1989
Sedimentation test
BS 812 : Part 105
Methods for determination of particle shape
BS 812 : Section 105.1 :

1989

particle shape. Flakiness index
BS 812 : Section 105.2 :

1990
Elongation index of coarse aggregate
BS 812 : Part 110 : 1990

Methods for determination of aggregate crushing

value (ACV)
BS 812 : Part 111 : 1990

Methods for determination of ten per cent fines value

(TFV)
BS 812 : Part 112 : 1990

Method for determination of aggregate impact value

(AIV)
BS 812 : Part 113 : 1990

Method for determination of aggregate abrasion

value (AAV)
BS 812-117: 1988
Testing aggregates. Method for determination of

water-soluble chloride salts
BS 812-2: 1995

density
BS 864 : Part 2 : 1983

(replaced by BS EN 12541-2:1998)
Specification for capillary and compression fittings

for copper tubes
BS 873
Road traffic signs and internally illuminated bollards
BS 873 : Part 1 : 1983
Methods of test

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BS 873 : Part 5 : 1983

(replaced by BS EN
12899-1:2001)
Specification for internally illuminated signs and

external lighting luminaries
BS 873 : Part 6 : 1983

(replaced by BS EN
12899-1:2001
Specification
for
retroreflective signs
BS 873 : Part 7 : 1984
Specification for posts and fittings
BS 882 : 1992
Specification for aggregates from natural sources for

concrete
BS 890 : 1995
Specification for building limes
BS 903
Physical testing of rubber
BS 903 : Part A1 1996
Physical testing of rubber. Determination of density
BS 903 : Part A2 : 2002
Physical testing of rubber. Determination of tensile

stress-strain properties
BS 903 : Part A3 : 1995
Determination of tear strength (trouser, angle and

crescent test pieces)
BS 903 : 1997
Determination
properties
BS 903 : Part A5 : 1974

(replaced by BS ISO
2285:2001)
Determination of tension set
BS 903-A5:1997
Physical testing of rubber. Determination of tension

set at normal and high temperatures
BS 903 : Part A6 :
1992(1998)
Determination of compression set after constant

strain
BS 903 : Part A9 : 1988
Determination of abrasion resistance
BS 903 : Part A16 : 1999
Determination of the effect of liquids
BS 903 : Part A18 : 1998
Physical testing of rubber Determination

equilibrium water vapour absorption
BS 903 : Part A19 : 1994
Heat resistance and accelerated ageing tests
BS 903 : Part A26 : 1994
Determination of hardness
BS 903-A26:1995
Physical testing of rubber. Method for determination

of hardness (hardness between 10 IRHD and 100
IRHD)
BS 903 : Part A43 :

1990(2002)
Method for determination of resistance to ozone

cracking (static strain test)
BS 903 : Part C2 :
1982(1995)
Determination of volume resistivity

5/24
of
retroreflective
compression
and
non-
stress-strain
of
January 2011
BS 907-1 : 1996
Specification for wrought steels for mechanical and

allied engineering purposes. General inspection and
testing procedures and specific requirements for
carbon, carbon manganese, alloy and stainless
steels
BS 952
Glass for glazing
BS 952 : Part 1 :: 1995
Classification
BS 952 : Part 2 : 1980
Terminology for work on glass
BS 970 : Part 1 : 1983

(replaced by BS EN
10084:1998, BS EN
10085:2001, BS EN
10087:1999, BS EN
10095:1999 and BS EN
10250-4:2000)
General inspection and testing procedures and

specific
requirements
for
carbon,
carbon
manganese, alloy and stainless steels
BS 1004 : 1972 (1985)

(replaced by BS EN
12844:1999 and BS EN
1774:1998)
Specification for zinc alloys for die casting and zinc

alloy die casting
BS 1010 : Part 2 : 1973
Draw-off taps and above-ground stopvalves
BS 1014 : 1975 (1986)

(replaced by BS EN
12878:1999)
Specification for pigments for Portland cement and

Portland cement products
BS 1070 : 1973(2000)
Specification for black paint (tar-based)
BS 1154 : 1992
Specification for natural rubber compounds
BS 1155 : 1992(1997)
Specification for natural rubber compounds for

extrusion
BS 1161 : 1977(1991)
Specification for aluminium

structural purposes
BS 1181 : 1999
Specification for clay flue linings and flue terminals
BS 1191
Specification for gypsum building plasters
BS 1191 : Part 1
:1973(1994)
Excluding premixed lightweight plasters
BS 1194 : 1999
Specification for concrete porous pipes for underdrainage
BS 1199 and 1200 : 1976

(replaced by BS EN
13139:2002)
Specification for building sands from natural sources
BS 1203 : 2001
Specification for synthetic resin adhesives (phenolic

and aminoplastic) for plywood
BS 1204
Synthetic
resin
adhesives
aminoplastic) for wood

6/24
alloy
sections
(phenolic
for
and
January 2011
BS 1204 : Part 1 : 1979

(1991) (replaced by BS
1204:1993, BS EN
301:1992 and BS EN 3021-4:1992)
Specification for gap-filling adhesives
BS 1212
Float operated valves
BS 1212 : Part 1 : 1990
Specification for piston type float operated valves

(copper alloy body)(excluding floats)
BS 1212 : Part 2 : 1990
Specification for diaphragm type float operated

valves (copper alloy body)(excluding floats)
BS 1212 : Part 3 : 1990
Specification for diaphragm type float operated

valves (plastic bodied) for cold water services only
(excluding floats)
BS 1247 : 1990
Manhole steps
BS 1305 : 1974
Specification for batch type concrete mixers
BS 1336 : 1971(2002)
Specification for knotting
BS 1369
Steel lathing for internal plastering and external

rendering
BS 1369 : Part 1 :
1987(1994)
Specification for expanded metal and ribbed lathing
BS 1377 : 1990
Methods of test for soils for civil engineering

purposes (as modified in accordance with GEO
Report No. 36, entitled "Methods of Test for Soils in
Hong Kong for Civil Engineering Purposes (Phase 1
Tests)", except for Clauses 7.39(1) & 9.43(5) where
the year of edition remains to be 1975)
BS 1387 : 1985 (1990)
Specification for screwed and socketed steel tubes

and tubulars and for plain end steel tubes suitable
for welding or for screwing to BS 21 pipe threads

by BS EN 1982:1999)
Specification for copper alloy ingots and copper alloy

and high conductivity copper castings
BS 1449 : Part 1 : 1983

(replaced by BS 1449-1.11.5:1991 and BS EN
10130:1991)
Specification for carbon and carbon-manganese

plate, sheet and strip
BS 1449 : Part 2 : 1983

(replaced by BS EN
10029:1991, BS EN
10048:1997, BS EN
10051:1992 BS EN
10095:1999 BS EN
10258:1997 and BS EN
10259:1997)
Steel plate, sheet and strip. Specification for

stainless and heat-resisting steel plate, sheet and
strip

by BS EN 1561:1997)
Specification for flake graphite cast iron

7/24
January 2011

by BS EN 485-1-4:1994,
BS EN 515:1993 and BS
EN 573-1-4:1995)
Specification for wrought aluminium and aluminium

alloys for general engineering purposes : plate,
sheet and strip

by BS EN 515:1993, BS
EN 573-3-4:1995 and BS
EN 754-1-2:1997,-78:1998)

alloys for general engineering purposes - drawn tube
BS 1473 : 1972

alloys for general engineering purposes - rivet, bolt
and screw stock

by BS EN 515:1993, BS
EN 573-3-4:1995, BS EN
755-1-9:1996 and BS EN
12020-1-2:2001)

alloys for general engineering purposes : bars,
extruded round tubes and sections
BS 1490 : 1988
Specification for aluminium and aluminium alloy

ingots and castings for general engineering
purposes
BS 1494 : Part 2 : 1967

(withdrawn)
Sundry fixings

by BE EN ISO 75001:1999, BS EN 100023:1995 and BS EN ISO
7500-2:1999)
Materials testing machines and force verification

equipment

by BS EN 12373-1:2001)
Method for specifying anodic oxidation coatings on

aluminium and its alloys
BS 1706 : 1990
Method for specifying electroplated coatings of zinc

and cadmium on iron and steel
BS 1722 : Part 1: 1999
Specification for chain link fences
BS 1740 : Part 1 : 1971

EN 10241:2000)
Specification for wrought steel pipe fitting (screwed

BS 21 R-series thread)
BS 1881-124: 1988
Testing concrete. Methods for analysis of hardened

concrete
BS 1924 : 1990
Stabilized materials for civil engineering purposes
BS 2000
Methods of test for petroleum and its products
BS 2015 : 1965 (1985)

(replaced by BS 2015 :
1992 (2000) and BS EN
971-1:1996)
Glossary of paint terms

8/24
January 2011
BS 2451 : 1963 (1988)

(replaced by BS EN ISO
11124-3:1997, BS 70794:1994)
Specification for chilled iron shot and grit
BS 2456: 1990
Specification for floats (plastics) for float operated

valves for cold water services

by BS 2494 : BS
7874:1998, BS EN 681-12:1996 and BS EN
682:2002)
Specification for elastomeric seals for joints in

pipework and pipelines
BS 2499 1-3:1992
Specification for hot applied joint sealants for

concrete pavements
BS 2523 : 1996(2000)
Specification for lead-based priming paints
BS 2569 : Part 1 : 1964

EN 22063:1994)
Specification for sprayed metal coatings. Protection

of iron and steel by aluminium and zinc against
atmospheric corrosion
BS 2600
Radiographic examination of fusion welded butt

joints in steel
BS 2600 : Part 1 : 1983

(replaced by BS EN
1435:1997)
Methods for steel 2 mm up to and including 50 mm

thick
BS 2600 : Part 2 : 1973

(replaced by BS EN
1435:1997)
Methods for steel over 50 mm up to and including

200 mm thick
BS 2633 : 1987(2001)
Specification for Class I arc welding of ferritic steel

pipework for carrying fluids
BS 2648 : 1995(2000)
Performance requirements for electrically-heated

laboratory drying ovens
BS 2752 : 1990
Specification for chloroprene rubber compounds
BS 2760 : 1973
Specification for pitch-impregnated fibre pipes and

fittings for below and above ground drainage
BS 2782
Methods of testing plastics
BS 2782-3 : 2002
Mechanical properties
BS 2782-4 : 1983
Chemical properties
BS 2782-6 : 1991
Dimensional properties
BS 2782 : Part 3 :
Tensile strength, elongation and elastic modulus
Methods 320A to 320F :

1976(1996)
BS 2782 : Part 3 :
Method 365A : 1976(2002)
Determination of softness number of flexible plastics

materials
9/24
January 2011
BS 2782 : Part 3 :
Method 365D : 1997
Determination of hardness of plastics and ebonite by

the ball indentation method
BS 2782 : Part 4 :
Determination of water absorption at 23C.
Methods 430A to 430D :

1983
Determination of water absorption at 23C with

allowance for water-soluble matter.
Determination of boiling water absorption.
Determination of boiling water absorption with
allowance for water-soluble matter.
BS 2782 : Part 6 :
Methods 620A to 620D :
1980 (replaced by BS
2782 : Part 6 : Methods
620A to 620D : 1991 and
BS EN ISO 1183-3:1999)
Determination of density of solid plastics excluding

cellular plastics (immersion method).
cellular plastics (pyknometer method).
Determination of plastics (sink-float method).
cellular plastics (density gradient column method).

by BS EN 1563:1997)
Specification for spheroidal graphite or nodular

graphite cast iron
BS 2846 : Part 3 : 1975

(1985)
Determination of a statistical tolerance interval
BS 2846 : Part 4 : 1976

(1985)
Techniques of estimation and tests relating to means

and variances
BS 2869 : Part 2 : 1998
Specification for fuel oil for agricultural and industrial

engines and burners (classes A2, C1, C2, D, E, F, G
and H)
BS 2871 : Part 1 : 1971

(replaced by BS EN
1057:1996)
Copper tubes for water, gas and sanitation

by BS EN 12163:1998, BS
EN 12164:1998 and BS
EN 12167:1998)
Specification for copper and copper alloy rods and

sections (other than forging stock)
BS 2901 : Part 1 : 1983
Filler rods and wires for gas-shielded arc welding.

Ferritic steels

by BS EN 1435:1997)
Methods for radiographic examination of fusion

welded circumferential butt joints in steel pipes

by BS EN 10143:1993)
Specification for continuously hot-dip zinc coated

and iron-zinc alloy coated steel : wide strip,
sheet/plate and slit wide strip
BS 2989:1992
Specification for continuously hot-dip zinc coated

and iron-zinc alloy coated steel flat products:
tolerances on dimensions and shape

10/24
January 2011
BS 3019 : Part 1 : 1984

Specification for TIG welding

magnesium and their alloys
BS 3019 : Part 2 : 1960
Austenitic stainless and heat resisting steels
BS 3049 : 1995
Specification for pedestrian guard rails (metal)
BS 3100 : 1991(2001)
Specification for steel

engineering purposes
BS 3148 : 1980
Methods of test for water for making concrete

(including notes on the suitability of the water)
BS 3262 : Part 1 : 1989

(withdrawn)
Specification for constituent materials and mixtures
BS 3262 : Part 3 : 1989

(withdrawn)
Specification for application of material to road

surfaces
BS 3382 : Part 1 and 2

1961(1998)
Plating thickness, sampling, inspection procedures,

thickness determination, Resistance to corrosion,
purity, adhesion, porosity, reduction of hydrogen
embrittlement, finish and appearance, plating
thickness,
passivation.
Cadmium
on
steel
components. Zinc on steel components
BS 3410 : 1961
Specification for metal

BS 3416 : 1988(2000)
Specification for bitumen-based coatings for cold

application, suitable for use in contact with potable
water
BS 3468 : 1986
Specification for austenitic cast iron

by BS EN 1452-1-5:2000)
Specification for unplasticized polyvinyl chloride

(PVC-U) pressure pipes for cold potable water
BS 3506 : 1969
Specification for unplasticized PVC pipe for industrial

uses
BS 3571 : Part 1 : 1985

Specification for MIG welding of aluminium and

aluminium alloys
BS 3600 : 1976 (1988)

1997)
Specification for dimensions and masses per unit

length of welded and seamless steel pipes and tubes
for pressure purposes
BS 3601 : 1987(1993)
Specification for carbon steel pipes and tubes with

specified room temperature properties for pressure
purposes
BS 3690 : Part 1 : 1989

Part 1 : 1989 and BS EN
12591:2000)
Specification for bitumens for roads and other paved

areas
BS 3690 : Part 2 : 1989

Part 2 : 1989(1997))
Specification for bitumens for industrial purposes

11/24
castings
washers
of
aluminum,
for
for
general
general
January 2011

by BS 3692 : 2001)
Specification for ISO metric precision hexagon bolts,

screws and nuts. Metric units
BS 3698 : 1964 (1979)

1964(2000))
Specification for calcium plumbate priming paints
BS 3892 : Part 1 : 1997
Pulverized-fuel ash. Specification for pulverized-fuel

ash for use as a cementitious component in
structural concrete. Specification for pulverized-fuel
ash for use with Portland cement.
BS 3900 : Part E10 : 1979

EN 24624:1993(2000))
Mechanical tests on paint films Pull-off test for

adhesion
BS 3923 : Part 1 : 1986

(replaced by BS EN
1714:1998)
Methods for ultrasonic examination of welds.

Methods for manual examination of fusion welds in
ferritic steels
BS 3923 : Part 2 : 1972
Methods for ultrasonic examination of welds.

Automatic examination of fusion welded butt joints in
ferritic steels
BS 3981 : 1976(2000)
Specification. Iron oxide pigments for paints
BS 3987 : 1991
Specification for anodic oxide coatings on wrought

aluminium for external architectural applications
BS 3998 : 1989
Recommendations for tree work
BS 4027 : 1996
Specification for sulphate-resisting Portland cement
BS 4072 : 1999
Wood
preservation
by
means
copper/chromium/arsenic compositions
BS 4102 : 1990 and BS

EN 10223-1,-4-6:1998
Specification for steel wire and wire products for

fences
BS 4147 : 1980 (1987)
Specification for bitumen-based hot-applied coating

materials for protecting iron and steel, including
suitable primers where required
BS 4168 : Part 1 : 1981

4762:1998)
Hexagon socket screws and wrench keys: metric

series. Specification for hexagon socket head cap
screws

by BS 4190 : 2001)
Specification for ISO metric black hexagon bolts,

screws and nuts
BS 4211 : 1994
Specification for ladders for permanent access to

chimneys, other high structures, silos and bins

12/24
of
January 2011

by BS 7079-0:1990, BS
7079-A1:1989, ISO 85011:1988, BS 7079:Part
A1:Supplement 1:1989,
BS EN ISO 8503-1:1995,
BS 7079-C1:1989, BS EN
ISO 8503-2:1995, BS
7079-C2:1989, BS EN ISO
8503-3:1995, BS 7079C3:1989, BS EN ISO
8503-4:1995, BS 7079C4:1989(1998))
Specification for surface finish of blast-cleaned steel

for painting
BS 4254 : 1983
Specification
sealants
BS 4320 : 1968
Specification for metal washers

engineering purposes. Metric series
BS 4345 : 1968 (1986)
Specification for slotted angles
BS 4346
Joints and fittings for use with unplasticized PVC

pressure pipes
BS 4346 : Part 1 : 1969

Injection moulded unplasticized PVC fittings for

solvent welding for use with pressure pipes,
including potable water supply
BS 4346 : Part 2 : 1970

Mechanical joints
unplasticized PVC
BS 4346 : Part 3 : 1982

Specification for solvent cement

by BS 7613:1994, BS
7668:1994, BS EN
10029:1991, BS EN
10113-1-3:1993, BS EN
10155:1993 and BS EN
10210-1:1994)
Specification for weldable structural steels
BS 4393 : 1969 (1985)

1991)
Specification for tin or tin-lead coated copper wire
BS 4395
Specification for high strength friction grip bolts and

associated nuts and washers for structural
engineering
BS 4395 : Part 1 :
1969(1998)

engineering. General grade

13/24
for
two-part
and
polysulphide-based
fittings,
for
general
principally
of
January 2011
BS 4395 : Part 2 :
1969(1998)

engineering. Higher grade bolts and nuts and
general grade washers
BS 4395 : Part 3 : 1973
Higher grade bolts (waisted shank), nuts and general

grade washers
BS 4447 : 1973
Specification for the performance of prestressing

anchorages for post-tensioned construction
BS 4449 : 1978 (1984)

(excluding AMD 4337 and
AMD 4540 and clauses
12.2.1 and 12.2.2)
(replaced by BS
4449:1997)
Specification for hot rolled steel bars and carbon

steel bars for the reinforcement of concrete
BS 4461 : 1997
Specification for cold worked steel bars for the

reinforcement of concrete

by BS 8666:2000 and BS
EN ISO 4066:2000)
Specification for scheduling, dimensioning, bending

and cutting of steel reinforcement for concrete
BS 4482 : 1985
Specification for cold reduced steel wire for the

reinforcement of concrete
BS 4483 : 1985 (1998)
Specification for steel fabric for the reinforcement of

concrete
BS 4486 : 1980
Specification for hot rolled and hot rolled and

processed high tensile alloy steel bars for the
prestressing of concrete
BS 4500 : Part 3 : 1973
ISO limits and fits. Working limits on untoleranced

dimensions
BS 4504 : Section 3.1 :

1989 (replaced by BS EN
1092-1:2002, BS EN
1515-1:2000)
Circular flanges for pipes, valves and fittings (PN

designated) - Specification for steel flanges
BS 4514 : 2001
Specification for unplasticized PVC

ventilating pipes, fittings and accessories
soil
and
BS 4515 : 1984 (BS 4515 : Specification for welding of steel pipelines on land
2000)
and offshore
BS 4550
Methods of testing cement
BS 4550 : Part 1 : 1978

Methods of testing cement Sampling
BS 4550 : Part 2 : 1970
Methods of testing cement Chemical tests
BS 4550 : Part 3 : 1978
Methods of testing cement Physical tests
BS 4551 : 1980
Methods of testing mortars, screeds and plasters

14/24
January 2011
BS 4568
Specification for steel conduit and fittings with metric

threads of ISO form electrical installations
BS 4568 : Part 1 : 1970
Steel conduit, bends and couplers
BS 4568 : Part 2 : 1970

EN 50086-1:1994)
Fittings and components
BS 4570 : 1985
Specification for fusion welding of steel castings
BS 4576 : Part 1 : 1989,

BS EN 607:1996, BS EN
1462:1997 and BS EN
12200-1:2000
Unplasticized polyvinyl chloride (PVC-U) rainwater

goods and accessories - Half-round gutters and
pipes of circular cross-section
BS 4604
Specification for the use of high strength friction grip

bolts in structural steelwork
BS 4604 : Part 1 : 1970

bolts in structural steelwork. Metric series. General
grade
BS 4604 : Part 2 : 1970

bolts in structural steelwork. Metric series. Higher
grade (parallel shank)
BS 4620 : 1970 (1988)
Specification for rivets for general engineering

purposes
BS 4622 : 1970 (1983)
Specification for grey iron pipes and fittings
BS 4652 : 1970(2000)
Specification for metallic zinc-rich priming paint

(organic media)
BS 4660 : 2000
Specification for unplasticized polyvinyl chloride

(PVC-U) pipes and plastics fittings of nominal sizes
110 and 160 for below ground gravity drainage and
sewerage
BS 4662 : 1970 (1989)
Specification for boxes for the enclosure of electrical

accessories
BS 4677 : 1984(2001)
Specification for arc welding of austenitic stainless

steel pipework for carrying fluids
BS 4756 : 1998
Specification for ready mixed aluminium priming

paints for woodwork

by BS 4772 : BS EN
545:1995, BS EN
598:1995 and BS EN
969:1996)
Specification for ductile iron pipes and fittings
BS 4848
Specification for hot-rolled structural steel sections
BS 4848 : Part 2 : 1975

(replaced by BS EN
10210-2:1997)
Hollow sections

15/24
January 2011
BS 4848 : Part 4 : 1972

(replaced by BS EN
10056-1:1999)
Equal and unequal angles
BS 4848 : Part 5 : 1980

(replaced by BS EN
10067:1997)
Bulb flats
BS 4865 : Part 1 : 1989

Specification for non-metallic flat gaskets (including

gaskets for flanges to BS 4772)
BS 4870 : Part 1 : 1981

Specification for approval testing

procedures - Fusion welding of steel
BS 4871 : Part 1 : 1982

Specification for approval testing of welders working

to approved welding procedures - Fusion welding of
steel
BS 4872 : Part 1 :
1982(1999)
Specification for approval testing of welders when

welding procedure approval is not required - Fusion
welding of steel
BS 4873 : 1986
Specification for aluminium alloy windows
BS 4921 : 1988(1994)
Specification for sheradized coatings on iron or steel
BS 4933 : 1973
Specification for ISO metric black cup and

countersunk head bolts and screws with hexagon
nuts

by BS EN 818-1:1996, BS
EN 818-3:1999 and BS
EN 818-7:2002)
Short link chain for lifting purposes
BS 5075 : Part 1 : 1982,

BS EN 480 and BS EN
934
Concrete admixtures. Specification for accelerating

admixtures, retarding admixtures and water reducing
admixtures
BS 5075 : Part 3 : 1985,

BS EN 480 and BS EN
934
Concrete
admixtures.
superplasticizing admixtures

by BS EN 1011-1:1998
and BS EN 1011-2:2001)
Specification for arc welding of carbon and carbon

manganese steels
BS 5150 : 1990
Specification for cast iron gate valves
BS 5154 : 1991
Specification for copper alloy globe, globe stop and

check, check and gate valves
BS 5163 : 1986
1986(1991)
Specification for predominantly key-operated cast

iron gate valves for waterworks purposes
BS 5212 : 1990
Cold applied joint sealant systems for concrete

pavements
BS 5215 : 1986
Specification for one-part gun grade polysulphidebased sealants

16/24
of
welding
Specification
for
January 2011
BS 5252F : 1976 (1986)

(replaced by BS 5252F :
1976(2002))
Colour matching fan
BS 5255 : 1989, BS EN
1329-1:2000, BS EN
1455-1:2000, BS EN
1519-1:2000, BS EN
1565-1:2000 and BS EN
1566-1:2000
Specification for thermoplastics waste pipe and

fittings
BS 5268 : Part 2 : 2002
Structural use of timber - Code of practice for

permissible
stress
design,
materials
and
workmanship
BS 5284 : 1993
Methods. Sampling and testing mastic asphalt and

pitchmastic used in building
BS 5289 : 1976 (1983)

(replaced by BS EN
970:1997)
Code of practice. Visual inspection of fusion welded

joints
BS 5328
Concrete
BS 5395 : Part 1 :2000
Code of practice for the design of straight stairs
BS 5400
Steel, concrete and composite bridges
BS 5400 : Part 2 : 1978,

BS 5400-9.1-9.2:1983
Specification for loads
BS 5400 : Part 4 : 1990
Code of practice for design of concrete bridges
BS 5400 : Part 6 : 1980

(1999)
Steel, concrete and composite bridges. Specification

for materials and workmanship, steel
BS 5400 : Part 9 : 1983
Bridge bearings
BS 5400 : Section 9.2 :

1983
Specification for materials,

installation of bridge bearings
BS 5481 : 1977 (1989)

Specification for unplasticized PVC pipe and fittings

for gravity sewers
BS 5490 : 1977
Specification for classification of

protection provided by enclosures
BS 5493 : 1977, BS EN
ISO 12944-1-8:1998 and
BS EN ISO 14713:1999
Code of practice for protective coating of iron and

steel structures against corrosion
BS 5531 : 1988
Code of practice for safety in erecting structural

frames
BS 5573 : 1996
Code of practice for safety precautions in the

construction of large diameter boreholes for piling
and other purposes
BS 5589 : 1989(1997)
Code of practice for preservation of timber
BS 5756 : 1997
Specification for tropical hardwoods graded for

structural use

17/24
manufacture
degrees
and
of
January 2011
BS 5812
Materials for plain bearings
BS 5896 : 1980
Specification for high tensile steel wire and strand for

the prestressing of concrete
BS 5911
Precast concrete
products
BS 5911 : Part 2 : 1982
Specification for inspection chambers and street

gullies
BS 5911 : Part 3 : 1982

(replaced by BS 5911110:1992)
Specification for pipes and fittings with ogee joints
BS 5911 : Part 100 : 1988
Specification for unreinforced and reinforced pipes

and fittings with flexible joints
BS 5911 : -200:1994
Specification for unreinforced and reinforced

manholes and soakaways of circular cross section

by BS 5930 : 1999)
Code of practice for site investigations
BS 5931 : 1980
Code of practice for machine laid in situ edge details

for paved areas
BS 5950-1 : 1990
Structural use of steelwork in building. Code of

practice for design. Rolled and welded sections
BS 5950 -2:2001
Structural use of steelwork in building. Specification

for materials, fabrication and erection : hot rolled
sections; and Rolled & welded sections
BS 5950-3 : 1990
Code of practice for design of simple and continuous

composite beams
BS 5950-4 : 1994
Code of practice for design of composite slabs with

profiled steel sheeting
BS 5950-5 : 1998
Code of practice for design of cold formed thin

gauge sections
BS 5950-6 : 1995
Code of practice for design of light gauge profiled

steel sheeting
BS 5950-7 : 1990
Structural use of steelwork in building. Specification

for materials and workmanship: cold formed sections
BS 5975 : 1996
Code of practice for falsework

by BS EN 10160:1999)
Methods for ultrasonic testing and specifying quality

grades of ferritic steel plate
BS 5996:1993
Specification for acceptance levels for internal

imperfections in steel plate, strip and wide flats,
based on ultrasonic testing

by BS EN 1436:1998 and
BS EN 1871:2000)
Specification for pavement marking paints

18/24
pipes,
fittings
and
ancillary
January 2011
BS 6072 : 1981 (1986)

9934-1:2001)
Method for magnetic particle flaw detection
BS 6088 : 1981 (1985)

(replaced by BS
6088:1981(1993) and BS
EN 1423:1998)
Specification for solid glass beads for use with road

marking compounds and for other industrial uses
BS 6089 : 1981
Guide to assessment of concrete strength in existing

structures

by BS EN ISO 3506-12:1998)
Specification for corrosion-resistant stainless steel

fasteners
BS 6150 : 1991
Code of practice for painting of buildings
BS 6232
Thermal insulation of cavity walls by filling with blown

man-made mineral fibre
BS 6262-4: 1994
Code of practice for glazing for buildings
BS 6323 : 1982 (1990)
Specification for seamless and welded steel tubes

for automobile, mechanical and general engineering
purposes
BS 6323 : Part 1 : 1982

(1990)

purposes. General requirements
BS 6323 : Part 3 : 1982

(1990)
Specific requirements for hot finished seamless steel

tubes
BS 6323 : Part 8 : 1982

(1990)

purposes. Specific requirements for longitudinally
welded stainless steel tubes
BS 6349 1:2000
Code of practice for maritime structures General

criteria
BS 6362 : 1990(2001)
Specification for stainless steel tubes suitable for

screwing in accordance with BS 21 'Pipe threads for
tubes and fittings where pressure-tight joints are
made on the threads'
BS 6363 : 1983
Specification for welded cold formed steel structural

hollow sections
BS 6404
Magnetic materials
BS 6405 : 1984(1998)
Specification for non-calibrated short link steel chain

(grade 30) for general engineering purposes : class
1 and 2
BS 6431
Ceramic floor and wall tiles
BS 6431 : Part 1 :
1983(1996)
Specification for classification and marking, including

definitions and characteristics

19/24
January 2011
BS 6431 : Part 2 :
1984(1996)
Specification for extruded ceramic tiles with a low

water absorption (E 3%). Group A1
BS 6431 : Part 3
Extruded ceramic tiles with a water absorption of 3%

< E 6%. Group A11a
BS 6431 : Part 3 : Section

3.1 : 1986(1996)
Specification for general products

3.2 : 1986(1996)
Specification for products (terre cuite, cotto, baldosin

catalan)
BS 6431 : Part 4
Extruded ceramic tiles with a water absorption of 6%

< E 10%. Group A11b

4.1 : 1986(1996)
Specification for general products

4.2 : 1986(1996)
Specification for specific products (terre cuite, cotto,

baldosin catalan)

by BS EN 571-1:1997)
Method for penetrate flaw detection
BS 6463
Quicklime,
carbonate
BS 6463 -101:1996
Methods of sampling
BS 6463 -102:2001
Methods of chemical analysis
BS 6463 -103:1999
Methods of test for physical properties of hydrated

lime and lime putty
BS 6510 : 1984
Specification for steel windows, sills, window boards

and doors

by BS EN 187000:1994
and BS EN 187000:1994)
Optical fibres and cables
BS 6566 (replaced by BS
EN 636-1-3:1997)
Plywood
BS 6588 : 1985 (1996)

Specification for Portland pulverized-fuel ash cement
BS 6657 : 1991
Guide for prevention of inadvertent initiation of

electro-explosive
devices
by
radio-frequency
radiation

by BS EN 1562:1997)
Specification for malleable cast iron
BS 6700 : 1997
Specification for design, installation, testing and

maintenance of services supplying water for
domestic use within buildings and their cartilages
BS 6780 : 1986
Specification for through thickness reduction of area

of steel plates and wide flats

20/24
hydrated
lime
and
natural
calcium
January 2011
1.2.3
BS 6925 : 1988
Specification for mastic asphalt for building and civil

engineering (limestone aggregate)
BS 6949 : 1991(2000)
Specification for bitumen-based coatings for cold

application, excluding use in contact with potable
water
BS 7295
Fusion bonded epoxy coated carbon steel bars for

the reinforcement of concrete
BS 7263 : 1990
Precast concrete flags, kerbs, channels, edgings and

quadrants
BS 7263 : Part 1 : 1990

(replaced by BS 72631:2001 and BS 72633:2001)
Specification
BS 8004 : 1986
Code of practice for foundations
BS 8005 : Part 1 : 1987

Guide to new sewerage construction
BS 8110 : 1985
Structural use of concrete
BS 8118 : Part 2 : 1991
Specification for materials, workmanship and

protection
BS EN 10025 : 1993
Hot rolled products of non-alloy structural steels.

Technically delivery conditions
CP 144
Roof coverings
CP 144 : Part 4 : 1970

(replaced by BS
8218:1998)
Mastic asphalt. Metric units
American Standards
AASHTO Designation
M252-81
Standard specification for corrugated polyethylene

drainage tubing
ASTM A775
Standard specification for epoxy-coated reinforcing

steel bars
ASTM A 775M (replaced

by ASTMa775m-01)
Specification for epoxy-coated reinforcing steel bars
ASTM C 127-88 (replaced

by ASTMC127-01)
Test method for specific gravity and absorption of

coarse aggregate

by ASTM C128-01)
Test method for specific gravity and absorption of

fine aggregate
ASTM C 138-81 (1987)

(replaced by ASTM C13101)
Test method for resistance to degradation of smallsize coarse aggregate by abrasion and impact in the
Los Angeles Machine

21/24
January 2011
ASTM C 136-84A
(replaced by ASTM c13601)
Method for sieve analysis of fine and coarse

aggregates

by ASTM c188-95)
Test method for density of hydraulic cement
ASTM C-494 Type C
Standard specification for chemical admixtures for

concrete Type C Accelerating admixtures

by ASTM c939-97)
Test method of flow of grout for preplaced-aggregate

concrete
ASTM C 939-94
Standard test method for flow of grout for preplacedaggregate concrete (flow cone method)
ASTM D 5-86 (replaced by

ASTM d5-97)
Test method for penetration of bituminous materials
ASTM D 113-86 (replaced

by ASTM d113-99)
Test method for ductility of bituminous materials

by ASTM d140-01)
Method for sampling bituminous materials

by ASTM d24295(2000)e1)
Specification for mineral filler for bituminous paving

mixtures
ASTM D 512-81, Method

B
Standard test methods for chloride ion in water
ASTM D 516-80, Method

A
Standard test method for sulfate ion in water

by ASTM d546-99e1)
Method for sieve analysis of mineral filler for road

and paving materials

by ASTM d854-00e1)
Test method for specific gravity of soils

by ASTM d946-82(1999))
Specification for penetration-graded asphalt cement

for use in pavement construction

by ASTM d979-01)
Methods for sampling bituminous paving mixtures
ASTM D 1293-78
Standard test methods for pH of water
ASTM D 1559-82
(replaced by ASTM
(discontinued))
Test method for resistance to plastic flow of

bituminous mixtures using Marshall apparatus
ASTM D 1754-87
(replaced by ASTM
d1754-97)
Test method for effect of heat and air on asphaltic

materials (thin-film over test)
ASTM D 2000-86
(replaced by ASTM
d2000-01)
Classification system for

automobile applications
ASTM D 2027-76 (1986)

(replaced by d2027-97)
Specification for cutback asphalt (medium-curing

type)

22/24
rubber
products
in
January 2011
1.2.4
ASTM D 2041-78
Test method for theoretical maximum specific gravity

of bituminous paving mixtures
ASTM D 2042-81 (1985)

Test method for solubility of asphalt materials in

trichloroethylene
ASTM D 2171-88
Test method for viscosity of asphalts by vacuum

capillary
ASTM D 2172-88
(replaced by d2172-01e1)
Test method for quantitative extraction of bitumen

from bituminous paving mixtures
ASTM D 2726-88
Test method for bulk specific gravity of compacted

bituminous mixtures using saturated surface-dry
specimens
ASTM D 3203-88
(replaced by d320394(2000))
Test method for percent air voids in compacted

dense and open bituminous paving mixtures
ASTM D 3289-85
Test method for specific gravity or density of semisolid and solid bituminous materials by nickel
crucible
AWWA C 203-86
Coal-tar enamel protective coatings for steel water

pipes
Hong Kong Standards and Codes of Practice

CS1 : 1990
Testing concrete
CS2 : 1995
Carbon steel bars for the reinforcement of concrete
PNAP
Practice note for authorized persons and registered

structural engineer
PNAP 1
Buildings Department practice notes in force
PNAP 66
Pile foundations
PNAP 71
Demolition works Measures for public safety
PNAP 122
Testing of reinforcement for concrete
PNAP 132
Site investigation and ground investigation
PNAP 161
Development in the area numbers 2 & 4 of

scheduled areas
PNAP 187
Code of practice for the structural use of concrete

1987
PNAP 214
New contractor registration system and the

contractors registration committee
PNAP 242
Quality supervision requirements for foundation

works
PNAP 243
Construction and Demolition Waste
Geospec 1
Model specification for prestressed ground anchors,

2nd edition (1989)
Geospec 3
Model specification for soil testing
Geoguide 1
Guide to retaining wall design 2nd Edition
Geoguide 2
Guide to site investigation (1987)

23/24
January 2011
Geoguide 3
Guide to rock and soil descriptions (1988)
Geoguide 6
Guide to reinforced fill structure and slope design
GEO Report No.36
Methods of test for soils in Hong Kong for civil

engineering purposes (Phase 1) tests (1994)
GCO 1/90
Review of design methods for excavation
GCO 1/96
Pile design and construction
Geotechnical manual for slopes, 2nd Edition

Stormwater drainage manual
Sewerage manual (Part 1) Key planning issues and gravity collection system
Sewerage manual (Part 2) Pumping station and rising mains
Drainage services department standard drawings
Transport planning and design manual
Code of practice for lighting, signing and guarding of road works
Code of practice for site safety supervision
Technical memorandum for site safety
Public lighting design manual
Structures design manual for highways and railways
Guidelines on design of noise barriers
Highways standard drawings
Civil Engineering design manual
Civil Engineering Department standard drawings
1.2.5
Other International Standards

Swedish Standards
SIS 05 59 00

Surface preparation standard for painting steel

surfaces
24/24
January 2011
SECTION 2
TEMPORARY WORKS
2.1
INTRODUCTION
2.1.1
This Section specifies materials and workmanship required for the design and
construction of Temporary Works.
2.1.2
Any details of Temporary Works shown on the Employers Drawings are for
reference only and such details shall not relieve or reduce the Contractors full
design responsibility for all Temporary Works under the Contract.
2.2
DESIGN AND PERFORMANCE CRITERIA
2.2.1
Design
2.2.2
2.2.3
(a)
Unless otherwise stated in the Contract, Temporary Works shall be designed

by the Contractor who shall submit for the Project Manager's review without
objection copies of calculations and drawings of the Temporary Works in
accordance with the requirements stated in the Contract.
(b)
The Contractor shall design Temporary Works in accordance with the

principles of BS 5975 except that the criteria as set out in Appendix A2.2 shall
prevail when designing for Hong Kong conditions.
(c)
Where appropriate, Temporary Works design shall comply with the

requirements of the Building Ordinance.
Temporary Works Co-ordinator

(a)
The Contractor shall appoint a person "the Temporary Works Co-ordinator"

whose duties shall in general follow the recommendations of Clause 10.2.2 of
BS 5975. The Contractor shall submit for review without objection by the
Project Manager the details and duties of the Temporary Works Co-ordinator.
(b)
The Temporary Works Co-ordinator shall certify the design, loading, and
dismantling of falsework in accordance with Appendices A2.2 and A2.3.
Checking Engineer
Unless the Contract provides expressly to the contrary, the design of
Temporary Works shall be checked and certified as being satisfactory by
Checking Engineer in accordance with Appendices A2.2 and A2.3; and all
certificates endorsed by the Checking Engineer in relation thereto shall
submitted to the Project Manager for review without objection.
2.2.4
the
the
the
be
Method
The Contractor shall submit for the Project Manager's review without objection,
method statements giving full details of materials, Contractor's Equipment and
timing and sequence of operations involved in the construction of Temporary
Works.

Section 2 Temporary Works
1/14
January 2011
2.2.5
2.2.6
2.2.7
Construction and Removal

(a)
Temporary Works shall be constructed to the same workmanship and quality

standards as the Permanent Works save that the Temporary Works need not
be new.
(b)
The Contractor shall ensure that the Temporary Works are constructed, used
and removed in accordance with the certified design. If the Contractor wishes
to change the construction, use or removal of the Temporary Works he shall
submit to the Project Manager for review without objection details of such
changes together with further certification in accordance with Appendices
A2.2 and A2.3. Such details shall be reviewed without objection by the
Project Manager before the Contractor implements any such change.
(c)
Erection of falsework may not commence until the design has been certified
by the Temporary Works Co-ordinator and the Checking Engineer in
accordance with Appendix A2.2.
(d)
Loading or dismantling of falsework may not commence prior to certification

by the Temporary Works Co-ordinator and the Checking Engineer in
(e)
Temporary Works whether above or below ground or water level shall be

dismantled and completely removed after completion of the Permanent Works
as shown on the Contractor's Drawings unless otherwise shown on the
Employer's Drawings.
Scaffolding and Staging

(a)
Scaffolding and staging shall be provided and erected in accordance with the
Construction Sites (Safety) Regulations (Cap. 59). In addition, all walkways
and elevated working platforms shall have properly constructed kickboards
and handrailing.
(b)
The use of "bamboo" for scaffolding or staging shall not be permitted without
the prior consent of the Project Manager and if permitted shall be subject to
compliance with the requirements of the Construction Site (Safety)
Regulations in relation to Scaffold, Working Platforms and Ladders.
Sheet Piling and Trench Support Systems

(a)
Sheet piles shall be of the interlocking type and shall be of a suitable class for
a particular location.
(b)
Sheet piles shall be rolled from mild steel complying BS 4360. Each pile shall
be in one length throughout but where required may be extended by welding
an additional length subject to the permission of the Project Manager.
Welding shall be in accordance with the requirements of Section 22 of this
General Materials and Workmanship Specification.
(c)
Holes in the piling for ties and attachment of waling etc. shall be drilled after
driving. Burning of holes shall not be carried out without the permission of the
Project Manager.

2/14
January 2011
2.2.8
2.2.9
(d)
The sheet piles shall be driven to the line and to the tolerances shown on the
Temporary Works drawings and shall be pitched in panels.
(e)
Propriety trench support systems shall be reviewed without objection by the

Project Manager prior to use on Site. Propriety systems shall be installed in
accordance with the manufacturers recommendations and shall comply with
CIRIA Technical Note 95; 1986.
(f)
Hard driving for piling works shall not be permitted without the prior consent of
the Project Manager.
Anchors
(a)
Where the Contractor proposes to use anchors as part of his Temporary

Works he shall, as part of his method statement, submit to the Project
Manager for review without objection a detailed specification for the anchors
based on the current edition of the Government publication: Geospec 1,
Model Specification for Ground Anchors, and shall include in the relevant
quality plan a detailed scheme for installation of the anchors. Work shall not
commence on Site until the Project Manager has reviewed without objection
the Contractor's proposals. Anchors may be subject to the approval of the
Building Ordinance Office and/or the Geotechnical Engineering Office and the
Contractor must take full cognizance of the time required for the approval
procedure in such a case.
(b)
As soon as progress of the Works permits, and with the permission of the
Project Manager, temporary ties shall be destressed and as far as is
practicable, physically severed from any part of the Works.
Temporary Piling
Piling to Temporary Works shall not adversely affect the geotechnical properties of
the strata on which foundations for Permanent Works are to be constructed.
Temporary Works piling adjacent to or in the near vicinity of foundations for
Permanent Works shall be subject to the review without objection of the Project
Manager.
2.2.10
Temporary Decking
(a)
Temporary deck panels, unless of concrete construction, shall have an antiskid surface such as a graded calcined bauxite aggregate bedded in epoxy
resin. The skid resistance value of the surface shall be in excess of 45,
measured in accordance with BS 3262.
(b)
The drainage of the temporary deck shall be such that all the surface water
shall be retained within the plan area of the temporary deck and be
discharged properly and effectively through connections to the existing
drainage system.
(c)
The finished level, falls and camber of the temporary deck shall be in
accordance with the existing roadway. Walkways, which shall be drained
properly and effectively, shall be provided to replace existing pavements
which are overlapped by the temporary decking. Where walkways are
covered they shall be lit for pedestrian safety.

3/14
January 2011
(d)
2.2.11
2.2.12
Minimum standard headroom under temporary structures shall be 5.1 m over

highways and roadways and 2.3 m over footpaths. Lighting of roadways
covered by temporary structures shall be provided in accordance with the
requirements for temporary lighting detailed in Section 3 of the General
Specification.
Dewatering of Excavations, Drainage and Pumping

(a)
The Contractor shall install, operate and maintain all temporary pumping plant
and drainage facilities and remove all accumulated silt and debris necessary
for the proper execution and completion of the Works.
(b)
Groundwater control and drawdown shall be in accordance with the

requirements of Clauses 8E.4.16-8E.4.19 of this General Materials and
Workmanship Specification.
Fire Hazard
All materials which present a fire hazard or which may give off noxious fumes in the
event of ignition will be rejected for use in the Temporary Works and the Contractor
shall immediately remove such materials from Site.
2.2.13
Welding
The Contractor's Equipment used for welding shall be in accordance with the
appropriate British Standard and the safety regulations applicable in Hong Kong
Construction Safety Regulations. Welding shall be carried out in compliance with
Section 22 of this General Materials and Workmanship Specification.

4/14
January 2011
APPENDIX A2.1
TEMPORARY WORKS DESIGN CRITERIA
A2.1.1 Preamble
This Appendix specifies the criteria which shall be used for the design of Temporary
Works.
A2.1.2 Ground Movement
(1)
The design of the Temporary Works shall investigate, evaluate and define
acceptable limits for ground movement within and around the Site and
thereby avoid damage to adjacent property, land footways, roads and utilities.
(2)
The installation of any wall (prior to dewatering and excavation) shall not
produce settlement in the adjacent ground or buildings greater than 25 mm.
No dewatering will be permitted during the wall installation. In general,
dewatering of an excavation will not be permitted until a closed perimeter of
impermeable wall is completed.
(3)
The Contractor shall establish an adequate number of settlement monitoring

points on both the front and back of adjacent land. Readings at appropriate
intervals shall be continued throughout the duration of the Contract. If any of
the following criteria are reached, irrespective of whether or not damage has
occurred, the Contractor shall notify the Project Manager immediately:
(a)
5 mm - settlement between consecutive readings;
(b)
angular distortion exceeding 1/1000; or
(c)
25 mm - total settlement of any part of a building or other structure.
These requirements are in addition to any other requirements which may be

required by the Contract.
A2.1.3 Ground Water
The ground water level at the Airport may be at or near to ground level and the
effect of ground water must be taken into account in the design of Temporary
Works.
A2.1.4 Construction Method
The design of Temporary Works shall take full account of the proposed construction
method. The Temporary Works drawings and calculations shall demonstrate the
adequacy of the proposed construction method at each construction stage.
A2.1.5 Loads and Forces
The design of Temporary Works shall take account of all the applied external forces
and imposed structural deformations.

5/14
January 2011
A2.1.6 Excavation
(1)
The Temporary Works design shall take into account the temporary condition
when the excavation nears the bottom of permanent or temporary retaining
walls. Unless otherwise stated on the Employer's Drawings, the factors of
safety against base failure from bottom heave, failure from inward yielding,
failure from piping or blows, shall be a minimum value of 1.5.
(2)
The design of Temporary Works associated with earthworks, including

temporary slopes, stockpiles and drainage, shall be such that the risk of
failure is not more than that which would be adopted if the Temporary Works
were to be permanent. Allowance may be made in the design of the
Temporary Works for the shorter design life and for the risk to persons and
property and the surface water and groundwater conditions which are likely to
occur during construction.
A2.1.7 Design Life

The design of Temporary Works may take into account the limited duration over
which the Temporary Works are expected to function. Drawings submitted by the
Contractor shall make clear where provision for limited life has been taken into
account, particularly where this may have an influence on the stability of the
Temporary Works.
A2.1.8 Cofferdams and Temporary Retaining Walls
(1)
The type of cofferdam and retaining wall proposed shall be suitable for the
designed purpose, taking into account the ground and other local conditions.
(2)
Calculations shall be carried out in accordance with the relevant British

Standards.
(a)
(b)
For loads, the following shall apply :

(i)
the influence of wind, temperature, settlement, creep and the like

shall be taken into account;
(ii)
the applied load shall be calculated as accurately as possible;
(iii)
the most onerous load combination shall be obtained;
(iv)
the primary load resisting system shall be designed at basic

permissible stress; and
(v)
the secondary load resisting system may be designed with

permitted overstress.
All materials used as load carrying elements shall conform to the

relevant British Standard. The design shall be based on the basic
permissible stresses as recommended in the relevant British Standard
and the Building (Construction) Regulations (Cap. 123) where
appropriate.

6/14
January 2011
(c)
(3)
(4)
Materials not conforming with the relevant British Standard may be

used, but only if the yield stress can be established. In this case the
basic permissible stresses shall be calculated by applying the same
partial safety factor on that yield stress as used in the relevant British
Standard.
Where the loading combination can be assessed with confidence,

overstressing to 25% greater than the basic permissible stress may be
permitted, except for the most onerous load combination condition or when
the excavation is at its lowest level. Overstress may also be allowed for
abnormal or extreme load calculations, when calculating the most onerous
condition, which have a low probability of concurrent occurrence. For these
latter two conditions, overstressing of the primary support system of walling
and struts shall not be allowed.
(a)
An overstress of 25% greater than the basic permissible stresses may

be allowed on a secondary load resisting system, such as steel sheet
piles, provided that a method exists to rectify the system if over
deflection or similar signs of distress become apparent.
(b)
The following materials and sections

overstressed by the amounts stated:
in
cofferdams
may
be
(i)
steel sheet piling: 25% increase in allowable bending and shear

stresses;
(ii)
steel walings: for transient loads a 25% increase in allowable

bending and shear stresses; and
(iii)
reinforced concrete walings: 25% overstress during the early

stages of excavation and during the installation of frames.
(c)
Overstressing shall not be allowed in struts (concrete or steel) or Hpiles supporting lateral loads (concrete, steel or timber).
(d)
Struts require a factor of safety of 2 against buckling. Calculated strut

loads shall be further increased by the load induced due to a
temperature change of 34C.
(e)
Tendons for ground anchors shall not be stressed to greater than 64%
of their nominal failure load.
The design and construction of a cofferdam shall limit ground movement

around the Site and avoid damage to adjacent property, roads, footways and
utilities.
(a)
Settlement of adjoining structures, resulting from lateral deflection of the

waling systems, shall not exceed 25 mm.
(b)
During dewatering the piezometric pressure in the soil level effectively

supporting the adjacent property shall be maintained. This piezometric
pressure may be lowered by a maximum of 2 m.

7/14
January 2011
A2.1.9 Temporary Decks and Pedestrian Bridges

(1)
The design of temporary decks which are required to carry traffic shall be
carried out by:
(a)
using HA highway loading;
(b)
obtaining the most onerous load combination; and
(c)
checking with 22.5 units HB highway loading.
Where loads from Contractor's Equipment are likely to exceed these design
loads the deck and supporting structure shall be strengthened accordingly.
(2)
The design of the temporary decks and support systems shall allow for
environmental loads, including temperature difference.
(3)
Temporary pedestrian overbridges together with supporting structures shall

be designed for a characteristic load of 5.0 kN/m2.
(4)
Permissible stresses shall comply with the relevant British Standard and the
Building (Construction) Regulations (Cap. 123) where appropriate. An
overstress of 25% shall be allowed when checking the design of temporary
road decks using HB loads only.
(5)
All other types of temporary decks shall be designed using loading criteria
reviewed without objection by the Project Manager.
A2.1.10 Falsework
(1)
The design shall demonstrate that it includes full allowance for all dead,
environmental (wind and temperature, as appropriate), and applied loads.
The latter shall include an allowance for vertical loading on all parts of the
falsework, for access and working conditions, which shall not be less than 1.5
kN/m2. Where heavy items of Contractor's Equipment are used or materials
stored on the falsework or on the completed structure before it becomes selfsupporting, this allowance shall be increased. The drawings shall be clearly
marked with the maximum safe limit for loading of the falsework from items of
Contractor's Equipment or materials.
(2)
The falsework shall be designed to sustain the following horizontal loading,

which may act transversely or longitudinally, separately or simultaneously.
(a)
Dynamic pressure head due to a wind speed in accordance with the

recommendations stated in the "Code of Practice on Wind Effects,
Hong Kong".
(b)
Horizontal loads arising from the unintentional non-verticality of vertical

load carrying members.

8/14
January 2011
(3)
(c)
Horizontal forces derived from impulse and impacts upon or

attachments to the falsework, unbalanced horizontal forces derived
from the application of vertical loads to non-vertical surfaces,
movements of the falsework due to temperature, creep, shrinkage,
settlement, post-tensioning operations, external ties and anchorages.
(a)
The design of the Temporary Works shall ensure that the falsework
receives the loads from, and maintains in the required position,
elements of the Permanent Works until they become self supporting.
Facilities shall be provided for compensating for falsework deflections,
the order of magnitude of which shall be calculated by the Contractor
and reviewed without objection by the Project Manager.
(b)
Loads imposed on the permanent structure by the falsework shall be

within the allowable load capacity of the permanent structure. Sufficient
load spreading elements shall be used to achieve this as necessary.
The design of the falsework shall include calculations to prove that the
permanent structure is not overloaded.
(4)
Falsework erected in close proximity to traffic or construction vehicles shall

be protected against impact from vehicles by crash barriers. These shall be
capable of sustaining a load of a 1.5 tonne vehicle striking the barrier at
110km/hour and at an angle of 20 without permitting the vehicle or barriers
to come into contact with any part of the falsework.
(5)
Foundations for falsework shall be designed to sustain the calculated

maximum loads without failure or unacceptable settlement. The calculations
shall by reference to soil data or tests demonstrate the validity of
assumptions made in respect of permissible settlements and earth pressures
under falsework foundations.
(6)
All materials used as load carrying elements in the falsework shall conform to
the relevant British Standards and the Building (Construction) Regulations
(Cap. 123) where appropriate in respect of quality, and the design shall use
the basic permissible stresses in those standards. Materials not conforming
with the relevant British Standard may be used, but only if the yield stress can
be established. In which case the basic permissible stress shall be
calculated by applying the same safety factor on that yield stress as used in
the relevant British Standard.
(7)
A minimum factor of safety of 1.2 is required against instability of the

falsework under any combination of vertical and horizontal load.
(8)
Testing of materials or components shall be carried out when their quality or

adequacy is in doubt. As far as possible, such tests shall conform to the
appropriate British Standards or shall be as stated in the Contract.
(9)
Where materials are re-used, the basic permissible stresses shall be reduced
to suit the condition of the material.

9/14
January 2011
A2.1.11 Formwork
Formwork shall be designed by the Contractor to withstand the worst combination
of the following without causing bulging or deflection:
(1)
total weight of reinforcement, live concrete and formwork;
(2)
construction loading including the dynamic effects of placing and compacting

concrete and construction traffic; and
(3)
wind loads.
A2.1.12 Earthworks
Notwithstanding the requirements of Section 7, the design of Temporary Works
associated with earthworks, including temporary slopes, stockpiles and drainage,
shall not prejudice the long term integrity or stability of the Permanent Works or
present a risk to persons, property, the surface or groundwater conditions.

10/14
January 2011
APPENDIX A2.2
CERTIFICATION OF THE DESIGN OF TEMPORARY WORKS
Part 1
(To be signed by a professionally qualified member of the Contractors staff, or of his subcontractors staff, responsible for the Contractors Design)
Contract No. & Name:
Part of Works Designed:
Drawings as Listed in Attachment 1 (Number of Drawings:

Calculations
no.)
Title:
Prepared by:
Dated:
Method Statement
No. of Pages
Rev.:
Title:
Submission No.:
Rev.:
Certification
I certify that the Temporary Works described above has been designed in accordance with
the Contract and that the design and drawings have been checked and found satisfactory by
the undersigned.
Signed:
Date:
For and on behalf of the Contractor
Name and qualifications of signatory:

11/14
January 2011
Part 2
(To be signed by the Checking Engineer)
Certification
I certify that the Temporary Works described above has been designed using all the skill
and care to be expected of a professionally qualified and competent designer experienced in
work of a similar nature and scope and that I have checked the design and drawings and
found them satisfactory.
Signed:
Date:
Name and qualifications of the Checking Engineer:

Name of firm or company:
Refer to Attachment 1 (also to be endorsed by Contractor and Checking Engineer)

12/14
January 2011
Attachment 1 to the Certificate of the Design of Temporary Works

Contract No. & Name:
Element of Works Designed:
Drawing No.
Rev
Title
Signed:
Date:
For and on behalf of the Contractor
Signed:
Date:
Checking Engineer
General Materials and Workmanship Specification

Issue No. 5, Volume 1 Civil and Structural Works
13/14
January 2011
APPENDIX A2.3
CERTIFICATION OF LOADING,
DISMANTLING OR REMOVAL OF TEMPORARY WORKS
A2.3.1 Loading / Dismantling / Removal * of Temporary Work
Part 1 : To be signed by the Temporary Works Co-ordinator.
Description of Temporary Works (full description including drawing references, if any):
a)
I certify that the Temporary Works described above have been constructed in
accordance with the Contractor's Drawings and that they have been checked and
found satisfactory for loading by the undersigned.
b)
I certify that any structure supported by the falsework described above has been
checked by the undersigned and that it has become self supporting and that the
Temporary Works may be dismantled or removed.
[a)/*b)]
Date
Signed
Name [of Temporary Works Co-ordinator]

For and on behalf of [Contractor's name]
Part 2 : To be signed by the Checking Engineer.
a)
I certify that the Temporary Works described above have been constructed in
accordance with the Contractor's Drawings and that they have been checked and
found satisfactory for loading.
b)
I certify that any structure supported by the Temporary Works described above has
become self supporting and that the Temporary Works may be dismantled or
removed.
[a)/*b)]
Date
Signed
Print name of Checking Engineer, qualifications, and name of any company he represents
*
Use only one of the alternatives, as appropriate.
General Materials and Workmanship Specification

Issue No. 5, Volume 1 Civil and Structural Works
14/14
January 2011
SECTION 3
SITE CLEARANCE AND DEMOLITION
3.1
GENERAL
3.1.1
The works and materials specified below shall comply with the Sections stated,
unless otherwise stated in this Section.
3.1.2
(a)
The abandonment of pipes and manholes shall comply with Section 6.
(b)
Earthworks, shall comply with Section 7.
Methods of Demolition
Use of the following demolition methods will not be permitted;
(a)
wrecking ball;
(b)
drop ball; and
(c)
blasting.
3.2
3.2.1
Applicable Regulations and Codes

All demolition works shall be carried out in accordance with Building (Demolition
Works) Regulations, Code of Practice for Demolition of Buildings, Technical
Memorandum for Supervision Plans and Code of Practice for Site Safety
Supervision issued by the Buildings Department; approved demolition plans by the
Buildings Department, Practice Note for Authorized Persons and Registered
Structural Engineers (PNAP) No. 71, all other relevant PNAP and all relevant
requirements issued by the HK Government and/or Statutory Authorities.
3.2.2
Employment of Registered Structural Engineer

The Contractor shall appoint a Registered Structural Engineer registered under the
Buildings Ordinance for the preparation of demolition method statement,
supervision and control of demolition works, scaffolding, shoring and strutting etc.
3.3
SUBMISSIONS
3.3.1
Survey
Areas to be cleared and any structures to be demolished shall be surveyed by the
Contractor, and the results submitted to the Project Manager for information, no
less than 7 days before demolition starts.

Issue No. 5, Volume 1- Civil & Structural Works
Section 3 Site Clearance & Demolition
1/7
January 2011
3.3.2
Registered Demolition Contractor and Supervisor

Particulars of the Registered Demolition Contractor, and the Supervisor employed
on the demolition works shall be submitted to the Project Manager for review.
3.3.3
Particulars of Operators of Powered Mechanical Plant or Equipment

The personnel particulars, qualifications and experience of the operators of any
powered mechanical plant or equipment proposed to be used in demolition works
shall be submitted to the Project Manger for review without objection, in a form
suitable for onward submission to the Buildings Department for application for
consent to commence demolition works.
3.3.4
Particulars of Method of Demolition

Before commencement of demolition works the Contractor shall submit to the
Project Manager for review without objection a method statement indicating the
following:
3.3.5
(a)
proposed method of demolition of each type of structural elements;
(b)
sequence of demolition;
(c)
method of transporting debris from the upper floors to ground level;
(d)
method of raising mobile plant to the roof or upper floors and movement
between floors;
(e)
the weight and size of plants used above ground. The support to the floors
and other restrictions must be illustrated;
(f)
design calculations and drawings showing the maximum debris loadings for
all areas and combinations thereof, layout of all necessary falsework or
temporary works required for all stages of the works; and
(g)
location of all chutes for conveying debris down the building floors, and offsite.
Demolition Waste
A Waste Management Plan shall be prepared in accordance with PNAP 243 and
submitted to the Project Manager for review.
3.3.6
Sorting and Disposal of Materials

A method statement for the sorting, processing and disposal of materials arising
from or in connection the demolition work shall be prepared in accordance with
PNAP 243 and Section 7 of the General Specification and submitted to the Project
Manager for review without objection before the commencement of any demolition
works.

2/7
January 2011
3.3.7
Site Safety Supervision Plan

The Contractor shall submit to the Project Manager for review without objection, the
Site Safety Supervision Plan, prepared in accordance with the Technical
Memorandum for Supervision Plan and Code of Practice for Site Safety Supervision
of Building Works and Street Works.
3.4
WORKMANSHIP
3.4.1
Existing Services
Before commencement of demolition works the Contractor shall:
3.4.2
(a)
locate and identify the position of existing services and utilities affected by the
works; and
(b)
arrange with the relevant Authorities for the disconnections or diversion of all
services and utilities and the removal of all associated fittings and equipment.
Trees
(a)
The roots of trees and shrubs which have been cut down shall be grubbed up.
Branches shall not be removed from trees which are to be retained unless
permitted by the Project Manager; if permitted, the branches shall be removed
in accordance with BS 3998 and the cut surfaces shall be treated with a
wound sealant.
(b)
In respect of existing trees and woodland the Contractor shall ensure for the
duration of the Contract, the following:
(i)
there is no unnecessary intrusion into areas of woodland or scrubland;
(ii)
the limits of site clearance shall be reviewed without objection by the

Project Manager on Site before site clearance commences. All trees to
be cleared shall be marked by the Contractor and reviewed without
objection by the Project Manager before felling;
(iii)
trees not required to be trimmed, pruned or felled shall not be marked;
(iv)
nails or other fixings shall not be driven into trees;
(v)
fencing or signs shall not be attached or painted on trees;
(vi)
trees shall not be used as anchors for ropes or chains used in guying,
pulling and the like; and
(vii) fires shall not be lit under or in the close proximity of trees.
(c)
As soon as the Site or any part thereof becomes available the Contractor shall
erect temporary protective fencing reviewed without objection by the Project
Manager around any tree and group of trees which are required to be
protected. The fence shall not be closer than 2 m from the trunk of any such
tree and all such work shall be executed using only hand-held tools.

3/7
January 2011
3.4.3
Stripping Topsoil
At the commencement of any excavation and prior to any filling the Contractor shall
strip any humus topsoil capable of being used as soil conditioner and set it aside for
subsequent use in the Works. Any topsoil surplus to the requirement of the Works
shall be disposed of in accordance with Clause 7.5.9. Temporary stockpiles of
topsoil shall not exceed 2 m in height.
3.4.4
Precautionary Measures
Demolition works shall not commence until all the required precautionary measures
have been installed in accordance with Building (Demolition Works) Regulations,
Code of Practice for Demolition Works, Technical Memorandum for Supervision
Plans and Code of Practice for Site Safety Supervision issued by the Buildings
Department; approved demolition plans by the Buildings Department, PNAP 71, all
other relevant PNAP and all other relevant requirements issued by the HK
Government and/or Statutory Authorities.
3.4.5
Prevention of Overloading
The Contractor shall;
3.4.6
(a)
not overload the structure under demolition with demolition plant and/or
resulting debris;
(b)
comply with the propping requirements or temporary propping system during

the operation of mechanical plant on suspension floor as stipulated in the
Code of Practice for Demolition of Buildings;
(c)
provide all temporary shoring, strutting and/or propping required;
(d)
secure and wedge tight top and bottom supports to props. The props shall be
braced to provide lateral restraints in at least 2 directions;
(e)
not allow mobile equipment to move to within 2 m of the building edge, 1 m of

any floor opening or on to any cantilevered structures; and
(f)
provide adequate spreaders for props bearing on ground, where necessary, to

avoid any undue settlement;
Warning Signs
The Contractor shall erect warning signs in prominent positions indicating
demolition works are in progress in both Chinese and English.
3.4.7
Overhead Wires
The Contractor shall prevent damage to overhead wires during demolition
operations.
3.4.8
Risk of Fire Explosion

The Contractor shall take precautions to prevent fire or explosion from gas or
vapour release, electricity or any other source, especially when removing tanks or
pipes which may have contained flammable liquids or gases.

4/7
January 2011
3.4.9
3.4.10
Weatherproofing Retained Areas of Partially Demolished Buildings

(a)
Where partially demolished buildings or structures are to be retained the

Contractor shall protect the retained building structure and interiors exposed
during the course of demolition works with a temporary weather-tight screen
erected 1000 mm back from the perimeter edge of floors.
(b)
Screens shall be constructed with close boarding fixed to framing and faced
outside with roofing felt of a type reviewed without objection. The exposed
floor beyond the screening shall be covered with roofing felt of similar type to
that used to face screens and a waterproof seal formed between floor and
screen. Doors in the screens shall be constructed and fixed with secure
fastenings and hanging devices as necessary to provide authorised access.
Partly Demolished Structures

The Contractor shall leave the Site and partly demolished structures in a safe
condition at the end of each days work. No accumulation of debris shall be
allowed, particularly at working floors and at ground floor, which causes excessive
pressure on the floors, slopes, retaining structures, hoardings/covered walkways,
catchfans and walls of adjoining structures.
3.4.11
Care of Electric Cables

The Contractor shall take every precaution to prevent damage and to exercise
extreme care during execution of the work in the vicinity of live electrical cables.
3.4.12
Disused Drains
The Contractor shall disconnect and seal off all storm water drains or sewers from
the last manhole to the Government storm water drain or sewer in accordance with
the requirements of the Relevant Authorities.
3.4.13
Burning
The Contractor shall not burn any rubbish or materials arising from the demolition
on Site.
3.4.14
3.4.15
Spoil Heaps
(a)
The Contractor shall prevent excessive lateral pressure due to stockpiling of

debris against walls, adjoining structures and steel hoardings adjoining the
public footpaths or carriageways.
(b)
Spoil heaps shall be not be placed on catch platforms or on top of covered

walkways. Spoil heaps shall be cleared away immediately to prevent
overloading any part of the existing structure.
Reinstatement
(a)
Areas affected by Site clearance shall be reinstated as follows:

(i)
Fine fill material shall be deposited and compacted in voids which are
left in the ground.
(ii)
Holes which are left in structures and pavements shall be made good
using material similar to the material in the adjoining area.

5/7
January 2011
3.4.16
3.4.17
(iii)
The ends of fences, walls, structures, utilities and other items shall be
made good in such a manner that the affected parts will not corrode or
deteriorate, and will remain stable.
(iv)
Straining posts shall be fixed at the end of strained fences which have
been cut and the fences shall be restrained.
Materials and Equipment for Re-use and Storage

(a)
Items to be re-used or taken to store shall be dismantled and removed by a

suitable method so as to avoid or minimise damage. The items shall be
cleaned before taking to store.
(b)
Items to be re-used in the Works shall be kept in stores provided by the

Contractor.
(c)
Items which are to be taken to the Employer's store shall be delivered by the
Contractor.
(d)
Materials or equipment which are to be reused or taken to store and which are
damaged due to the Contractors negligence shall be repaired by the
Contractor by a method reviewed without objection by the Project Manager.
Materials or equipment which are lost or which are not capable of being
repaired satisfactorily shall be replaced by the Contractor. Except for items
which are to be re-used or taken to store, demolished items, trees, shrubs,
vegetation, boulders, debris, rubbish and other items arising from site
clearance shall be disposed of by the Contractor and shall become the
property of the Contractor when they are removed from the Site.
(e)
All construction and demolition materials arising from or in connection with the
demolition work shall be sorted on-Site and separated into different groups for
disposal at landfills, public filling areas, in filling areas provided by the
Contractor, or recycling as appropriate.
(f)
Unless otherwise stated in the Contract, all construction and demolition

materials arising from or in connection the demolition work shall become the
property of the Contractor. The Contractor shall promptly remove all sorted
and processed materials arising from or in connection with the demolition
work from the Site on a regular basis as demolition work proceeds.
Remove debris
(a)
All construction and demolition materials arising from or in connection with the
demolition work shall be sorted on-Site and separated into different groups for
disposal at landfills, public filling areas, in filling areas provided by the
Contractor, or recycling as appropriate.
(b)
Unless otherwise stated in the Contract, all construction and demolition

materials arising from or in connection the demolition work shall become the
property of the Contractor. The Contractor shall promptly remove all sorted
and processed materials arising from or in connection with the demolition
work from the Site on a regular basis as demolition work proceeds.

6/7
January 2011
3.5
INSPECTION
3.5.1
Joint Inspections
Prior to the commencement of site clearance and demolition, and after completion,
the Contractor shall undertake joint inspections with the Project Manager of all
existing structures to be retained within the Site and produce a Condition Survey
Report submitted to the Project Manager for review. Any damage noted to the
structures during the second inspection shall be made good by the Contractor to the
satisfaction of the Project Manager. Photographic records, taken by the Contractor
and reviewed without objection by the Project Manager, shall be kept as part of the
joint inspection.

7/7
January 2011
SECTION 4
LANDSCAPING WORKS
4.1.
GENERAL
4.1.1
4.1.2
(a)
Site clearance shall comply with Section 3.
(b)
Earthworks shall comply with Section 7.
(c)
Landscape hardworks shall comply with Section 11.
(d)
Geotechnical works shall comply with Section 8.
Weather and Ground Conditions

Soiling, cultivation, planting and other similar landscape softworks and
establishment works operations shall not be carried out at times when weather or
ground conditions may adversely affect the Permanent Works.
4.1.3
Use of Chemicals
Chemicals shall not be used for landscape softworks and establishment works
except with the permission of the Project Manager. Chemicals shall be used,
stored, mixed and applied in accordance with the manufacturer's
recommendations. Containers for chemicals shall be disposed of off-Site by
methods reviewed without objection by the Project Manager.
4.2.
DEFINITIONS AND ABBREVIATIONS
4.2.1
Landscape Softworks
Landscape softworks are all works of a horticultural nature, and shall include the
placing, cultivation and preparation of topsoil and subsoil layers, and the supply
and planting of trees, shrubs and other plant material, and any associated works.
4.2.2
Landscape Hardworks
Landscape hardworks shall include the paving, tree grilles, tree guards and tree
rings and any other items stated as such in the Contract.
4.2.3
Establishment and Landscape Works

(a)
Establishment works shall include the regular inspections, cultivation,

watering, fertilizing and other operations specified to be performed during the
period stated in the Contract for such inspections and operations.
(b)
Landscape works means landscape softworks, landscape handworks and

establishment works.

Issue No. 5, Volume 1 - Civil & Structural Works
Section 4 Landscaping Works
1/20
January 2011
4.3.
4.3.1
British Standards Relevant to Landscape Softworks and Establishment

Works
A list of British Standards publications relevant to landscape softworks and
establishment works is included as Appendix A4.1. Works shall comply with these
standards.
4.4.
MATERIALS
4.4.1
Seedling Trees
Seedling trees shall have the following characteristics:
4.4.2
(a)
less than 2 years old;
(b)
single slender stem;
(c)
well developed vigorous root system;
(d)
height above soil level of between 150 mm and 900 mm; and
(e)
grown in a container at least 50 mm diameter and 150 mm deep.
Whip Trees
Whip trees shall have the following characteristics:
4.4.3
(a)
less than 3 years old;
(b)
single central stem well furnished with side branches according to species;
(c)
(d)
height above soil level of between 900 mm and 2000 mm; and
(e)
grown in a container at least 75 mm diameter and 150 mm deep.
Light Standard Trees

Light standard trees shall have the following characteristics:
(a)
sturdy straight stem at least 1500 mm high from soil level to the lowest
branch;
(b)
stem diameter of between 20 mm and 25 mm measured at a height of 1 m

from soil level;
(c)
according to species, either a well balanced branching head or a well defined

straight and upright leader with branches growing out from the stem with
reasonable symmetry;

2/20
January 2011
4.4.4
(d)
total height above soil level of between 2000 mm and 3000 mm; and
(e)
rootball at least 300 mm diameter and 250 mm deep.
Standard Trees
Standard trees shall have the following characteristics :
4.4.5
(a)
sturdy straight stem at least 1800 mm high from soil level to the lowest
branch;
(b)

from soil level;
(c)

(d)
total height above soil level of between 2750 mm and 3500 mm; and
(e)
Heavy Standard Trees

Heavy standard trees shall have the following characteristics :
4.4.6
(a)
sturdy, straight stem at least 2100 mm high between the soil level and the
lowest branch;
(b)

from soil level;
(c)

(d)
total height above soil level exceeding 3500 mm; and
(e)
Small Shrubs
Small shrubs shall have the following characteristics :
(a)
at least two one-year old vigorous stems arising at or near the base;
(b)
well developed, vigorous root system;
(c)
according to species, height above soil level not less than the height stated in
the Contract; and
(d)
grown and supplied in a container at least 75 mm diameter and 125 mm deep.

3/20
January 2011
4.4.7
Large Shrubs
Large shrubs shall have the following characteristics :
4.4.8
(a)
bush with at least three one-year old vigorous stems arising at or near the
base, with an overall diameter equal to 2/3 of the height;
(b)
(c)
according to species height above soil level not less than the height stated in
the Contract; and
(d)
grown and supplied in a container at least 100 mm diameter and 125 mm

deep.
Conifers
Conifers shall have the following characteristics :
(a)
well developed stem well furnished with leaf or needle bearing side shoots;
(b)
(c)
size not less than that stated in the Contract; and
(d) grown and supplied in a container with dimensions not less than the
dimensions stated in the Contract.
4.4.9
Palms
Palms shall have the following characteristics:
4.4.10
(a)
well developed upright habit with a well balanced, symmetrical head;
(b)
(c)
for single stem species, height above soil level to the growth point not less
than the height stated in the Contract;
(d)
for multi-stemmed species, height above soil level to the growth point not less
than the overall height stated in the Contract; and
(e)
rootball or grown and supplied in a container at least 300 mm diameter and

300 mm deep.
Bamboo
Bamboo shall have the following characteristics :
(a)
(b)
for single stem species, a single shoot or trunk with height above soil level not
less than the height stated in the Contract;

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January 2011
4.4.11
(c)
for multi-stemmed species, a clump of at least three stems with height above
soil level not less than the height stated in the Contract; and
(d)
rootball or grown and supplied in a container at least 200 mm diameter and

200 mm deep.
Herbaceous Plants
Herbaceous plants shall have the following characteristics :
(a)
well developed vigorous shoots;
(b)
a well developed vigorous root system;
(c) height above soil level or diameter of plant for clumps not less than the height
or diameter stated in the Contract; and
(d)
4.4.12
healthy well developed bulbs, corms, rhizomes or tubers.
Containerised Plants
Containerised plants shall be grown in open ground and then lifted and placed in a
rigid or semi-rigid container. Plants shall be left to grow in the containers for at least
3 months before being delivered to Site. The dimensions of containers shall not be
less than the relevant rootball or container dimensions stated in Clauses 4.4.1 to
4.4.10.
4.4.13
4.4.14
4.4.15
Grass Seed
(a)
Grass seed shall be supplied true to species and variety and shall not contain
impurities except as stated in Clause 4.6.13(b). Containers shall be labeled
with the origin of all seed contained therein and the name of the supplier.
(b)
The quality of grass seed shall be gauged by purity, germination percentage

and freedom from weeds. The total weed seed content shall not exceed 0.5%
by mass and the total content of other crop seeds shall not exceed 1% by
mass.
Turf
(a)
First quality turf shall consist of 75%-85% axonopus compressus and 15%25% cynodon dactylon and other stoloniferous species unless otherwise
stated in the Contract.
(b)
The grass shall be of even density, forming a turf which is sufficiently fibrous
to hold together when handled. The grass shall be free from pest or disease.
Turf shall consist of sods with soil and roots.
Sprigs
Sprigs shall consist of axonopus compressus, cynodon dactylon, paspalum
distichum and other stoloniferous grasses. Axonopus compressus shall not be
used on slopes exceeding 15 to the horizontal. Sprigs shall be at least 100 mm
long.

5/20
January 2011
4.4.16
Soil-mix
Soil-mix shall consist of friable, completely decomposed granite and soil
conditioner in the proportions 3 : 1 by volume. Soil-mix shall be free from grass or
weed growth, sticky clays, salt, stones exceeding 50 mm diameter, the materials
stated in Clause 7.2.1(b) and other deleterious material.
4.4.17
Soil Conditioner
(a)
(b)
4.4.18
Soil conditioner shall be organic material and shall be free from impurities and
substances injurious to plants. Soil conditioner shall have the following
properties :
(i)
the pH value shall be between 5.0 and 7.5;
(ii)
the moisture content measured in accordance with Clause 7.5.11(b)

shall be between 30% and 50%;
(iii)
the consistency shall be fine and freely flowing; and
(iv)
the carbon/nitrogen ratio shall be between 25 and 70.
Soil conditioner shall be peat moss or properly composted organic material.

Composted organic material shall be stable and shall not be liable to
decompose further generating heat.
Mulch
Mulch shall be a composted organic material either as stated in Clause 4.4.17 for
soil conditioner or granulated tree bark or wood shavings. The properties of mulch
shall be as stated in Clause 4.4.17 for soil conditioner except that the consistency
shall be coarser to avoid being blown away by wind.
4.4.19
Mulch for Hydroseeding

Mulch for hydroseeding shall be a proprietary type manufactured from cellulose or
paper based materials and reviewed without objection by the Project Manager.
4.4.20
Fertilizer
(a)
Pre-planting fertilizer shall be provided in the ratio of 15:9:15:2 (nitrogen /

phosphorus / potassium / magnesium) slow release granular fertilizer.
(b)
Post-planting fertilizer shall be 12:12:17 (nitrogen/phosphorus/potassium)

granular fertilizer.
(c)
Hydroseeding fertilizer shall be 15:15:15 (nitrogen/phosphorus/potassium).
(d)
Phosphate fertilizer shall be triple superphosphate powder.
(e)
Fertilizer shall be supplied in sealed waterproof bags.

6/20
January 2011
4.4.21
Soil Binder
Soil binder shall be a proprietary type reviewed without objection by the Project
Manager and shall consist of a binding medium applied in aqueous suspension by
spraying onto the surface of the soil to stabilise and condition the soil. The binding
agent shall not be injurious to plant growth.
4.4.22
4.4.23
Stakes, Ties and Guys

(a)
Steel stakes for heavy standard trees shall be 25 mm x 25 mm x 4 mm or

40 mm x 40 mm x 4 mm angle iron and shall have the appropriate lengths
stated in Clauses 4.6.3(d), 4.6.3(h)(ii) and 4.6.3(i)(ii); steel stakes shall have
all sharp edges removed to avoid damage to the tree.
(b)
Ties shall be rot-proof rope or straps fitted with plastic, bamboo or other
spacers and a protective sleeve to fit around the plant; ties shall be capable of
adjustment after fixing.
(c)
Guys shall be a multi-strand twisted galvanized steel wire of between 4 mm

and 6 mm diameter. Each guy shall be fitted with a flexible rubber or plastic
sleeve to prevent chafing, rubbing or abrasion of the plant, and a turnbuckle
for adjustment.
Protective Fabric Material

Protective fabric material for hydroseeding shall be a proprietary type of degradable
fabric reviewed without objection by the Project Manager. The fabric shall not
degrade within 100 days after application or until the specified grass cover has
been established.
4.5.
SUBMISSIONS
4.5.1
Particulars of Seed Mixture, Turf, Sprigs, Soil Conditioner and Water

(a)
The following particulars of the proposed materials for landscape softworks

and establishment works shall be submitted to the Project Manager for review
without objection:
(i)
origin of trees, shrubs, turves, sprigs and other plant material;
(ii)
details of nurseries;
(iii)
a certificate or a numbered seed analysis report for each seed mixture

issued within 6 months before the date of use of the seed showing the
species and variety of the seed, the date of testing and including results
of tests for;
percentage germination of pure seed in a fixed time under standard
laboratory conditions; and
percentage composition by weight, including details of impurities;

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January 2011
4.5.2
a certificate of analysis for soil conditioner including details of the

composition and results of tests for;
pH value;
moisture content; and
carbon/nitrogen ratio; and
(v)
source of water for watering.
Particulars of Hydroseeding
(a)
4.5.3
(iv)
The following particulars of the proposed materials and methods for

hydroseeding shall be submitted to the Project Manager for review without
objection:
(i)
species and rate of application of grass seed;
(ii)
type and rate of application of fertilizer, mulch and soil binder;
(iii)
type and colour of dye;
(iv)
type of protective fabric material;
(v)
details of the company employed to carry out the hydroseeding and the
equipment to be used; and
(vi)
manufacturer and details of mulch for hydroseeding.
Representative Samples of Materials

(a)
Representative samples of the following proposed materials shall be

submitted to the Project Manager at the same time as particulars of the
material are submitted:
(i)
each seed mixture;
(ii)
turf;
(iii)
sprigs; and
(iv)
soil-mix.
(b)
Representative samples of materials for landscape works and establishment

works shall be made available for inspection by the Project Manager, at
nurseries and other sources before the materials are delivered to the Site.
(c)
A certificate of purity of the grass seed to be used in the Works shall be

submitted to the Project Manager. The batch number of the certificate shall be
checked against that on the bag. The certificate shall not be more than 6
months operations, a 500 g seed sample shall be supplied and retained under
refrigeration by the Project Manager until the viability of the seed is proven or
disproven on Site. Impurities in the seed mix such as stores, soil, twigs and
other foreign matter shall not be accepted.

8/20
January 2011
(d)
Before any turf is delivered to the Site, the Contractor shall provide a sample
of at least 4 m2 from the source for review without objection by the Project
Manager.
4.6.
WORKMANSHIP
4.6.1
Handling, Storage and Transport

(a)
Handling and storage of rootballed stock:

Plants grown in open ground shall be well watered before lifting and shall be
lifted in such a manner that the specified rootball is obtained with minimum
disturbance to the roots. The rootball shall be securely wrapped immediately
after lifting to prevent loss of soil and moisture using hessian or straw. The
wrapping material shall not be removed until the plant is required for planting.
(b)
Handling and storage of container grown and containerised stock:

Container grown and containerised stock shall be well watered before
despatch from the nursery and shall remain in the containers until required for
planting.
(c)
Transport of plants:
Plants shall be wrapped and protected to prevent mechanical damage during
lifting and transportation. The trunk from soil level to the lower branches of
trees in the light standard, standard and heavy standard categories shall be
securely wrapped to prevent moisture loss using hessian or straw. All plants
which are to be removed while in leaf shall be covered with tarpaulins during
transport to reduce excessive transpiration.
(d)
(e)
Storage of plants:
(i)
Plants shall be protected from exposure to conditions which may affect

the plant adversely.
(ii)
Plants shall be protected from damage and damaged plants shall not be
used in the Permanent Works unless permitted by the Project Manager.
If the Project Manager permits damaged plants to be used, damaged
material shall be pruned and wounds shall be dressed as stated in
Clause 4.6.5(g).
Storage of trees and shrubs:

Trees and shrubs which are not immediately planted in their permanent
positions shall be supported upright on level ground, regularly watered and
maintained in good condition.
(f)
Handling and storage of turf and sprigs:

Turf and sprigs shall not be lifted when waterlogged or very dry and shall be
packed to avoid drying out. Turf and sprigs shall be stored by spreading out
and shall not be stacked. Turf and sprigs shall be kept moist and in good
condition and shall be delivered and laid within 72 hours of lifting.

9/20
January 2011
(g)
Storage of grass seed:

Grass seed shall be stored in bags off the ground in a clean, dry, well
ventilated location free from vermin. Prolonged storage shall be carried out
under controlled conditions of temperature and humidity.
(h)
Storage of fertilizer:
Fertilizer shall be stored off the ground in sealed waterproof bags and shall be
protected from exposure to conditions which may adversely affect the
fertilizer.
4.6.2
Pre-planting Works
(a)
Preparatory works:
Before soiling or planting for landscape softworks and establishment works
starts, preparatory works shall be carried out by one or more of the treatments
stated in Clauses 4.6.2(b) to 4.6.2(i), as appropriate or as stated elsewhere in
the Contract.
(b)
Cleaning ground:
Weeds, rubbish, litter, stones exceeding 50 mm diameter and all deleterious
material shall be removed from the surface of the ground. Vegetation shall be
cleared without using herbicide unless permitted by the Project Manager. If
permitted, the herbicide shall be a proprietary type reviewed without objection
by the Project Manager and shall be applied in accordance with the
manufacturer's recommendations.
(c)
Ripping:
The ground shall be ripped by drawing a tine through the soil to a depth of
300 mm at 500 mm centres. All obstructions to cultivation or deleterious
material brought to the surface shall be removed and voids left by the ripping
operation shall be filled with soil of the same type as existing. Ground at a
slope exceeding 15 to the horizontal shall not be ripped.
(d)
Contaminated ground:
Ground which is contaminated by oil, chemicals or other substances which
may affect plant growth adversely shall be excavated to 300 mm below the
contaminated depth and beyond the extent of the contamination. Voids left by
excavation shall be filled with uncontaminated soil of the same type as
existing.
(e)
Soiling:
Soil-mix shall be spread and levelled to the depth stated in the Contract. The
depth of uncompacted soil-mix shall be sufficient to allow the level of the area
to comply with finished levels after natural settlement has taken place. The
finished level of soil-mix over areas to be grassed shall be 25 mm above
adjacent kerbs, paving, covers, frames and other hardware.

10/20
January 2011
(f)
(g)
Cultivation:
(i)
Cultivation shall be carried out to a minimum depth of 150 mm or as

stated in the Contract. Pre-planting fertilizer and soil conditioner shall
be spread to a thickness of 50 mm over the surface before cultivation.
(ii)
Stones exceeding 50 mm diameter shall be removed from the surface of

the soil after cultivation.
Scarifying:
Scarifying shall be carried out by loosening the soil to a depth of between
10 mm and 20 mm using a pronged implement such as a rake but without
turning the soil.
(h)
(i)
Protection of prepared ground:

(i)
Prepared ground shall be protected from compaction, erosion and

siltation and shall not be used by Contractor's Equipment, other vehicles
or pedestrian traffic.
(ii)
Prepared ground which becomes compacted, eroded, silted up or

damaged shall be replaced or dealt with by methods reviewed without
objection by the Project Manager.
Removal of material:
Weeds, rubbish, litter, stones exceeding 50 mm diameter and deleterious
material removed during ground preparation shall be disposed of by the
Contractor by methods reviewed without objection by the Project Manager.
4.6.3
Planting
(a)
General:
Planting shall be carried out between 1st March and 30th September unless
otherwise specified in the Contract.
(b)
Use of excavated material:

Material excavated from planting pits which complies with the specified
requirements for decomposed granite shall be used for soil-mix. Material
excavated from planting pits which does not comply with the specified
requirements for decomposed granite shall be disposed of by the Contractor
and shall be replaced by material which complies with the specified
requirements for decomposed granite.
(c)
Planting:
(i)
Plants shall be well watered several hours before planting; the soil in the
container or rootball shall be moist and cohesive. Containers or rootball
wrapping shall not be removed until the time of planting and the rootball
shall not be disturbed by loosening or breaking.

11/20
January 2011
(d)
(e)
(ii)
Each plant shall be placed upright in the pit and set at the same level as
planted in the nursery or container.
(iii)
Soil-mix shall be deposited and compacted in layers around the rootball

until level with the surrounding ground in such manner that the rootball
is not disturbed. Plant shall be well watered to soak the rootball and
soil-mix immediately after planting.
Staking, tying and guying:

(i)
Stakes shall be driven into the ground after the pit has been excavated
and before planting in such a manner that the rootball and aerial parts of
the plant are not damaged. The stake shall be secure after driving and
shall be higher than 70% of the overall height of the plant.
(ii)
Guys and sleeves shall be fixed to prevent chafing, rubbing and

abrasion of the plant and shall be secured to a well driven steel stake or
other anchor. Each plant shall be fitted with three guys secured at a
point not higher than 60% of the overall height of the plant. Turnbuckles
shall be adjusted as necessary after planting.
(iii)
Bamboo stakes shall be used in locations stated in the Contract.

Bamboo stakes shall be securely tied with "scaffold tie" to form a tripod
not exceeding 60% of the overall height of the plant.
Mulching:
After planting and watering, mulch shall be spread to a consolidated thickness
of at least 50 mm on areas of bare ground as stated in the Contract.
(f)
Notch planting of seedlings:

Notch planting of seedlings shall be carried out by forming a notch making two
cuts at approximately 90 using a hand held pick or spade with the apex
pointing up any slope; the notch shall be sufficiently deep to accommodate
the root system of the seedling. The notch shall be opened on the second cut
to receive the plant and shall then be pushed firmly back into place.
(g)
Pit planting of seedlings, shrubs, whips and herbaceous plants:

(i)
The size of pits for seedlings, shrubs, whips and herbaceous plants
shall be 100 mm greater than the rootball or container diameter and
50 mm deeper than the rootball or container. 50g of pre-planting
fertilizer shall be mixed into the soil-mix.
(ii)
Whips which require staking shall be secured using one 2 m long stake
and one tie.

12/20
January 2011
(h)
Pit planting of light standard and standard trees:

(i)
The size of pits for light standard trees and standard trees shall be
200 mm greater than the rootball or container diameter and 100 mm
deeper than the rootball or container. The bottom of the pit shall be
broken up to a depth of 150 mm. 150 g of pre-planting fertilizer shall be
mixed into the soil-mix.
(ii)
(i)
(j)
Each tree shall be secured using two 2.5 m long steel stakes and two
ties.
Pit planting of heavy standard trees:
(i)
The size of pits for heavy standard trees shall be 300 mm greater than
the rootball or container diameter and 150 mm deeper than the rootball
or container. The bottom of the pit shall be broken up to a depth of
150 mm. 250 g of pre-planting fertilizer shall be mixed into the soil-mix.
(ii)
Each tree shall be secured using two 3 m long steel stakes and two ties.
Trees exceeding 4 m overall height shall be guyed.
Pit planting of bamboos and palms:

Bamboos and palms shall be planted in accordance with the following :
(k)
(i)
height not exceeding 2000 mm
: Clause 4.6.3(g)
(ii)
height exceeding 2000 mm and not exceeding 2500 mm

4.6.3(h)
(iii)
height exceeding 2500 mm
Clause
: Clause 4.6.3(i)
Pit planting on slopes:

Pits excavated for planting on or adjacent to slopes shall not be left open
during wet weather.
4.6.4
Grassing
(a)
Hydroseeding:
Hydroseeding shall be carried out between 1st March and 30th September
unless otherwise specified in the Contract.
(b)
Hydroseeding cover:
Hydroseeding shall achieve a cover by grass species of at least 90% of the
surface area of each 10 m of the area to be hydroseeded within 100 days
after the area has been hydroseeded. The grass cover shall be healthy,
vigorous and free from
perennials and other weeds. The method of determining the cover shall be as
stated in Clauses 4.7.1(a) to 4.7.1(g).

13/20
January 2011
(c)
Surface conditions for hydroseeding:

The surface to be hydroseeded shall be finished to a coarse open textured
surface and shall not be smooth or glazed. Finishing work on slopes by
machines shall be carried out across the slope. Vehicle track marks and
bucket teeth marks shall not be left parallel to the line of maximum gradient of
the slope.
(d)
(e)
Application of hydroseeding:
(i)
Hydroseeding shall be carried out using a proprietary type of

hydroseeding equipment reviewed without objection by the Project
Manager.
(ii)
Materials for hydroseeding shall be well mixed on the Site in the

hydroseeding equipment immediately before spraying. Seed shall not
be damaged from the hydroseeding process.
(iii)
Soil binders shall be applied at the rate recommended by the

manufacturer, modified as necessary to suit conditions in Hong Kong.
Dye shall be used to demonstrate that adequate cover has been
achieved, unless in the opinion of the Project Manager runoff or water
courses will be coloured to an unacceptable level.
(iv)
The hydroseeding mixture shall be constantly agitated during spraying

to keep it homogeneous and avoid blockage to pipes. Measures shall
be taken during application to ensure that material is not lost due to
runoff.
(v)
Walking on areas that have been hydroseeded shall be restricted to

access for fixing protective material and for patching up.
Protective material:
Areas which have been hydroseeded shall be covered with protective material
within 2 days after hydroseeding. The material shall be spiked or stapled to
the soil surface with a minimum of 150 mm overlap.
(f)
Patching up:
(i)
Immediately after germination and a general greening of the

hydroseeded area is apparent, areas where germination has been
unsuccessful shall be resprayed. Areas affected by repairs to washout
and gullies and other erosion on slopes shall be resprayed.
(ii)
Areas which in the opinion of the Project Manager are not accessible or
are too small for the use of a hydroseeder shall be patched up by
broadcasting seed. The area shall be lightly scarified with a rake or
similar implement and the seed and fertilizer shall be broadcast over the
area at a rate of not less than 75 g/m. The seed shall be covered by
lightly working into the surface or by spreading sufficient soil to just
cover the seed. Broadcast seeding shall be carried out using Bermuda
grass (cynodon dactylon) perennial ryegrass (lolium perenne) or carpet
grass (axonopus compressus).

14/20
January 2011
(g)
Post-planting fertilizer:
Post-planting fertilizer shall be applied between 2 months and 9 months after
application of hydroseed and shall be applied between 1st March and 30th
September.
(h)
(i)
(j)
Turfing:
(i)
Turf shall not be laid on slopes exceeding 15 to the horizontal.
(ii)
The area to be turfed shall be cultivated by applying pre-planting

fertilizer at a uniform rate of 40 g/m and shall then be raked and
consolidated to the required level. The finished level after turfing shall
be 25 mm above adjacent kerbs, paving, covers, frames and other
hardware.
(iii)
The turves shall be laid on the prepared soil and shall be firmed into
position using wooden beaters; the beaters shall be frequently scraped
clean of accumulated soil or mud. A top dressing of soil-mix shall be
applied and well worked into joints and spaces. Irregularities in finished
levels due to variation in turf thickness or uneven consolidation of the
soil shall be adjusted.
(iv)
Turfed areas shall be watered immediately after turf has been laid and
as often as is necessary to ensure establishment. If shrinkage occurs
and the joints open, soil-mix shall be worked in and well watered.
Sprigging:
(i)
Sprigging shall not be used on slopes exceeding 45 to the horizontal.
(ii)
The area to be sprigged shall be scarified before sprigging and sprigs

shall be evenly spread over the area at approximately 50 mm centres.
The area shall be topdressed with soil-mix to just cover the sprigs and
pre-planting fertilizer shall be applied at a uniform rate of 40 g/m.
Completion of turfing and sprigging:

(i)
Turfing and sprigging shall be considered to be complete when the

first flush of growth achieves 90% cover. The method of determining
the cover shall be as stated in Clauses 4.7.1(a) to 4.7.1(g).
(ii)
Bare patches or areas which fail to become established shall be returfed

or resprigged to maintain 90% cover throughout the establishment
period. Areas affected by repairs to washouts and gullies and other
erosion shall be returfed or resprigged.

15/20
January 2011
4.6.5
Establishment Works
(a)
(b)
(c)
Establishment works:
(i)
The establishment period shall be 12 months. During the establishment

period, the Contractor shall carry out regular inspections and cultivating
operations to ensure that all grass, trees and other plants thrive and
become established. The Contractor shall keep the Site neat and tidy at
all times. Inspections with the Project Manager shall be carried out on a
monthly basis. The Contractor shall report to the Project Manager
before and after carrying out any establishment works and the
associated records shall be submitted in duplicate to and of a style
reviewed without objection by the Project Manager. The forms shall be
countersigned by the Project Manager.
(ii)
All necessary measures shall be taken to ensure that grass, trees and
other plants become established and to keep the landscape softworks
neat and tidy and free from litter and rubbish.
Replacement of plants and grass:

(i)
Plant which are dead, dying or otherwise unsatisfactory shall be

replaced. Replacement planting shall be carried out in season as stated
in Clause 4.6.3(a)(ii) using plant material of a similar size to that already
established.
Measures shall be taken to ensure satisfactory
establishment of the replacement plants before the end of the period for
establishment works.
(ii)
90% cover of the grass area shall be maintained throughout the period
for establishment works and the grass shall provide effective cover of
90% of the area at the end of the period for establishment works. The
grass shall be healthy, vigorous and free from perennials and other
weeds. Areas which do not comply with this requirements of the
Contract shall be reseeded by hydroseeding or broadcast seeding as
stated in Clause 4.6.4(f)(ii) or returfed as stated in Clause 4.6.4(h) or
sprigged as stated in Clause 4.6.4(i). Measures shall be taken to ensure
satisfactory establishment of the replacement grass or turf before the
end of the period for establishment works.
Security of stakes and ties:

The Contractor shall be responsible for the security of stakes and ties
throughout the establishment period. An inspection of stakes and ties shall be
carried out each month by the Contractor; broken, damaged and other
unsatisfactory stakes and ties shall be replaced and ties which are causing
chafing or abrasion of the plant shall be adjusted.
(d)
Firming up plants:
Plants which become loose as a result of wind, rock or other causes shall be
firmed up.

16/20
January 2011
(e)
(f)
Watering:
(i)
Fresh water shall be used for watering landscape softworks. Water

shall be applied using a rose or sprinkler of a type reviewed without
objection by the Project Manager and in such a manner that
compaction, washout of soil or loosening of plants will not be caused;
any damage caused shall be made good immediately.
(ii)
All planted areas shall be watered to ensure successful establishment of

the plant. Any plant reaching permanent wilting point shall be watered
immediately.
(iii)
An inspection to determine water requirements shall be made in dry

weather by the Contractor and the Project Manager twice weekly.
(iv)
The Contractor shall complete watering operations within 24 hours of an

instruction from the Project Manager.
Weeding:
(i)
All grassed and planted areas shall be kept free from weeds throughout
the period for establishment works.
(ii)
Weeding shall be carried out by hand or by mechanical methods

reviewed without objection by the Project Manager provided in all cases
that no damage to the grass and planted areas will be caused. All
weeds, litter and other rubbish resulting from the weeding operation
shall be disposed of by the Contractor.
Planted areas in bare ground shall be weeded to remove all unwanted
vegetative growth including aerial parts and roots, over the complete
area. Planted areas other than in bare ground shall be weeded to
remove all competing and overhanging vegetative growth by cutting the
growth down to not more than 50 mm above soil level.
(iii)
(g)
Pruning:
Pruning and removal of branches shall be carried out using sharp, clean
implements. Pruning shall be carried out with the cut just above and sloping
away from an outward facing healthy bud. Removal of branches shall be
carried out by cutting outside of a line drawn between the branch bark ridge
and the branch collar in such a way that no part of the stem is damaged or
torn, and leaving no snags or stumps.
(h)
Grass cutting:
(i)
Grassed areas shall be cut by manual or mechanical methods reviewed

without objection by the Project Manager and in such a manner that
does not cause pulling of roots or damage to planting in or near the
grassed area. All cuttings shall be raked off and disposed of within 24
hours after cutting.
(ii)
Category 1 grass shall be as stated in the Contract and shall be

reduced by cutting to a height of 50 mm when it reaches 100 mm high.

17/20
January 2011
(i)
(iii)
Category 2 grass shall be as stated in the Contract and shall be

reduced by cutting to a height of 100 mm when it reaches 300 mm high.
(iv)
Category 3 grass cutting shall be cutting of areas of hydroseeding which

are stated in the Contract to be subsequently maintained as mown
grass.
Litter collection:
All litter exposed by grass cutting shall be gathered up and disposed of within
24 hours.
(j)
Post-planting fertilizer:
Post-planting fertilizer shall be applied not less than 100 days, and not more
than 300 days, after grassing or planting. The fertilizer shall be applied at a
rate of :
(k)
(i)
100 g/m for amenity grass and shrub planting;
(ii)
100 g for each light standard, standard and heavy standard tree;
(iii)
50 g for each seedling and whip tree; and
(iv)
40 g/m for grass on slopes and grass grown by hydroseeding.
Control of pests and disease:

Pesticide or fungicide shall be applied in accordance with the manufacturer's
recommendations to control pests and disease.
(l)
Forking over:
Surfaces of bare ground which are subject to surface panning or compaction
of the soil shall be forked over in such a manner that roots are not disturbed
and plants are not loosened; plants which are disturbed or loosened shall be
firmed up and well watered immediately.
(m) Mulching:
All mulch which is disturbed by replacement planting, weeding or watering
shall be made good. The Contractor shall also provide additional mulching
over areas of forking-over and over areas disturbed by others.
(n)
Completion of work:
Immediately before the end of the period for establishment works :
(i)
all tree and shrub planting shall be free from weeds;
(ii)
all planted and grassed areas shall be free from litter;
(iii)
all replacement planting and patching up of grass shall be completed;

18/20
January 2011
(iv)
all stakes and ties shall be secure; and
(v)
all grassed areas shall be cut and the edges trimmed.
4.7.
INSPECTION, TESTING AND COMMISSIONING
4.7.1
Testing : Grass Cover
4.7.2
(a)
Tests shall be carried out to determine the grass cover. The tests shall be
carried out 100 days after grassing and at the end of the period for
establishment works. The grass shall be cut to a height of 300 mm if
necessary over the parts of the area to be tested.
(b)
The method and number of tests shall be reviewed without objection by the
Project Manager.
(c)
Testing to determine the grass cover will be carried out by the Contractor in
the presence of the Project Manager.
(d)
Tests shall be carried out at locations which are representative of the grassed
area as a whole. At each test location an approximately square area of 10 m
shall be marked.
(e)
The percentage of bare ground other than rock and other hard material in
each 10 m test area shall be measured.
(f)
At least 90% of each test area shall be covered with grass.
(g)
If the result of any test for grass cover of landscape softworks and
establishment works does not comply with the specified requirements for
gross cover the area shall be rehydroseeded or reseeded in accordance with
Clause 4.6.4(f)(i) or (ii) determined by the Project Manager, depending upon
the size of the defective area.
Inspection of Establishment Works

An inspection of landscape softworks and establishment works shall be carried out
jointly by the Contractor and the Project Manager at monthly intervals to determine
the establishment works which are required. The Project Manager shall instruct the
Contractor to carry out establishment works which are necessary; the work
instructed shall be completed within 14 days after the date of the Project Manager's
instruction.

19/20
January 2011
APPENDIX A4.1
BRITISH STANDARDS PUBLICATIONS
B.S. 1992 : Part 4 : 1984
Recommendation for landscape drawings
B.S. 3882 : 1965 (1978)
Recommendation and classification for top soil
B.S. 3936 :
Specification for nursery stock : Part 1 : 1980

Specification for trees and shrubs : Part 4 : 1980
Specification for forest trees : Part 9 : 1968
Bulbs, corms and tubers : Part 10 : 1981
Specification for ground cover plants
B.S. 3969 : 1968 (1975)
Recommendations for turf for general landscape purposes
B.S. 3975 :
Glossary for landscape work : Part 4 : 1966

Plant description : Part 5 : 1969
Horticultural, arboricultural and forestry practice
B.S. 3998 : 1989
Recommendations for tree work
B.S. 4043 : 1989
Recommendations for transplanting root-balled trees
B.S. 4156 : 1967 (1979)
Peat
B.S. 4428 : 1989
Recommendations for general landscape operations

(excluding hard surfaces)
B.S. 5236 : 1975
Recommendations for the cultivation and planting of trees

in the advanced nursery stock category
B.S. 5551 :
Fertilizers
B.S. 5837 : 1980
Code of practice for trees in relation to construction (under

review)
HONG KONG GOVERNMENT PUBLICATIONS

SIL Technical Guide to Tree Planting and Maintenance

20/20
January 2011
SECTION 5
5.1
FENCING
GENERAL
The Permanent Works and materials specified below shall comply with the Sections
stated, unless otherwise stated in this Section:
(a)
handrailing shall comply with Section 35;
(b)
earthworks shall comply with Section 7;
(c)
pedestrian guardrailing shall comply with Section 11;
(d)
formwork and finishes to concrete shall comply with Section 18;
(e)
reinforcement shall comply with Section 19;
(f)
concrete shall comply with Section 20;
(g)
steelwork shall comply with Section 22; and
(h)
vehicular parapets shall comply with Section 23.
5.2
5.2.1
Acrylic Sheet Sound Barriers

(a)
The design working load for acrylic sheets shall be 6.9 kPa. Each panel shall
be assumed to be simply supported unless the Contractor can demonstrate
the amount of fixity that the support can offer either by test on Site which is
acceptable to the Project Manager or by producing satisfactory test results
performed under similar conditions.
(b)
Movement joints shall be designed to allow for thermal movement of the

sheeting due to a temperature variation of 50 and the movement of the
structure without affecting their performance in any respect. Sealing
compounds, taps and gaskets should be sufficiently flexible to permit
movement of the sheeting.
5.3
MATERIALS
5.3.1
Wire
(a)
Wire for fencing, including plastic coated wire, shall be galvanised mild steel
complying with BS 4102.
(b)
Barbed wire shall consist of two line wires and point wire formed in
accordance with BS 4102, Clause 4.1.
(c)
Galvanised coatings to steel wire shall comply with BS 443.
(d)
Plastic coatings to steel wire shall comply with BS 4102, Section 6.

Section 5 - Fencing
1/7
January 2011
5.3.2
Chain Link Fence

Chain link fence shall comply with BS 1722 Part 1.
5.3.3
Plywood
Plywood for hoardings shall comply with BS 6566 and shall have a grade 2 veneer.
The bonding adhesive between veneer layers shall be phenol formaldehyde resin
adhesive, classified as weather-proof and boil-proof in accordance with BS 1203.
5.3.4
5.3.5
Timber
(a)
Timber for fencing shall be of mature growth and shall be seasoned and free
from large, loose or dead knots, wood wasp holes, infestation, splits and other
defects that will reduce the strength or produce blemishes. The moisture
content in timber at the time of fabrication shall not exceed 20%.
(b)
Hardwood shall be San Cheung (Kapore) and shall have a minimum density
of 720 kg/m3 at 15% moisture content.
(c)
Softwood shall be cedar, spruce or China fir.
(d)
Timber that is not to be painted shall be preserved with coal tar creosote. The
creosote shall comply and be applied by pressure impregnation in accordance
with BS 144.
Steel
(a)
Steel for fencing shall comply with the following:

(i) Hot rolled Sections
BS 4 Part 1;
(ii) Hot rolled structural Sections:

-
Equal and unequal angles
BS 4848 : Part 4;
Hollow Sections
BS 4848 : Part 2; and
(iii) Metal washers for general engineering

purposes
5.3.6
BS 4360.
Bolts, Nuts, Washers and Fittings

(a)
Bolts, nuts and washers for fences shall comply with the following:
(i)
ISO metric black hexagon bolts, screws and nuts
BS 4190;
(ii) ISO metric black cup and countersunk head bolts and
screws with hexagon nuts
BS 4933; and
(iii) Metal washers for general engineering purposes
BS 4320.
(b)
The length of bolts shall be such that the threaded portion of each bolt projects
through the nut by at least one and not more than four, threads.
(c)
Fittings, including eye bolt strainers, cleats, winding brackets, stretcher bars,
extension arms, hook bolts and base plates, shall be galvanised mild steel.

Section 5 - Fencing
2/7
January 2011
5.3.7
5.3.8
(d)
Bolts, nuts, washers and fittings for fixing to concrete and timber shall be
galvanised. Bolts, nuts, washers and fittings for fixing to steel shall have the
same protective treatment as the steel.
(e)
Staples shall be D Section galvanised wire.
Acrylic Sheet Sound Barriers

(a)
Acrylic sheets for sound barriers shall be manufactured from

polymethylmethacrylate resin and shall be supplied and erected by a
proprietary manufacturer acceptable to the Project Manager.
(b)
The light transmission measured in accordance with DIN 5036 shall not be
less than 90% for a 4 mm thick sample.
(c)
Acrylic sheets shall comply with BS 6262, and in no case be less than 15 mm
thick. The tolerance in thickness shall not exceed 5%.
(d)
Acrylic sheets shall carry the manufacturer's guarantee under outdoor

conditions in Hong Kong on the following properties:
(i)
Light transmittance; over a period of 10 years the light transmittance

shall not decrease by more than 5% from the original value.
(ii)
Modulus of elasticity; after 10 years the elastic modulus shall not be less
than 2800 MPa
(iii)
Tensile strength; after 10 years the tensile yield stress shall not be less
than 60 MPa.
(e)
Acrylic sheets shall have impact strength in compliance with Class A materials
according to BS 6206.
(f)
All exposed edges of acrylic sheets shall be polished.
(g)
All steel fixings and accessories shall have corrosion protection treatment not
inferior to the structural steel frame shown on the Employers Drawings and
they shall be painted to the same colour as the structural steel frame.
(h)
All acrylic sheets shall be covered with a protective sheeting to the

manufacturer's recommendation during transport, storage on Site, and
construction until the application for the Completion Certificate
(i)
Fixing details, which require drilling holes in the acrylic sheets are not
acceptable.
Fabrication of Steelwork
Steelwork shall be fabricated in accordance with BS5950: Part 2.

Section 5 - Fencing
3/7
January 2011
5.3.9
5.3.10
5.3.11
5.3.12
5.3.13
Galvanising to Steel
(a)
Steel to be galvanised shall be hot-dipped galvanised in accordance with BS

729 with a minimum coating thickness of 500 g/m2.
(b)
Galvanising to steel shall be applied, as far as possible, after welding, drilling

and/or cutting are complete.
Welding Steel
(a)
Welds to steel for fencing shall be in accordance with Clause 22.5.2. Weld
surfaces shall be clean and flush before application of the protective coating.
(b)
Steel shall not be welded after galvanising except with the express permission
of the Project Manager. If permitted, the welded areas shall be free from scale
and slag and shall be treated after welding, with an alternative galvanising or
zinc coating system, reviewed without objection by the Project Manager.
Concrete Posts
(a)
Concrete posts and struts for fencing shall be precast units using Grade 30/10
concrete. The finish to formed surfaces shall be Class F4 and the finish to
unformed surfaces shall be Class U5. The tops of posts and all arises shall be
rounded or chamfered.
(b)
Reinforcement for concrete posts and struts shall be Grade 250 plain round
steel bars.
(c)
No concrete posts shall be removed from the mould for a period of at least 24
hours and shall not be shifted or transported until at least seven days have
elapsed since casting.
Gates
(a)
Steel gates shall be of welded construction. The frame shall be square with
the corners mitred or saddled.
(b)
Chain link infilling in gates shall be of the same type and size as in the
adjoining fence and shall be attached to the framework by stretcher bars.
Storage of Fencing
(a)
Plywood and timber posts, rails and struts for fencing shall be stored on level
supports in a dry, weatherproof store.
(b)
Gates, concrete and steel posts and struts for fencing shall be stored off the
ground on level supports.
(c)
Damaged fencing materials shall not be used in the Works.

Section 5 - Fencing
4/7
January 2011
5.4
SUBMISSIONS
5.4.1
Particulars of Fencing
The following particulars of the proposed fencing shall be submitted to the Project
Manager for review:
(a)
Contractors Drawings showing the fabrication details of fences and gates;
(b)
details of the source, type and properties of all fencing materials; and
(c)
5.4.2
Contractors Drawings showing details, fixings and movement joints (including

calculations) for all acrylic sheet sound barriers.
Samples
The following samples of the proposed materials shall be submitted to the Project
Manager together with the particulars referred to Clause 5.4.1 above:
(a)
each type of wire and fitting;
(b)
chain link;
(c)
acrylic sound barriers;
(d)
plywood; and
(e)
precast concrete, steel and timber posts.
5.5
WORKMANSHIP
5.5.1
Tolerances
Fencing shall comply with the following requirements:
5.5.2
(a)
the position of posts shall be within 75 mm of the specified position;
(b)
the level of the top of posts shall be within 25 mm of the specified level; and
(c)
posts shall be vertical to within 5 mm over the height of the post.
Alignment of Fencing
Fencing shall be erected to a smooth alignment with no abrupt irregularities. The
ground shall be trimmed or filled in such a manner that the bottom of the fence will
approximately follow the level of the ground. The distance between the bottom of
either chain link mesh or hoardings, and the ground, shall not exceed 100 mm.

Section 5 - Fencing
5/7
January 2011
5.5.3
5.5.4
5.5.5
Posts for Fencing

(a)
Straining posts for fencing shall be provided at all ends and corners, at
changes in direction, at abrupt changes in level, at gate posts and at intervals
not exceeding 30 m along straight lengths of fencing. Struts shall be fitted to
straining posts in the direction of each wire secured to the post.
(b)
Intermediate posts shall be provided at intervals not exceeding 3.5 m.
Erecting Posts for Fencing

(a)
Posts and struts for fencing shall be set in excavations for foundations and the
excavations shall be filled with Grade 30/20 concrete up to 50 mm below
ground level.
(b)
Struts shall be fitted into slots in timber and concrete posts and bolted to steel
posts.
(c)
The ground surface around posts shall be made good with the same material
as in the adjoining area.
Fixing Wire for Fencing

(a)
Line wire, chain link mesh and barbed wire for fencing shall be strained tightly
between straining posts. Winding brackets shall be used for straining between
steel posts. Winding brackets or eye bolt strainers shall be used for straining
between concrete and timber posts. The tension in the wire on each side of
straining posts shall be equal. Wire shall not be strained until at least 14 days
after concrete has been placed in the foundation.
(b)
Chain link mesh shall be secured at each straining post by a stretcher bar and
shall be tied to the line wire by tying wire at 150 mm intervals.
(c)
Each line wire and each line of barbed wire shall be secured to each
intermediate post by one of the following methods as stated in Table 5.1:
(i)
a hairpin staple shall be passed through a hole in the post and secured
to the wire by three complete turns on each side of the post;
(ii)
a stirrup shall be passed through a hole in the post and the ends bent
over twice;
(iii)
the wire shall be threaded through a hole in the post;
(iv)
the wire shall be stapled to the post; or
(v)
a hook bolt shall be passed through a hole in the post and secured with
a nut and washer.

Section 5 - Fencing
6/7
January 2011
Table 5.1: Method of Securing Wire to Intermediate Posts

Type
of
Fence
Strained Wire
Type of Wire
Type of Post
Method of Securing Wire
Line wire
Concrete
Steel
Timber
Concrete
Steel
Timber
Concrete
Steel
Timber
Concrete
Steel
Timber
(i), (ii) or (iii)

(i), (ii) or (iii)
(i), (ii) or (iv)
(i) or (ii)
(i)
(i) or (iv)
(i), (ii) or (v)
(i) or (iii)
(iv)
(i), (ii) or (v)
(i)
(iv)
Barbed wire
Chain link
Line wire, mesh wire
Barbed wire
5.5.6
Fixing Gates
Gates shall be hung plumb and shall not be installed until the wire has been
strained.
5.5.7
Fixing Timber for Fencing

The ends of timber rails for fencing shall be closely butted together and the rails
shall be securely nailed to each post. The ends of plywood sheets in hoardings shall
be closely butted together and the sheets shall be securely nailed to each post and
to the horizontal rails.

Section 5 - Fencing
7/7
January 2011
SECTION 6
6.1
DRAINAGE WORKS
GENERAL
stated, unless otherwise stated in this Section.
(a)
Metalwork for handrailing, ladders, stairs, metal flooring, toe plates and safety
chains shall comply with Section 35 and Section 22.
(b)
(c)
Formwork and finishes to concrete shall comply with Section 18.
(d)
Steel reinforcement shall comply with Section 19.
(e)
Concrete shall comply with Section 20.
(f)
Materials for grout shall comply with Section 20.
(g)
Water supply pipeworks shall comply with Section 14.
(h)
Cable duct systems for electrical and mechanical installations shall comply
with Section 13.
6.2
GLOSSARY OF TERMS
6.2.1
Pipes
Pipes for drainage works are pipes for conveying sewage, greywater and surface
water.
6.3
MATERIALS
6.3.1
Precast Concrete Pipes and Fittings
6.3.2
(a)
Precast concrete pipes and fittings shall comply with BS 5911:Part 100.
(b)
Precast concrete pipes and fittings shall have flexible spigot and socket joints.
Vitrified Clay Pipes and Fittings

(a)
Vitrified clay pipes and fittings shall comply with BS 65; the pipes and fittings
shall be glazed and shall be the chemical resistant type.
(b)
Vitrified clay pipes and fittings shall have flexible mechanical joints.

Section 6 Drainage Works
1/51
January 2011
6.3.3
6.3.4
DI Pipes and Fittings

(a)
DI pipes and fittings shall comply with BS 4772. Pipes and fittings shall be
lined internally with cement mortar in accordance with BS 4772, Appendix C.
Pipes and fitting shall be coated externally with bituminous coating in
accordance with BS 4772 Section 16.3.
(b)
Flexible joints in DI pipes and fittings shall be the push-in type and shall be
capable of withstanding a minimum angular deflection of 4. Flexible joints
shall also be capable of withstanding axial movements and shall allow a
minimum withdrawal of 38 mm when there is no deflection of the joint.
(c)
Flanged joints in DI pipes and fittings shall be PN 16 rating complying with BS

4504: Section 3.1.
(d)
Pipes to be built in to structures shall have puddle flanges welded on.
Grey Iron Pipes and Fittings

Grey iron pipes and fittings shall comply with BS 4622.
6.3.5
UPVC Pipes and Fittings

(a)
Unplasticised (UPVC) pipes and fittings shall comply with the relevant British
Standard stated in Table 6.1.
(b)
UPVC pipes and fittings above ground shall have solvent welded spigot and
socket joints. UPVC pipes and fittings below ground shall have either solvent
welded spigot and socket joints or flexible spigot and socket joints with
elastomeric joint rings as stated in the Contract.
(c)
Joints and fittings for UPVC pressure pipes complying with BS 3506 shall
comply with the following:
(i)
(ii)
injection moulded UPVC fittings for solvent welding

for use with pressure pipes, including water supply
and
: BS 4346: Part 1;
mechanical joints and fittings principally of UPVC
: BS 4346: Part 2.
(d)
Solvent cement for UPVC pressure pipes shall comply with BS 4346: Part 3.
(e)
The class of UPVC pressure pipes complying with BS 3506 shall depend on
the pressure rating.

2/51
January 2011
6.3.6
GI Pipes and Fittings

(a)
(b)
GI pipes and fittings shall comply with the following:

(i)
steel tubes and tubulars suitable for screwing

to BS 21 pipe threads
: BS 1387, medium grade;
(ii)
pipe threads for tubes and fittings where

pressure-tight joints are made on the threads : BS 21; and
(iii)
wrought steel pipe fittings (screwed

BSP thread)
: BS 1740: Part 1.
GI pipes and fittings shall be medium class thickness and shall be galvanized
in accordance with BS 729.
Table 6.1: UPVC Pipes and Fittings

Use
Nominal diameter (mm)
British Standard
32 - 50
BS 5255
82 - 160
BS 4514
63 - 75
BS 4576: Part1
82 - 160
BS 4514
Gravity sewage and storm

water pipes and fittings
below ground
110 - 160
BS 4660
200 - 630
BS 5481
Pressure pipes and fittings

above and below ground
10 - 600
BS 3506
Gravity sewage pipes and

fittings above ground
Gravity surface water pipes
and fittings above ground
6.3.7
Polyethylene Pipes and Fittings

(a)
Polyethylene pipes and fittings shall comply with the requirements set out in
the Appendix A6.6.
(b)
Size of polyethylene pipes and fittings shall be designated by the nominal size
in millimeters. Nominal Size shall mean the minimum outside diameter of a
pipe, or in the case of a fitting, the minimum outside diameter of the pipe with
which the fitting is intended to use. For the purpose of connecting to pipes of
other materials or connecting to other non-polyethylene standard fittings
which are of the same nominal internal bore, the foIlowing equivalent sizes in
DN shall be used:
Polyethylene nominal size
400
450
500
560
630
710
800

3/51
Equivalent DN
355
399
443
497
559
630
709
January 2011
6.3.8
Bolts, Nuts and Washers

(a)
6.3.9
6.3.10
Bolts, nuts and washers for flanged joints, detachable couplings and flange
adapters shall comply with the following:
(i)
: BS 4190;
(ii)
metal washers for general engineering purposes
: BS 4320; and
(iii)
the bolts, nuts and washers shall be hot-dip galvanised in accordance

with BS 729.
(b)
Stainless steel bolts and nuts shall comply with BS 6105, steel Grade A4 and
property Class 80. Washers shall be Grade 316 S 31 in the softened condition
complying with BS 1449: Part 2.
(c)
Spheroidal graphite iron bolts shall be Grade 500/7 metal complying with BS
2789.
(d)
Bolts, nuts and washers shall be insulated from electrochemically dissimilar

metal by non-metallic washers and sleeves.
(e)
Bolts and nuts shall be compatible with the type of joint and shall be obtained
from the same manufacturer as the joint.
(f)
The length of bolts shall be such that the threaded portion of each bolt
projects through the nut by at least one thread and by not more than four
threads.
Elastomeric Joint Rings

(a)
Elastomeric joint rings shall comply with BS 2494, Type D. The rings shall be
compatible with the type of joint and shall be obtained from the same
manufacturer as the joint.
(b)
Elastomeric joint rings for flanged pipes shall be the inside diameter bolt circle
type. The rings shall be natural rubber with a thickness of 3.2 mm and with
other dimensions complying with BS 4865: Part 1.
Detachable Couplings and Flange Adapters

(a)
Detachable couplings and flange adapters shall be a proprietary type

(b)
Detachable couplings and flange adapters shall accommodate the angular

deflection and straight draw stated in Table 6.2 for the different nominal
diameters of pipes connected.

4/51
January 2011
Table 6.2: Angular Deflection and Straight Draw

Nominal diameter
not exceeding 450 mm

exceeding 450 mm and
exceeding 1800 mm
6.3.11
Detachable coupling
Angular
Straight
deflection
draw
6
10mm
5
Flange adapter
Angular
Straight
deflection
draw
3
5mm
2.5
1.5
0.5
Anticorrosion Tape
(a)
Anticorrosion tape shall be a proprietary type reviewed without objection by

the Project Manager. The tape shall be a rubber/bitumen compound with
fabric reinforcement and shall be backed with PVC film. The tape shall have
a high resistance to cathodic disbonding, acids and alkalis and shall have the
minimum properties stated in Table 6.3.
(b)
Anticorrosion tape shall be applied to valves, flanged joints, slip-on couplings

and flange adapters. Type 1 shall be used for pipes smaller than 700 mm
diameter and Type 2 shall be used for pipes 700 mm diameter and above.
(c)
Primer and mastic filler for use with anticorrosion tape shall be compatible
with the tape and shall be a type recommended by the manufacturer of the
tape and reviewed without objection by the Project Manager.
Table 6.3: Properties of Anticorrosion Tape

(except where stated the values shown are minimum values)
Value
Property
Thickness of PVC backing (m)
Tensile strength (N/mm)
Elongation (%)
Tear strength (N)
Adhesion strength (N/mm)
Holiday test voltage (kV)
- single layer
- double layer
Impact strength (J)
Temperature range (C)
Total thickness (mm)
Mass (kg/m2)

5/51
Type 1
85
8
26
20
2
Type 2
500
10
26
36
2
10
15
3.5
5 - 60
1.6
1.8
10
15
8
8 - 60
2.0
2.4
January 2011
6.3.12
Bituminous Coatings
(a)
Bituminous coatings shall comply with the following:

(i)
(ii)
(b)
6.3.13
bitumen based hot applied coating

material for protecting iron and steel
including suitable primers where required
: BS 4147, Type I, Grade C
black bitumen coating solutions for cold

application
: BS 3416, Type II.
Bituminous coatings used for repairing joints and coatings shall be compatible
with the adjacent coating.
Aggregates for Granular Bed and Granular Fill

(a)
Granular bed shall be Type A material and granular fill shall be Type B
material.
(b)
Type A or Type B material shall consist of hard, clean, crushed slag, gravel,
crushed rock, crushed concrete or crushed inert demolition material having a
grading within the limits of Table 6.4. The ten percent fines values shall be at
least 50kN. The material passing the 425m BS test sieve shall be non-plastic
when tested in accordance with BS1377.
(c)
Type A and Type B material shall be obtained from a source reviewed without
(d)
Aggregates for granular bed shall have the compacting fraction values stated
in Clause 6.6.3(d).
Table 6.4: Type of Aggregates for Granular Bed

BS test sieve
Metric
63 mm
37.5 mm
20 mm
10 mm
3.35 mm
600 mm
75 mm
6.3.14
Percentage by mass passing

Type A
Type B
100
100
85 100
0 20
45 100
05
25 80
8 45
0 10
-
Joint Filler and Compressible Padding

(a)
Joint filler for joints in concrete bed, haunch and surround shall be a
proprietary type reviewed without objection by the Project Manager and shall
be a firm, compressible, single thickness, non-rotting filler. The thickness of
the filler shall be as stated in Table 6.5.

6/51
January 2011
(b)
Compressible padding between pipes and supports shall be bitumen

damp-proof sheeting complying with BS 743.
Table 6.5: Joint Filler for Concrete Bed, Haunch and Surround
6.3.15
Nominal diameter of pipe
Thickness of joint filler (mm)
less than 450 mm
18
450 mm - 1200 mm
36
exceeding 1200 mm
54
Polyethylene Sheeting
Polyethylene sheeting shall be impermeable and shall have a nominal thickness of
0.125 mm.
6.3.16
Precast Concrete Manholes

Precast concrete manhole units shall comply with BS 5911: Part 200. Cover slabs
and reducing slabs shall be reinforced as required to comply with the load test
requirements stated in BS 5911: Part 200. The type of cement for the manufacture
of precast concrete manhole units, cover slabs, and reducing slabs shall be as
stated in BS 5911: Part 200, or combination of PFA and OPC complying with BS
12, or PPFAC. The PFA content shall not exceed 40% by mass of the cementitious
content.
6.3.17
6.3.18
Chambers and Gullies

(a)
Precast concrete chambers and gullies shall comply with BS 5911: Part 2.
Cover slabs shall be reinforced as required to comply with the load test
requirements stated in BS 5911: Part 2. The types of cement for the
manufacture of precast concrete chambers and gullies, and cover slabs shall
be as stated in BS 5911: Part 2, or a combination of PFA and OPC complying
with BS 12, or PPFAC. The PFA content shall not exceed 40% by mass of
the cementitious content.
(b)
Vitrified clay gullies shall comply with BS 65.
Step Irons
Step irons shall comply with BS 1247. Step irons shall be malleable cast iron
complying with BS 6681 and shall be hot-dip galvanised in accordance with BS 729.
6.3.19
Manhole Covers, Gully Gratings and Kerb Overflow Weirs

(a)
Manhole covers, gully gratings and kerb overflow weirs shall be Grade 50 cast
iron complying with BS 1452; bolts and nuts shall comply with BS 4190.
(b)
Covers, gratings and weirs shall be cleanly cast, free from air holes, sand
holes, cold shuts and chill and shall be neatly dressed and fettled. Castings
shall be free from voids whether due to shrinkage, gas inclusions or other
causes. Bolts and nuts shall not be over tightened.

7/51
January 2011
(c)
The dimensions of the different types of covers, gratings and weirs shall be as
stated in the Contract; the test loads which the covers and gratings are
required to withstand, and the minimum masses of covers gratings and weirs,
shall be as stated in Tables 6.6, 6.7 and 6.8.
(d)
Covers, gratings and weirs shall have the manufacturer's name cast integrally
with the unit in a raised form and shall be protected with bituminous coating.
Covers shall have a raised design on the top surface as stated in the
Contract.
(e)
The Contractor shall provide the Project Manager two keys for each pattern of
cover used.
Table: 6.6: Details of Manhole Covers and Frames

Minimum
Type of manhole
cover and frame
Double triangular
manhole cover and frame
Double triangular
manhole cover for sewers
Frame
Double triangular
desilting manhole
cover for sewers
Frame
Double seal terminal
manhole cover
for sewers
- Type MA2-29/29A & B
- Type MA2-45/45A & B
- Type MC2-29/29A & B
- Type MC2-45/45A & B

Test requirements
mass (kg)
Grade
Diameter of
block (mm)
Test
load (t)
180
Medium duty
100
130
Heavy duty
300
30
105
290
Heavy duty
Heavy duty
300
300
30
30
165
Heavy duty
300
30
Heavy duty
Heavy duty
Medium duty
Medium duty
300
300
100
100
20
20
5
5
8/51
January 2011
Table 6.7: Details of Gully Gratings and Frames
Type of gully grating

and frame
Grating for hinged
gully grating
Type GA2-325
Frame
Grating for double
triangular gully grating
Type GA1-450
Shallow frame
- adjacent to kerb
- away from kerb
Deep frame
- adjacent to kerb
- away from kerb
Grating for hinged
grating Type GA2-450
Frame
gully
Test requirements
Diameter of
Test
block
load
(mm)
(t)
300
20
Minimum
mass
(kg)
Grade
28.0
Heavy duty
24.5
57.5
Heavy duty
Heavy duty
300
300
20
20
33.5
36.5
Heavy duty
Heavy duty
300
300
20
20
40.5
44.0
61.5
Heavy duty
Heavy duty
Heavy duty
300
300
300
20
20
20
37.0
Heavy duty
300
20
Table 6.8: Details of Kerb Overflow Weirs
6.3.20
Type of kerb overflow weir
Minimum mass (kg)
Type 1-325
39.5
Type 3-325
31.5
Type 1-450
44.0
Type 3-450
36.5
Type 4-450
33.0
Penstocks
(a)
Penstocks shall comply with the following requirements:

(i)
frames and gates shall be cast iron complying with BS 1452, Grade
220;
(ii)
stems shall be stainless steel complying with BS 970: Part 1, Grade 316
S 31;
(iii)
operating nuts shall be gunmetal complying with BS 1400, Grade LG2;
(iv)
sealing faces shall be phosphor bronze complying with BS 2874, Grade

PB 102;
(v)
sealing strips at inverts of flush invert penstocks shall be elastomer

complying with ASTM D 2000;
(vi)
assembly and fixing nuts and bolts shall be stainless steel complying
with Clause 6.3.7(b); and
(vii) adjustable wedges shall be phosphor bronze complying with BS 2874,

Grade PB 102 or stainless steel complying with BS 970: Part 1, Grade
316 S 31.
9/51
January 2011
6.3.21
(b)
Penstocks shall be designed for on-seating pressure or off-seating pressure

or both on-seating and off-seating pressures as stated in the Contract.
(c)
Sealing faces shall be of rectangular sections and shall be fixed to the frames
and gates using taperhead screws of the same material as the sealing faces.
(d)
Adjustable wedges shall have sufficient contact areas with the gates to
minimise wear.
(e)
Frames shall include guide rails or guide faces for gates. Clearance within
guides shall be as small as practicable such that the gates will not vibrate
under flow conditions.
(f)
Penstocks shall have rising stems unless otherwise stated in the Contract.
Rising stems shall have perspex protection tubes with open/close indicators.
Gate Valves
(a)
Gate valves shall comply with BS 5150 and with the following requirements:
(i)
bodies and wedges shall be cast iron complying with BS 1452, Grade
220 and shall have renewable gunmetal seat rings;
(ii)
gunmetal for renewable seat rings shall be Grade LG2 complying with
BS 1400;
(iii)
stem nuts shall be gunmetal complying with BS 1400, Grade LG2;
(iv)
stems shall be aluminium bronze complying with BS 2874, Grade CA

104; and
(v)
assembly and fixing nuts and bolts shall be stainless steel complying
with Clause 6.3.7(b).
(b)
Gate valves shall be double flange-ended solid wedge type with nominal
pressure designation PN 16. Flanges shall be PN 16 complying with BS
4504: Part 1.
(c)
Gate valves shall have outside screw rising stems unless otherwise stated in
the Contract. Rising stems shall have perspex protection tubes with
open/close indicators.
(d)
Gate valves shall be fitted with a plate showing the operating position of the
valve in the closed, quarter closed, half closed, three-quarters closed and
open positions.
(e)
Chains for chain operated gate valves shall be mild steel complying with BS
970:Part 1 and hot-dip galvanized in accordance with BS 729. The chains
shall be continuous.
(f)
Gear boxes shall have enclosures effectively sealed against the intrusion of
foreign bodies and moisture to the degree IP68 (i.e. dust-tight and protection
against complete and continuous submersion in water from 15m or 50ft) as
defined in the standard IEC 60529.

10/51
January 2011
6.3.22
Flap Valves
(a)
6.3.23
(i)
frames and flaps shall be cast iron complying with BS 1452, Grade 220;
and
(ii)
sealing faces and hinge pins shall be gunmetal complying with BS 1400,
Grade LG2.
(b)
The flap shall be hung with double hinges and secured with hinge pins.
(c)
Flanges for flange mounting types of flap valves shall be PN 16 complying

with BS 4504: Part 1.
Sludge Valves
(a)
6.3.24
Flap valves shall comply with the following requirements:
Sludge valves shall comply with the following requirements:

(i)
bodies and valve sections shall be cast iron complying with BS 1452,
Grade 220;
(ii)
sealing faces and stem nuts shall be gunmetal complying with BS 1400,
Grade LG2; and
(iii)
stems shall be aluminium bronze complying with BS 2874, Grade CA

104.
(b)
The stems of sludge valves shall operate through non-rising stem nuts
housed in bridges bolted over the body sections.
(c)
Outlet flanges of sludge valves shall be PN 16 complying with BS 4504:

Section 3.1.
Air Valves
(a)
Air valves shall be of the elongated body type and shall have a pressure
rating of 3 bars unless otherwise stated in the Contract.
(b)
Dual orifice air valves shall have:

(i)
a small orifice valve for releasing air at working pressure, and
(ii)
a large orifice valve for allowing air to pass at atmospheric pressure

during emptying and filling of pipework.
(c)
The bodies and covers of small and large orifice valves shall be cast iron
complying with BS 1452, Grade 220; the trim and float shall be stainless steel
complying with BS 970:Part 1, Grade 316 S 31.
(d)
Small orifice valves shall have an adjustable Vitron or equivalent orifice button
to ensure positive sealing. Large orifice valves shall have a Buna-N or
equivalent seat.

11/51
January 2011
6.3.25
6.3.26
(e)
The valve inlet of small orifice valves shall be 75 mm diameter and the valve
outlet shall be 25 mm diameter; the venting orifice shall be 5 mm diameter.
The valve inlet and the valve outlet of large orifice valves shall be 75 mm
diameter.
(f)
Air valves shall be provided with isolating gate valves.
Fittings for Penstocks and Valves

(a)
Handwheels and tee keys for penstocks and valves shall turn in a clockwise
direction for closing. Handwheels shall have smooth rims and the direction of
opening and closing shall be clearly cast on the handwheel. The opening
effort required at any point on the handwheel rim shall not exceed 250 N
when operated against the full unbalanced pressure.
(b)
Extension stems for penstocks and valves shall be stainless steel of the same
grade as the stems. Extension stems shall be connected by muff couplings.
(c)
Handwheels, tee keys, headstocks, guide brackets for stems, supporting

brackets, surface boxes and other fittings for penstocks and valves shall be
cast iron complying with BS 1452.
(d)
Bolts and nuts for fixing penstocks and valves to structures shall be stainless
steel complying with Clause 6.3.7(b). Bolts shall be indented foundation bolts.
(e)
Grout for filling rebates and box-outs shall be a proprietary type reviewed
without objection by the Project Manager and shall contain a non-shrink
admixture.
Foam Concrete
Foam concrete for filling abandoned pipes, culverts, manholes and voids shall be
composed of OPC (or PPFAC), fine aggregate, water, admixtures for accelerating
or retarding the setting time and foam to reduce the density and to produce a
flowing self levelling material.
6.4
SUBMISSIONS
6.4.1
Particulars of Pipes, Joints and Fittings

(a)
The following particulars of the proposed pipes, joints and fittings for drainage
works shall be submitted to the Project Manager for review without objection:
(i)
manufacturers' literature, including details of:

manufacturing process;
pressure and temperature ratings;
permissible values of straight draws and angular deflection of
flexible joints;
recommendations for handling, storage, laying, jointing and repair;
and
drilling and tapping equipment for connections to pipes; and

12/51
January 2011
(ii)
6.4.2
Particulars of Anticorrosion Tape and Joint Filler

(a)
6.4.3
a certificate for each material showing the manufacturer's name, the

date and place of manufacture and showing that the material complies
with the requirements stated in the Contract and including results of
tests required in accordance with the relevant British Standard.
The following particulars of the proposed anti-corrosion tape and joint filler for
drainage works shall be submitted to the Project Manager for review without
objection:
(i)
manufacturer's literature for the joint filler and anticorrosion tape; and
(ii)
certificates for anticorrosion tape and joint filler showing the

manufacturers' name, the date and place of manufacture and showing
that the material complies with the requirements stated in the Contract
and including results of tests in accordance with the Contract.
Particulars of Aggregates for Granular Bed

A certificate for each type of aggregate showing the source of the aggregate and
showing that the aggregate complies with the requirements stated in the Contract,
and including the results of tests in accordance with the Contract, shall be
submitted to the Project Manager for review without objection for the proposed
aggregates for granular bed for drainage works.
6.4.4
Particulars of Manholes, Chambers and Gullies

(a)
The following particulars of the proposed materials for manholes, chambers

and gullies for drainage works shall be submitted to the Project Manager for
review without objection:
(i)
a certificate for each type of manhole and chamber unit and for each
type of gully showing the manufacturer's name, the date and place of
manufacture and showing that the materials comply with the
requirements stated in the Contract and including results of tests
required in accordance with the relevant British Standard;
(ii)
a certificate for step irons showing the manufacturer's name, the date
and place of manufacture and showing that the step irons comply with
the requirements stated in the Contract, and including results of tests
required in accordance with the Contract; and
(iii)
a certificate for each type of manhole cover, gully grating and kerb
overflow weir showing the manufacturer's name, the date and place of
manufacture and showing that the materials comply with the
requirements stated in the Contract and including results of loading
tests in accordance with the Contract.

13/51
January 2011
6.4.5
Particulars of Penstocks and Valves

(a)
6.4.6
The following particulars of the proposed penstocks and valves for drainage
works shall be submitted to the Project Manager for review without objection:
(i)
manufacturer's literature, including details of:

materials;
pressure ratings; and
recommendations for handling, storage and installation; and
(ii)
Contractors Drawings showing details of the penstocks and valves,

including lengths of stems and details of handwheels, tee keys,
extension stems, headstocks, guide brackets for stems, supporting
brackets, surface boxes and other fittings, and positions and sizes of
rebates and box-outs.
Particulars of Foam Concrete and OPC/PFA Grout

(a)
The following particulars of the foam concrete mix (or grout mix) and
procedure for filling abandoned pipes, culverts, manholes and voids shall be
submitted to the Project Manager for review without objection:
(i)
proportions of each constituent;
(ii)
source of supply;
(iii)
details of mixing;
(iv)
setting time;
(v)
strength;
(vi)
shrinkage expected (for OPC/PFA grout);
(vii) details of mixing and grouting equipment; and

(viii) method of grouting, including details of trials.
6.4.7
Particulars of Tests
(a)
The following particulars of the proposed procedures for tests on pipelines

and penstocks for drainage works shall be submitted to the Project Manager
for review without objection:
(i)
test equipment and method of setting up the equipment;
(ii)
calibration certificates for pressure gauges;
(iii)
procedure for carrying out the test; and
(iv)
programme for testing.

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January 2011
6.4.8
Particulars of CCTV Inspections

(a)
6.4.9
The following particulars of the proposed procedure for CCTV inspections

shall be submitted to the Project Manager for review without objection:
(i)
names and experience of persons carrying out or supervising the

inspections;
(ii)
details of equipment;
(iii)
details of the format of report; and
(iv)
examples of video films and photographs obtained from inspections

employing the same equipment.
Particulars of Diversions of Flow

Particulars of the proposed procedures for diversions of existing flows shall be
6.5
WORKMANSHIP
6.5.1
Transport, Handling and Storage of Materials

(a)
(b)
Transport, handling and storage of pipes, joints and fittings:

(i)
Pipes, joints and fittings for drainage works shall be transported,

handled and stored in accordance with the manufacturers'
recommendations and in a manner which will not result in damage or
deformation to the pipes, joints and fittings or in contamination of the
pipes, joints and fittings.
(ii)
Pipes, joints and fittings shall be protected from damage and damaged
pipes, joints and fittings shall not be used in the Permanent Works.
Pipes, joints and fittings shall be securely packed and supported to
prevent movement when being transported.
(iii)
UPVC pipes, joints and fittings shall be protected from exposure to

conditions which may affect the material.
(iv)
Bolts and nuts shall be packed in sealed metal containers.
(v)
Elastomeric joint rings shall be packed in bags and lubricant for joints
shall be stored in sealed containers marked to identify the contents.
The rings and lubricant shall be protected from exposure to conditions
which may affect the material.
Handling of pipes and fittings:

(i)
Pipes and fittings shall be handled manually or by using lifting

appliances or chains, wire ropes or canvas slings of a type
recommended by the pipe manufacturer and reviewed without objection
by the Project Manager. Hooks shall not be used.

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January 2011
(c)
(d)
(ii)
Slings shall be placed around the pipes and fittings and padding shall
be provided at points of contact between pipes and fittings and metal
lifting appliances or slings. Pipes and fittings shall not be handled by
means of metal slings passed through the pipes.
(iii)
Pipes and fittings shall not be subjected to rough handling, shock

loading or dropping.
Storage of pipes:
(i)
Pipes shall be stored horizontally at least 75 mm above the ground on

wedged timber bearers and shall not be strung out along the route of
the pipeline. The pipes shall be securely wedged to prevent sideways
movement.
(ii)
Socket and spigot pipes shall be stored with the sockets alternating and
in such a manner that loads are not applied to the sockets.
(iii)
The height of stacks of pipes shall not exceed the maximum height
recommended by the pipe manufacturer.
Storage of anticorrosion tape and joint filler:

Anticorrosion tape and joint filler shall be stored in accordance with the
manufacturer's recommendations in a dry, weatherproof store with a raised
floor.
(e)
Handling and storage of aggregates for granular bed:

Aggregates for granular bed shall not be handled or stored in a manner which
will result in mixing of the different types and sizes or in contamination of the
aggregates. Different types and sizes of aggregates shall be stored in
separate stockpiles.
(f)
(g)
Handling and storage of units for manholes, chambers and gullies:

(i)
Units for manholes, chambers and gullies shall be lifted only at the lifting
points recommended by the manufacturer and shall not be subjected to
rough handling, shock loading or dropping.
(ii)
Units for manholes, chambers and gullies shall be stored off the ground
on level supports and in a manner which will not result in damage or
deformation to the units or in contamination of the units. The units shall
be protected from damage and damaged or deformed units shall not be
used in the Permanent Works.
Storage of covers, gratings, weirs, penstocks and valves:

Manhole covers, gully gratings, kerb overflow weirs, penstocks and valves,
including fittings, shall be stored off the ground on level supports and in a
manner which will not result in damage to the units or in contamination or
deformation of the units. The units shall be protected from damage and
damaged or deformed units shall not be used in the Permanent Works.

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January 2011
6.5.2
Excavation
(a)
Excavation for any section of a trench for drainage works shall not commence
until the nature, location and size of existing utilities which may be affected by
the excavation have been ascertained and the setting out details have been
(b)
The effective trench width of trenches for drainage works shall not exceed the
relevant effective trench widths stated in Table 6.9 for the different diameters
of pipe. Unless otherwise stated in the Contract, effective trench width for
different trench profiles shall be measured in accordance with the
requirements of the Hong Kong Government Drainage Services Department
Standard Drawings.
Table 6.9: Effective Trench Widths

Nominal
Diameter
of pipe
(mm)
100
150
225
300
375
450
525
600
675
750
825
900
975
1050
Effective
trench
width
(mm)
550
600
700
750
1050
1150
1200
1350
1450
1500
1600
1900
2000
2050
Nominal
diameter
of pipe
(mm)
1125
1200
1350
1500
1650
1800
1950
2100
2250
2400
2550
2700
2850
3000
Effective
trench
width
(mm)
2200
2300
2450
2600
2800
2950
3150
3350
3400
3500
3650
3800
3950
4150
(c)
The bottom of the excavation shall be formed to the levels and falls as stated
in the Contract and well rammed and consolidated. Any backfill in the areas
of overbreak shall be provided by material reviewed without objection by the
Project Manager.
(d)
The sides of trenches, manholes and other excavations shall be adequately

supported at all times. Where shown on the Employers Drawings or directed
by the Project Manager the supports shall be left in trenches or pits.
(e)
The materials excavated in forming pipe drains shall, if containing materials

as defined in Clause 7.3.1(b), be disposed of off Site and replaced with fill
material. Excavated fill material shall be set aside for use as fill.
(f)
Surplus material shall be used for fill or disposed of in accordance with Clause
7.5.1 as agreed with, or directed by the Project Manager.

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January 2011
6.5.3
Laying and Bedding Pips

(a)
Laying pipes
(i)
The Contractor shall allow the Project Manager to inspect trenches,

bedding, pipes, joints, fittings and valves before pipelaying for drainage
works starts. The Contractor shall notify the Project Manager before
pipelaying starts in any part of the Permanent Works.
(ii)
The Contractor shall inspect pipes, joints, fittings and valves, including
internal and external coatings, immediately before and after pipelaying;
valves shall be inspected to ensure that they are in working order and
are capable of being fully opened and closed. Deleterious material shall
be removed and damage shall be repaired immediately before and after
pipelaying.
(iii)
The inside of pipelines shall be kept clean and free from water, dirt,
stones, debris and deleterious material. Except when pipes are being
jointed, the open ends of pipelines shall be sealed with a wooden plug
or stopper.
(iv)
Measures shall be taken to prevent flotation of pipes.
(v)
Pipelaying, testing and backfilling shall follow as closely as practicable

on excavation of the trench.
(vi)
Pipelines shall be laid in an uphill direction with sockets facing uphill.
(vii) Pipes shall be laid in such a manner that water will not pond in locations
with zero or shallow gradients and such that the pipes will comply with
the specified tolerances.
(b)
(c)
Bedding pipes
(i)
Surfaces on which pipes for drainage works will be laid shall be cleaned
and objects which may damage the pipes shall be removed before
pipes are laid.
(ii)
The bottom of trenches on which pipes will be laid directly shall be

shaped to support the pipes uniformly along the length of the barrel;
holes shall be dug to prevent pipes resting on the sockets and to allow
the pipes to be jointed.
Laying of Polyethylene Pipe

(i)
The laying of poIyethylene pipe shall comply with CP 3 12: Part 3: 1973.
(ii)
Storage and jointing of polyethylene pipe and fittings shall be in strict

accordance with the manufacturer's recommendations and to the
satisfaction of the Project Manager.
(iii)
Hot bending of polyethylene pipe is not permitted.
(iv)
Dragging of polyethylene pipe over trench bottom or over the ground is

not permitted.

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January 2011
(v)
Polyethylene pipe and fittings to be surrounded by concrete shall be

wrapped with three layers of polythene sheeting having a nominal film
thickness of 0.1mm.
(vi)
Naked flame inside trench shall not be used unless with the permission
of the
(vii) Project Manager.

(viii) Before commencing laying of polyethylene pipe into trenches, the
Contractor
(ix)
6.5.4
6.5.5
shall request the Project Manager to examine the trench if it is

contaminated by strong acid, detergents and hydrocarbons including
petrol and solvents. If in the opinion of the Project Managert the area is
contaminated by such chemicals, the Contractor shall submit a remedial
proposal to the Project Manager for review without objection before
proceeding with the work.
Cutting Pipes
(a)
Pipes for drainage works shall be cut and the ends shall be prepared in
accordance with the manufacturers' recommendations; purpose-made
equipment recommended by the manufacturer and reviewed without objection
by the Project Manager shall be used for cutting the pipes.
(b)
Cut ends of pipes shall be square or cut to the correct angle and without
damage to the pipe or coating. Cut ends shall be trimmed and chamfered to
suit the type of joint and in such a manner that elastomeric joint rings will not
be damaged by the cut end.
(c)
Pipes requiring to be cut to form closing lengths shall not be cut until adjacent
pipes have been laid and jointed and the length to be cut can be accurately
measured.
(d)
Reinforcement in precast concrete pipes which are cut shall be cut back flush
with the concrete and protected with epoxy resin.
(e)
Pipes which terminate at the inside face of structures shall be cut such that
the end of the pipe is flush with the face.
Jointing Pipes
(a)
General:
(i)
Pipes for drainage works shall be jointed in accordance with the

manufacturers' recommendations and using jointing equipment and
jointing materials recommended by the manufacturer and reviewed
without objection by the Project Manager.
(ii)
The Contractor shall inspect pipes, joints, fittings and valves, including
internal and external coatings, immediately before and after jointing.
Deleterious material shall be removed and damage shall be repaired
immediately before and after jointing. Surfaces which are to be jointed
and jointing materials shall be cleaned immediately before jointing.
Pipes shall be cleaned out with clean water.

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January 2011
(b)
(c)
(d)
(iii)
All joints in pipelines shall be watertight.
(iv)
The widths of gaps at joints shall be in accordance with the

manufacturers' recommendations and shall be achieved by marking the
outside of the pipe by using metal feelers. The position of elastomeric
joint rings shall be checked by using metal feelers after jointing.
(v)
Gaps at joints in pipes shall be protected after jointing, by methods

reviewed without objection by the Project Manager, to prevent dirt,
stones or other material entering the joint.
Flanged joints:
(i)
Flanged joints in pipes for drainage works shall be provided as stated in

Clause 6.5.5(b)(ii).
(ii)
Bolt holes in flanged joints shall be orientated symmetrically about the

vertical diameter with no bolt holes on the vertical diameter.
Elastomeric joint rings shall be the correct size and shall not protrude
into the bore of the pipe. The rings may be temporarily fixed to the face
of the flange using a minimum amount of adhesive of a type
recommended by the manufacturer; jointing compound or paste shall
not be used for this purpose.
Flexible collar joints:

(i)
Flexible collar joints in pipes for drainage works shall be provided as

stated in Clause 6.5.5(c)(ii) to (iv).
(ii)
The elastomeric joint rings shall be placed in position inside the grooves
of the sleeve. The ends of the pipes shall be well smeared with
lubricant over a distance of at least 100 mm from the end of the pipe.
(iii)
The sleeve shall be placed on the end of the laid pipe and pushed home
to the location mark on the pipe. The location mark shall be at a
distance of half the length of the sleeve minus 3 mm from the end of the
pipe unless otherwise recommended by the manufacturer.
(iv)
The pipe which is to be jointed to the laid pipe shall be placed in the
sleeve and pushed home to the location mark on the pipe.
Push-in joints:
Push-in joints in pipes for drainage works shall be made by smearing the
elastomeric joint ring with lubricant and placing the ring in position on the
spigot end of the pipe. The spigot shall be placed in the socket of the laid
pipe and pushed home.
(e)
Detachable joints:
(i)
Detachable joints in pipes for drainage works shall be jointed as stated

in Clause 6.5.5(e)(ii) and (iii).

20/51
January 2011
(f)
(ii)
Both CI flanges, the elastomeric joint rings and the central collar shall
be placed over the ends of the pipes before the pipes are placed to the
required line and level; a gap of between 5 mm and 6 mm shall be left
between the ends of the pipes.
(iii)
The flanges, elastomeric joint rings and central collar shall be moved
into position at the ends of the pipes; the central collar shall be
positioned centrally over the gap between the ends of the pipe before
the bolts are tightened.
Flange adapters:
Joints with flange adapters in pipes for drainage works shall be made by
placing the flange adaptor on the plain end before the bolts are tightened.
(g)
Solvent welded joints:

Solvent welded joints in pipes for drainage works shall be made by applying
solvent cement to the pipes to be jointed and pushing the pipes home.
Surplus solvent shall be removed after jointing. Solvent welded pipes jointed
outside the trench shall not be placed in the trench until the solvent setting
period recommended by the manufacturer has elapsed. In addition, any
material or thing contaminated by the solvent shall not be left in the pipe or
trench.
(h)
Screw joints:
(i)
Screw joints in pipes for drainage works shall be made using a threaded
coupler. The threaded surfaces of the pipes and coupler shall be
cleaned and the threads shall be painted with two coats of bituminous
paint. The pipe thread shall be wrapped with three turns of spun yarn
and the joint tightened using purpose made tools. Coal tar compounds
or white lead paint shall not be used. Locking nuts to branch
connections shall be tightened. Branch connections shall not protrude
inside the pipe.
(ii)
Cast iron pipes shall be laid and bedded one at a time. Each cast iron
pipe should bear evenly on its bed. Joint holes shall be cut in the
foundation for the purpose of making joints. The spigot of each pipe
shall fit easily into the socket of the preceding pipe without any jamming
or twisting and shall be pushed well home so that the inverts of the
socket and spigot when joined shall be level. Joint gaskets shall be
formed with about 2 turns of yarn caulked tightly to the bottom of the
socket, a depth of at least 50 mm being left in the socket for lead
jointing, which shall be run in molten and caulked into the edge of the
socket. Proprietary joints may be proposed for review without objection
by the Project Manager.

21/51
January 2011
(i)
Jointing Polyethylene Pipes

(i)
Jointing system permitted for polyethylene pipes are as follows:
6.5.6
End-load-resistant, mechanical
-
metal flanged joint and flange adaptor
collar type with a metal body and metal or rubber compression

rings
Heat fusion
-
butt fusion (with external debeading)
electro-fusion
Heat fusion saddle
(ii)
Site fusion jointing shall be made in accordance with WIS No. 4-32-08
using automatic equipment with data printout facilities
(iii)
A specific joint number shall be assigned to each heat fusion joint and a
sketch showing the location of the joint shall be prepared. In case of butt
fusion joint, the removed beads shall be properly stored in a transparent
plastic bag which shall be marked to indicate the joint number and
whether the beads are external or internal beads. External and internal
beads for the same joint shall be placed in two different plastic bags.
The sketch, data printout, the name of the jointer, and all other
information as required by the Project Manager together with beads (if
the joint is a butt fusion joint) for each heat fusion joint shall be
submitted to the Project Manager for review without objection within
three calendar days after completion of the joint.
(iv)
For socket fusion, electro-fusion and heat fusion saddle jointings, the
fusion areas of polyethylene pipes shall be cleaned by using
isopropanol wipes before and after scrapping. The fusion areas of the
fittings shall also be cleaned by using isopropanol wipes before
connecting the polyethylene pipes to the fittings.
Protection of Joints
(a)
Flanged joints, detachable couplings and flange adapters on buried pipes for
drainage works shall be protected as stated in Clause 6.5.6(b) to (d).
(b)
The joint, including bolts and nuts, shall be cleaned to remove all moisture,
dust, oil, grease and deleterious material. Bolts and nuts shall be painted with
two coats of bituminous paint and the joint shall be coated with primer. Mastic
filler shall be applied in such a manner that all depressions, corners and voids
between the bolts and nuts are filled and a smooth surface is available on
which to apply the anticorrosion tape.
(c)
At least two layers anticorrosion tape shall be applied to all parts of the joint
and to the adjacent pipe for at least 200 mm beyond each end of the joint.
The tape shall be applied in accordance with the manufacturer's
recommendations and shall be wrapped spirally around the joint and pipe with
at least 55% overlap per spiral.
(d)
The tape shall be moulded manually after application to take up the contours
of the parts being protected.

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January 2011
6.5.7
Repairs to Coatings and Linings

Damage to coatings and linings of pipes for drainage works shall not be repaired
unless permitted by the Project Manager. If permitted, repairs shall be carried out
using materials recommended by the manufacturer and reviewed without objection
6.5.8
6.5.9
Thrust and Anchor Blocks

(a)
Thrust or anchor blocks shall be used to resist forces at bends, branches and
stopends in pressure pipelines for drainage works except where self
anchoring joints are used. Concrete for thrust and anchor blocks shall be
Grade 20.
(b)
The bearing face, and other faces stated in the Contract, of concrete anchor
and thrust blocks shall be cast directly against undisturbed ground; the faces
of excavations shall be trimmed to remove loose material before concreting.
Excavation required for the block beyond the trench width shall be carried out
after the pipe or fitting has been jointed. Excess excavation beyond the face
at the block shall be filled with concrete of the same grade as the block.
(c)
Internal pressure shall not be applied to the pipeline until thrust and anchor
blocks have developed the specified grade strength.
Bed, Haunch and Surround

(a)
(b)
Granular bed:
(i)
Granular bed to pipelines for drainage works shall be constructed as

stated in Clause 6.5.9(a)(ii) to (iv).
(ii)
Aggregates for granular bed shall be deposited in the trench in layers

not exceeding 150 mm thick and for the complete width of the trench.
Each layer shall be compacted using a plate vibrator or by other
(iii)
Holes shall be dug in the granular bed to prevent pipes resting on the
sockets and to allow the pipes to be jointed. The pipes shall be laid
directly on the granular bed; temporary supports shall not be used.
(iv)
After the pipes have been jointed, aggregate shall be deposited in

layers not exceeding 150 mm thick equally on both sides of the pipe to
the specified level for the complete width of the trench. Each layer shall
be compacted using a plate vibrator.
Concrete bed, haunch and surround:

(i)
Concrete bed, haunch and surround to pipelines for drainage works

shall be constructed as stated in Clause 6.5.9(b)(ii) to (vii).
(ii)
Concrete for concrete bed, haunch and surround shall be Grade 20.
(iii)
Polyethylene sheeting or a blinding layer shall be placed on the trench

bottom before concreting.

23/51
January 2011
(iv)
Pipes shall be supported at the required level by Grade 20 precast

concrete wedges, blocks or cradles. One support shall be placed
adjacent to each end of each pipe and the spacing between supports
shall not exceed 3 m. Compressible sheeting shall be placed between
the pipes and supports.
(v)
Flexible joints shall be formed in concrete bed, haunch and surround at

flexible joints in pipelines. Joint filler shall be placed next to the flexible
joint in the pipeline and shall extend for the complete thickness of the
bed, haunch and surround.
(vi)
Concrete shall be placed evenly over the complete width of the bed and
over the complete length of the pipe being concreted up to a level of 25
mm below the underside of the pipe. Concrete shall then be placed on
one side of the pipe only and worked under the pipe until the concrete
spreads under the pipe. Concrete shall then be placed equally on both
sides of the pipe to the specified level.
(vii) Pipes for drainage works which are 1 m or less below the surface of a
carriageway shall be protected with Grade 20 concrete surround.
(viii) The aggregate for Grade 20 concrete stated in Clause 6.5.9(b)(i) to (vii)
shall be natural stone, crushed rock or crushed concrete. Such Grade
20 concrete shall have the following minimum cementitous content:
Minimum cememtitous content (kg/m3)
280
330
Exposure condition
Moderate
Severe
(c)
(d)
Fill material surround:

(i)
Fill material surround to pipelines for drainage works shall be deposited

and compacted as stated in Clauses 7.4.34 and 7.4.35.
(ii)
Fill material surround to underfloor drainage pipes and perforated

perimeter drain pipes shall be uniform, clean and free draining granular
material with less than 5% passing 63 m.
Installation of drainage pipe support in structures:

(i)
The locations of the brackets shall be determined by the Contractor and

arranged to satisfy the following requirements:
- the maximum permitted spacing between brackets for pipe support
indicated on the Employers Drawings shall not exceeded;
- minor reductions in the maximum permitted spacing may be made to
avoid clamps coinciding with pipe joints; and
- a clear distance of at least 50 mm shall be maintained between
socket fixings and adjacent reinforcing bars or tendons.
(ii)
The interface between the brackets and the concrete shall be protected
by an inert layer of corrosion resisting tape reviewed without objection

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January 2011
6.5.10
Tolerances
(a)
6.5.11
Tolerances: pipelines drainage works:

(i)
Except as stated in Clause 6.5.10(a)(ii), pipelines for drainage works

shall comply with the following requirements:
the line of gravity pipelines shall be within 20 mm of the specified
line;
the invert level of gravity pipelines shall be within 6 mm of the
specified invert level and there shall be no backfall at any point;
the line of pressure pipelines shall be within 50 mm of the specified
line; and
the invert level of pressure pipelines shall be within 20 mm of the
specified invert level.
(ii)
Termination pipes in pipelines for drainage works which are designed to

connect to pipes or fittings laid by others shall comply with the following
requirements:
the position of the centre of the termination face of the pipe in the
longitudinal
direction shall be within 10 mm of the specified
position;
the position of the centre of the termination face of the pipe in the
lateral direction shall be within 3 mm of the specified position;
the gradient of the termination pipe shall be within 0.5 of the

specified gradient; and
the invert level at the termination face of the pipe shall be within 3
mm of the specified invert level.
Connections
(a)
Connections to structures:
(i)
The joints between pipes for drainage works and structures into which
the pipes are built shall be watertight; protective coatings shall be
removed over the length to be built in before the pipe is built in. Pipe
collars and sockets shall not be built in to structures.
(ii)
Two flexible joints shall be provided in pipelines adjacent to the outside

faces of structures into which pipes will be built. The distances from the
outside face of the structure to the first joint and from the first joint to the
second joint shall be as stated in Table 6.10.
(iii)
The ends of pipes which are built in to structures shall be temporarily

sealed with a blank flange, brickwork or timber boarding.
The
temporary seals shall be left in position until the Project Manager
permits their removal.

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January 2011
Table 6.10: Flexible Joints at Structures

Position of first flexible
joint from structure
Diameter of pipe
Minimum
Maximum
Distance of second
flexible joint from
first flexible joint
450 mm - 800 mm
exceeding 450 mm
but not exceeding
1050 mm
150 mm
500 mm or
diameter of pipe,
which-ever is less
exceeding 1050 mm
(b)
900 mm - 1200 mm
1500 mm - 1800 mm
Connections to pipes:
(i)
Pipe saddles shall be connected to concrete or vitrified clay pipes by

bedding the saddle on a cement mortar bed and forming a cement
mortar fillet to provide at least 50 mm cover to the base of the saddle.
Cement mortar shall consist of cement and sand in the proportions 1:3
by mass.
(ii)
UPVC pipe saddles shall be fixed to UPVC pipes using a purpose-made

mechanical clip or solvent cement of a type recommended by the
manufacturer and reviewed without objection by the Project Manager.
(iii)
Branch pipelines shall be connected to main pipelines using Y-junctions

of the same type and strength as the stronger of the pipes being jointed.
The angle of the Y-junction shall be such that the angle between the
direction of flow in the branch and main pipes shall be between 30 and
45.
(iv)
The positions of the pipe junctions relative to the manhole or structure

immediately downstream shall be measured and recorded before
backfilling.
(v)
The ends of connecting pipes not required for immediate use shall be
sealed with a blank flange or brickwork and the position measured and
recorded before backfilling.
(vi)
The Contractor shall allow for the existing flow of water when
connecting new sewers, drains and culverts to existing pipelines,
culverts, manholes and other drainage chambers.
(vii) Prior to the connection to existing pipelines, culverts, manholes and

other drainage chambers the Contractor shall check the invert level of
the existing drainage to which he has to connect and inform the Project
Manager of any discrepancies between the actual level and the level
specified on the Employers Drawings.

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January 2011
6.5.12
Manholes, Chambers, Gullies and Channels

(a)
Manholes, chambers and gullies:

(i)
Bases, inverts and benching for precast concrete manholes shall be

constructed in-situ using Grade 20 concrete, unless otherwise stated in
the Contract.
(ii)
Precast concrete units for manholes and chambers shall be set

vertically with step irons staggered and vertically aligned above each
other. Joints between precast units shall be the rebated type and shall
be sealed with cement mortar; lifting holes shall be filled with cement
mortar. Surplus cement mortar shall be removed and joints shall be
pointed.
(iii)
Concrete surrounds to manholes, chambers and gullies shall be Grade

20 concrete. Joints in concrete surrounds shall be staggered by at least
150 mm from joints in the precast units. Concrete surrounds to gullies
shall be placed up to the sides of the excavation.
(iv)
The frames for manhole covers and gully gratings shall be set to the
same levels as the surrounding surface, allowing for falls and cambers,
using brickwork and/or concrete. The number of courses of brickwork
used below frames shall not exceed three and the minimum grade for
concrete shall be Grade 20.
(v)
Cement mortar for fixing manhole covers and gully gratings in position
and bonding brickwork shall consist of cement and sand in the
proportions 1:3 by mass.
(vi)
Excavations around manholes and chambers in carriageways shall be

filled using Grade 10 concrete up to the carriageway formation level.
Fill material for excavations around other manholes and chambers shall
be fine fill material.
(vii) Manholes, chambers and gullies shall be water tight on completion.

(b)
Concrete open channels:

The top surfaces of side walls of concrete open channels shall be constructed
to the same levels as the adjoining Permanent Works. Excess excavation
beyond the channel walls shall be filled with Grade 10 concrete.
6.5.13
Marker Blocks
(a)
The ends of pipes which do not terminate at a manhole, chamber, gully or

structure shall be marked with marker blocks. The blocks shall be 150 mm x
150 mm x 150 mm and shall be constructed using Grade 20 concrete.
(b)
A wire shall be connected from a hook at the underside of the block to the
plug at the end of pipes.
(c)
Marker blocks shall be set flush level with the adjacent Permanent Works and
shall have the letters CD marked on the upper surface.

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January 2011
6.5.14
6.5.15
6.5.16
Installation of Penstocks and Valves

(a)
Penstocks and valves shall be installed in accordance with the manufacturer's

recommendations and in the closed position.
(b)
Frames for penstocks shall be fixed in position leaving a 20 mm gap between

the frame and the concrete surface. Contact between the penstock door and
frame shall be checked using a feeler gauge 0.1 mm thick or other size
recommended by the manufacturer.
(c)
Box-outs and rebates for penstock and valve frames and gaps between
frames and concrete surfaces shall be filled with cement mortar.
(d)
After installation, penstocks and valves shall be cleaned and moving parts
shall be lightly greased and checked for ease of operation. Penstocks and
valves shall be left in a closed position.
Pipes and Manholes to be Abandoned

(a)
Manholes, chambers and gullies which are to be abandoned shall be

demolished and removed unless otherwise stated in the Contract.
Abandoned pipes, culverts, manholes, chambers and gullies shall be filled
with foam concrete or grout, by pumping or by gravity. The lowest point of
abandoned pipelines shall be sealed with concrete or bricks. Filling shall start
from the lowest point and shall continue until all voids are completely filled.
(b)
If the top of a pipe or culvert, or the bottom of a manhole, chamber or gully to

be abandoned is 1 m or less below the finished ground level, the pipe,
manhole, chamber or gully shall be removed and disposed of by the
Contractor. The void shall be filled with foam concrete, granular fill material or
special fill material which has been reviewed without objection by the Project
Manager.
(c)
If the top of a pipe or culvert, or the bottom of a manhole, chamber or gully to

be abandoned is more than 1 m below the finished ground level, the pipe,
culvert, manhole, chamber or gully shall be filled with foam concrete or grout
as stated in Clause 6.3.25.
Cleaning of Pipelines
(a)
(b)
Pipelines for drainage works shall be cleaned by pigging or by high pressure

water jetting; manholes and chambers shall be cleaned and washed.
Cleaning shall be carried out:
(i)
before and after the complete pipeline, or parts of the pipeline if

permitted by the Project Manager, have been tested;
(ii)
after the Temporary Works required for testing have been removed; and
(iii)
after parts of the pipeline removed for testing have been reconnected.
Pipelines shall be cleaned not more than 7 days before the application for
Completion Certificate for the pipeline works is submitted.

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January 2011
6.5.17
Employment of Qualified Polyethylene Pipe Layers

(a)
A qualified polyethylene pipe layer shall mean a worker or supervisory staff

who has successfully completed the short course "Installation of Polyethylene
Pipes" organized by Hong Kong Institute Vocational Education and passed
the examination or equivalent.
(b)
All connections or jointing of polyethylene pipe works must be carried out by

qualified polyethylene pipe layers. The Contractor shall employ sufficient
number of qualified polyethylene pipe layers to suit the workload of
polyethylene pipe works.
(c)
The Contractor shall submit to the Project Manager within seven days a name
list and supporting document of the qualified polyethylene pipe layers
employed after commencement of polyethylene pipe works.
(d)
The Contractor shall keep records of the names and supporting documents of
the qualified polyethylene pipe layers employed and shall make such records
available for inspection by the Project Manager when required.
(e)
The Contractor shall demonstrate the competence of the qualified

polyethylene pipe layers by testing them periodically or whenever required by
the Project Manager who may witness all such tests. The Contractor shall
complete all necessary arrangements for the tests within seven days from the
notification of the Project Manager. The pipe layers shall be required to carry
out butt fusion, electrofusion and heat fusion saddle on site under the witness
of the representatives of the Project Manager. If the Project Manager is not
satisfied with the competence of the pipe layers, the pipe layers shall not be
counted as qualified polyethylene pipe layers and shall be prohibited to carry
out connections or jointing of polyethylene pipes works. The Contractor shall
arrange further training for these pipe layers. These pipe layers shall be
tested again after a minimum period of two months and counted as qualified
polyethylene pipe layers if they pass the test. If the Project Manager is still not
satisfied with the competence of these pipe layers, these pipe layers shall
refresh their knowledge and techniques by successful completing another
short course "Installation of Polyethylene Pipes" organized by the Hong Kong
Institute Vocational Education or equivalent before further testing.
6.6
6.6.1
Testing of Pipelines
(a)
Inspection of pipelines
The cleanliness, bore, linearity and joints of pipelines of 450 mm diameter or
less shall be checked by pulling a mandrel through the completed pipeline, or
parts of the pipeline if permitted by the Project Manager, after cleaning. The
mandrel shall be 750 mm long and 12 mm less in diameter than the nominal
diameter of the pipe.

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January 2011
(b)
Inspection of pipelines by CCTV

All pipelines shall be inspected internally by CCTV after cleaning in
accordance with Clause 6.5.16. The procedure for internal inspection by
CCTV shall be as stated in Appendix A6.1. The defects discovered by the
CCTV inspection shall be rectified in accordance with Clause 6.6.8(b).
6.6.2
Testing of Pipes for Drainage Works

(a)
Batch: pipes for drainage works
(b)
A batch of pipes or fittings for drainage works is any quantity of pipes or

fittings of the same type and nominal diameter, manufactured by the same
manufacturer, covered by the same certificates and delivered to the Site at
any one time.
Samples: pipes for drainage works
One sample of pipe for drainage works and each type of fitting shall be
provided from each 50 pipes or fittings or part thereof in a batch.
(c)
(d)
Testing: pipes for drainage works

(i)
Each sample of pipes and fittings for drainage works shall be tested in
accordance with the relevant British Standard.
(ii)
The method of testing shall be in accordance with the following:

Concrete pipes and fittings
: BS 5911: Part 100
Vitrified clay pipes, fittings and joints
: BS 65
Ductile iron pipes and fittings
: BS 4772
Grey iron pipes and fittings
: BS 4622
UPVC pipes for industrial purposes
: BS 3506
UPVC soil and ventilating pipes, fittings and accessories
: BS 4514
UPVC rainwater goods
: BS 4576:Part 1
UPVC underground drain pipes and fittings
: BS 4660
Plastic waste pipes and fittings
: BS 5255
UPVC pipes and fittings for gravity sewers
: BS 5481
Non-compliance: pipes for drainage works

(i)
If the result of any test required in accordance with the relevant British
Standard for pipes and fittings for drainage works does not comply with
the specified requirements for the test, one additional sample shall be
provided from the same batch and additional tests for the property shall
be carried out.
(ii)
The batch shall be considered as not complying with the specified

requirements for the property if the result of any additional test does not
comply with the specified requirements for the property.

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January 2011
6.6.3
Testing of Aggregates for Granular Bed

(a)
Batch: aggregates for granular bed

A batch of aggregates for granular bed is any quantity of aggregates for
granular bed of the same type, produced at the same time in the same place,
covered by the same certificates and delivered to the Site at any one time.
(b)
(c)
Samples: aggregates for granular bed

(i)
One sample of aggregates for granular bed shall be provided from each
batch of aggregates for granular bed delivered to the Site.
(ii)
The size of each sample shall be 40 kg.
(iii)
The method of sampling shall be in accordance with BS 812: Part 102.
(iv)
The moisture content of the sample shall be representative of the

moisture content of the material in the batch.
Testing: aggregates for granular bed

Each sample of aggregates for granular shall be tested to determine the
particle size distribution and ten percent fines value in accordance with BS
812:Part 103 and BS 812:Part 111, and the compaction fraction value in
(d)
Compliance criteria: compaction fraction value

The results of tests for compaction fraction value of aggregates for granular
bed shall comply with the following requirements:
6.6.4
(i)
The compaction fraction value for pipe bed not exceeding 300 mm
nominal diameter shall not exceed 0.3; and
(ii)
The compaction fraction value for pipe bed exceeding 300 mm nominal
diameter shall not exceed 0.15.
Testing of Precast Concrete Units for Manholes, Chambers and Gullies

(a)
Batch: manholes, chambers and gullies

A batch of precast concrete units for manholes, chambers or gullies is any
quantity of precast concrete units for manholes, chambers or gullies of the
same type and size, manufactured by the same manufacturer, covered by the
same certificates and delivered to the Site at any one time.
(b)
Samples: manholes, chambers and gullies

One sample of precast units for manholes, chambers or gullies shall be
provided from each batch of 50 precast concrete units for manholes,
chambers or gullies or part thereof delivered to the Site.

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January 2011
(c)
(d)
6.6.5
Testing: manholes, chambers and gullies

(i)
Each sample of precast concrete units for manholes, chambers or

gullies shall be tested in accordance with the relevant British Standard.
(ii)

Precast concrete units for manholes
: BS 5911: Part 200
Inspection chambers and gullies
: BS 5911: Part 2.
Non-compliance: manholes, chambers and gullies

(i)
If the result of any test required in accordance with the relevant British
Standard for precast concrete units for manholes, chambers or gullies
does not comply with the specified requirements for the test, one
additional sample shall be provided from the same batch and additional
tests for the property shall be carried out.
(ii)

Testing of Manhole Covers, Gully Gratings and Kerb Overflow Weirs

(a)
Batch: covers, gratings and weirs

A batch of manhole covers, gully gratings or kerb overflow weirs is any
quantity of covers, gratings or weirs of the same type, manufactured by the
same manufacturer, covered by the same certificates and delivered to the Site
at any one time.
(b)
Samples: covers, gratings and weirs

One sample of manhole covers, gully gratings or kerb overflow weirs shall be
provided from each batch of 20 covers, gratings or weirs or part thereof
delivered to Site.
(c)
(d)
Testing: covers, gratings and weirs

(i)
Each sample of manhole covers, gully gratings or kerb overflow weirs

shall be weighed to determine the mass, a load test shall be carried out
on each sample of covering and grating to determine the resistance to
fracture.
(ii)
The method of testing shall be as stated in Appendix A6.3. The test

loads shall be as stated in Table 6.6 and Table 6.7.
Compliance criterion: resistance to fracture of covers and gratings

Manhole covers and gully gratings shall withstand the test load without
fracture or cracking.

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January 2011
(e)
(f)
6.6.6
Non-compliance: mass of covers, gratings and weirs

(i)
If the result of any test for mass of any manhole cover, gully grating or
kerb overflow weir does not comply with the specified requirements for
mass, every cover, grating and frame in the batch shall be weighed to
determine its mass.
(ii)
If any cover, grating or weir does not comply with the specified
requirements for mass, it shall not be used in the Permanent Works.
Non-compliance: resistance to fracture of covers and gratings

(i)
If any manhole cover or gully grating does not comply with the specified
requirements for resistance to fracture, two additional samples shall be
provided from the same batch and tested to determine their resistance
to fracture.
(ii)

requirements for resistance to fracture if the result of either additional
test does not comply with the specified requirements for resistance to
fracture.
Testing of Watertightness of Penstocks

(a)
(b)
Testing: watertightness of penstocks

(i)
Penstocks shall be tested for watertightness after installation by

applying pressure using a head of water applied to one face of the
penstock and no head of water on the other face. The test pressure and
the face on which the pressure is to be applied shall be as stated in the
Contract.
(ii)
The method of testing shall be as submitted for review without objection

(iii)
The test pressure shall be maintained for 24 hours.
Compliance criteria: watertightness of penstocks

The results of tests for watertightness of penstocks shall comply with the
following requirements:
(c)
(i)
there shall be no leaks through the penstock during the test; and
(ii)
there shall be no leaks or damp patches visible at the joint between the
penstock and the structure during the test.
Non-compliance: watertightness of penstocks

If the result of any test for watertightness of penstocks does not comply with
the specified requirements for the test, the Contractor shall investigate the
reason. Remedial or replacement work reviewed without objection by the
Project Manager shall be carried out and the penstock shall be re-tested.

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January 2011
6.6.7
Testing of Gravity Pipelines for Drainage Works

(a)
Gravity pipelines for drainage works shall be tested as stated in Clause

6.6.7.(b) to (h).
(b)
Gravity pipelines for sewage shall be tested by the methods stated in Table
6.11 at the following times:
(c)
(i)
after the pipes have been jointed and the bedding has been placed and
immediately before haunch or surround is placed or fill material is
deposited;
(ii)
after haunch and surround has been placed and fill material has been
deposited and compacted; and
(iii)
not more than 7 days before a Completion Certificate for the pipeline
works is applied for.
Gravity pipelines for surface water shall be tested by the methods stated in
Table 6.11 at the following times:
(i)
deposited; and
(ii)
deposited and compacted.
(d)
Water tests and air tests on pipelines shall be carried out on the complete
pipeline between manholes, chambers and structures; pipelines shall not be
tested in parts unless the specified test pressure will be exceeded. Short
branch pipelines shall be tested with the main pipeline and long branch
pipelines shall be tested separately.
(e)
Infiltration tests shall be carried out on the complete pipeline between

manholes, chambers and structures, including manholes, chambers and
branches within the pipeline system.
(f)
The method of testing shall be in accordance with Appendix A6.4.
(g)
Visual inspections shall be carried out on the complete pipeline between

manholes, chambers and structures.
(h)
Visual inspections shall be carried out by the Contractor in the presence of the
Project Manager.

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January 2011
Table 6.11: Testing Gravity Pipelines

Type of
pipeline
Sewage
Sewage
6.6.8
Diameter
of pipeline
not exceeding
300 mm
not exceeding
900 mm
Sewage
exceeding
900 mm
Surface
Water
Surface
water
not exceeding
300 mm
not exceeding
900 mm
Surface
water
exceeding
900 mm
Time of test
Method of testing
as Clause 6.6.7(b)
Water test
as Clause 6.6.7(b)(i)
as Clause 6.6.7(b)(ii)
as Clause 6.6.7(b)(iii)
as Clause 6.6.7(b)(i)
as Clause 6.6.7(b)(ii)
as Clause6.6.7(b)(iii)
as Clause 6.6.7(c)
Water test or air test

Infiltration test
Visual inspection
Infiltration test
Water test
as Clause 6.6.7(c)(i)
Or
as Clause 6.6.7(c)(ii)
As Clause 6.6.7(c)(i)
as Clause 6.6.7(c)(ii)

Visual inspection
Compliance criteria: gravity pipelines for drainage works

(a)
(b)
The results of tests on gravity pipelines for drainage works shall comply with
the following requirements:
(i)
the leakage of water from the pipeline determined by the water test shall
not exceed the permitted leakage calculated in accordance with Clause
A6.4.8 of Appendix A6.4;
(ii)
there shall be no discernable leakage from the pipe or from any joint
during the water test;
(iii)
the air pressure shall remain above 75 mm head of water at the end of
the air test; and
(iv)
there shall be no infiltration or damage to pipes or joints as determined

by the visual inspection.
The Contractor shall investigate the reason for any non compliance.
Remedial or replacement work reviewed without objection by the Project
Manager shall be carried out and the pipeline shall be re-tested.

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January 2011
6.6.9
6.6.10
Testing of pressure pipelines for drainage works

(a)
Pressure pipelines for drainage works shall be tested as stated in Clause

6.6.9(b) to (g).
(b)
The pipeline shall be tested at the following times:

(i)
deposited; and
(ii)
deposited and compacted for the complete pipeline.
(c)
The test stated in Clause 6.6.9(b)(i) shall not be carried out on parts of a
pipeline unless permitted by the Project Manager. The test stated in Clause
6.6.9(b)(ii) shall be carried out on the complete pipeline.
(d)
The test pressure shall be as stated in the Contract. If the test pressure is not
stated in the Contract, the test pressure shall be 1.5 times the maximum
working pressure in the part of the pipeline tested.
(e)
Tests shall not be carried out simultaneously on more than one pipeline in the
same trench.
(f)
(g)
Testing of pressure pipelines by means of tests on individual joints shall not

be carried out instead of tests stated in Clause 6.6.9(b) to (f).
Compliance criteria: pressure pipelines for drainage works

(a)
(b)
The results of tests on pressure pipelines for drainage works shall comply with
(i)
The leakage of water from the pipeline determined by the pressure test
shall not exceed the permitted leakage calculated in accordance with
Clause A6.5.4 of Appendix A6.5.
(ii)
There shall be no discernable leakage of water from the pipeline or from

any joint during the pressure test.
If the result of any test on pressure pipelines for drainage works does not
comply with the specified requirements for the test, the Contractor shall
investigate the reason. Remedial or replacement work reviewed without
objection by the Project Manager shall be carried out and the pipeline shall be
re-tested.

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January 2011
APPENDIX A6.1
CCTV INSPECTION OF PIPELINES
A6.1.1 Scope
This method covers the internal inspection of pipelines by means of closed circuit
television. (CCTV)
A6.1.2 Equipment
(1)
The equipment specified in Clauses A6.1.2(l) (a) to (g) shall be provided:

(a)
A CCTV colour camera with integral lighting unit. The camera shall be a
type designed and constructed for the specified purpose and shall be
capable of operating in 100% relative humidity. The camera shall be
fitted with a rotating mirror for complete circumferential viewing. The
system shall be capable of producing a clear and high quality picture of
the entire periphery of the pipe on the monitor screen and recording
tape. The camera and lighting unit shall be mounted on a self-propelled
crawler or on skids linked to a manual or power operated winch.
(b)
A monitor screen which displays the camera view during the inspection.
The monitor screen shall be housed in covered accommodation with
facilities for inspection by the Project Manager and others.
(c)
A screen writer which displays on the monitor screen details of the

inspection including date, location, pipe material, diameter of pipe,
direction of view and comments on the condition of the pipe.
(d)
A linear measuring device which displays the chainage of the camera

position automatically on the monitor screen. The device shall be
capable of measuring the chainage to within an accuracy of 0.1% of the
length of the pipeline or 0.3 m whichever is the greater.
(e)
A control unit which controls camera movement, lighting intensity,

focusing and recording by a video system.
(f)
A VHS video recording system to record the inspection and information

displayed on the monitor screen.
(g)
A 35 mm single lens reflex (SLR) camera capable of producing

photographs with details of the date.

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January 2011
A6.1.3 Procedure
(1)
The procedure shall be as specified in Clause A6.1.3 (1) (a) (d)

(a)
The camera shall be moved through the pipeline in the direction

directed by the Project Manager at a speed not exceeding 0.15 m/s. If
the camera cannot pass through the complete pipeline in one operation,
the inspection shall be carried out from both ends of the pipeline.
(b)
The camera shall be stopped whenever directed by the Project Manager

to allow inspection by the Project Manager.
(c)
The video system shall be operated during the complete inspection to

provide a continuous record of the inspection and information on the
monitor screen.
(d)
Photographs of the monitor screen shall be taken whenever required by

A6.1.4 Recording of Results

(1)
(2)
Records of the inspections shall be kept by the Contractor on the Site and a
report shall be submitted to the Project Manager for review within 14 days of
completion of the inspection. The report shall contain the following details:
(a)
key map showing pipelines inspected and associated manholes,

chambers and structures,
(b)
tables listing details of inspection, including date, location, pipe material,

diameter of pipe, chainage, manholes, junctions and other features and
the condition of pipes and joints; the condition of pipes and joints shall
be illustrated by a coding systems in accordance with the `Manual of
Sewer Condition Classification' (1980) published by the U.K. National
Water Council, and
(c)
a summary showing the number and type of defects in each pipeline

inspected.
The following items shall be submitted at the same time as the report:
(a)
video film providing a continuous record of the inspection and

information on the monitor screen together with an index showing the
location on the video tape of commencement of each pipe inspection;
and
(b)
photographs of the monitor screen including date and chainage; the

photographs shall be 3R size and shall be mounted in photograph
albums.

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APPENDIX A6.2
DETERMINATION OF THE COMPACTION FRACTION VALUE
OF AGGREGATES FOR GRANULAR BED
A6.2.1 Scope
This method covers the determination of the compaction fraction value of
aggregates for granular bed.
A6.2.2 Apparatus
The following equipment shall be provided:
(1)
a steel open-ended cylinder, 150 mm internal diameter by 250 mm high, with

a wall thickness of not less than 3.5 mm;
(2)
a steel rammer of 40 mm diameter weighing approximately 1 kg; and
(3)
a steel rule calibrated to 1 mm.
A6.2.3 Procedure
(1)
The procedure shall be as described in Clauses A6.2.5 (1) (a) (e)

(a)
The sample shall be placed on a clean surface and shall be divided by

quartering or by using a riffle box to obtain a specimen weighing
approximately 10 kg.
(b)
The cylinder shall be placed on a firm level surface and shall be filled
without tamping with material taken from the sample. Surplus material
shall be struck off level with the top of the cylinder, and cleared from the
area around the cylinder.
(c)
The cylinder shall be lifted clear of the contents and placed alongside
the material.
(d)
Approximately one quarter of the material shall be placed in the cylinder

and compacted using the rammer until no further compaction can be
achieved. The procedure shall be repeated for each of the remaining
three quarters of the material. The top surface shall be compacted as
level as practicable.
(e)
The distance (d) from the top of the cylinder to the top surface of the
material shall be measured to the nearest 1 mm.

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A6.2.4 Calculation
The compaction fraction value of the material shall be calculated from the equation:
Compaction fraction value = d/h
where:
d is the distance from the top of the cylinder to the top surface of the material
(mm),
h is the height of the cylinder (mm).
A6.2.5 Reporting of Results
The following shall be included in the report submitted to the Project Manager:
(1)
identification of sample;
(2)
compaction fraction value to the nearest 0.01;
(3)
source and type of material;
(4)
date of test; and
(5)
statement that the test method used was in accordance with this General
Materials and Workmanship Specification.

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APPENDIX A6.3
DETERMINATION OF THE RESISTANCE
TO FRACTURE OF MANHOLE COVERS AND GULLY GRATINGS
A6.3.1 Scope
This method covers the determination of the resistance to fracture of manhole
covers and gully gratings by means of a load test.
A6.3.2 Equipment
(1)
manufacturer's recommended test frame for the manhole cover or gully

grating or a fabricated test frame of a type reviewed without objection by the
Project Manager which will simulate the normal conditions of use of the cover
or grating;
(2)
circular hardwood bearing block faced with hard rubber or other resilient
material. The diameter of the block shall be as stated in Table 6.6 or Table
6.7 for the relevant cover or grating. The block shall be sufficiently rigid to
ensure that the load is equally distributed over the whole area of the block;
(3)
test loads; and
(4)
equipment for measuring the loads applied, readable and accurate to 0.05 t or
2% of the specified test load, whichever is greater.
A6.3.3 Procedure
The procedure shall be as follows:
(1)
the full bearing area of the frame shall be rigidly supported;
(2)
the cover or grating shall be placed in the frame. The bearing block shall be
placed centrally on the cover or grating;
(3)
the specified test load as stated in Table 6.6 and 6.7 shall be applied without
shock; and
(4)
the specified test load shall be maintained for at least 30 seconds and
removed.

The following shall be induced in the report submitted to the Project Manager:
(1)
identification of sample;
(2)
the load applied, to the nearest 0.05 t or 2% of the specified test load,
whichever is greater;
(3)
details of any fracture or cracks; and
(4)

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APPENDIX A6.4
TESTS ON GRAVITY PIPELINES FOR DRAINAGE WORKS
A6.4.1 Scope
This method covers water tests, air tests, visual inspections and infiltration tests on
gravity pipelines for drainage works.
A6.4.2 Equipment
(1)
expanding disc stoppers or air bags for sealing pipes;
(2)
struts and wedges;
(3)
force pump for water test;
(4)
standpipe for water test;
(5)
measuring vessel for water test, readable and accurate to 0.01 litre;
(6)
U-tube for air test; and
(7)
trolleys to obtain access inside pipelines for visual inspections. Mechanical

fans shall be provided to ensure that an adequate air supply is available;
internal combustion engine driven fans shall be fitted with a flexible exhaust or
other methods of keeping exhaust fumes clear of the fresh air intake.
A6.4.3 Procedure: before Tests and Inspections

The procedure before tests and inspections shall be as follows:
(1)
debris and water shall be removed from the pipeline; and
(2)
openings to the pipeline shall be sealed using expanding disc stoppers or air
bags and the seals secured against movement.
A6.4.4 Procedure: Water Test

The procedure for the water test shall be as follows:
(1)
the pipeline shall be filled with water and shall be kept filled for two hours
before testing starts to allow absorption to take place;
(2)
test pressure of 1.2 m head of water above the soffit of the pipe at the high
end shall be applied at the standpipe and maintained for 30 minutes; the test
pressure applied shall not exceed 6 m head of water at the invert of the low
end of the pipe;
(3)
the head of water at the standpipe shall be topped up at 5 minute intervals

during the test, and shall be filled to the specified head at the end of the test
period; the amounts of water added to the standpipe shall be measured using
the measuring vessel; and

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(4)
the leakage of water from the pipeline shall be measured as the amount of
water added to maintain the specified head of water.
A6.4.5 Procedure: Air Test

The procedure for the air test shall be as follows:
(1)
air shall be pumped into the pipeline until a test pressure of slightly more than
100 mm of water is registered on a U-tube manometer connected to the
pipeline. Five minutes shall be allowed for stabilisation of the air temperature,
and the air pressure shall then be adjusted to 100 mm of water; and
(2)
the pressure shall be read from the U-tube at the end of a five-minute period
without further pumping.
A6.4.6 Procedure: Visual Inspection

The inside of the pipeline shall be inspected visually, and infiltration or damage to
pipes or joints shall be recorded.
A6.4.7 Procedure: Infiltration Test
The procedure for the infiltration test shall be in accordance with BS 8005: Part 1
Clause 13.6.
A6.4.8 Calculation
The permitted leakage of water from the pipeline during the water test shall be
calculated from the equation:
Permitted leakage = d x 1 x
t
60
x P litre
where:
-
d is the internal diameter of the pipe (m),

l is the length of pipeline tested (m),
t is the test period (min),
P is the average test pressure (m).

(1)
nominal internal diameter of the pipe to the nearest 1 mm;
(2)
location and length of pipeline tested to the nearest 0.3 m;
(3)
test pressure applied during the water test to the nearest 0.01 m, and during
the air test to the nearest 1 mm head of water;
(4)
test period to the nearest 1 min;
(5)
leakage and permitted leakage for the water test to the nearest 0.1 litre;

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(6)
amount of infiltration and permitted amount of infiltration for the infiltration test
to the nearest 0.1 litre;
(7)
details of any discernable leakage of water from the pipe or from any joint
during the water test; and
(8)

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APPENDIX A6.5
TESTS ON PRESSURE PIPELINES FOR DRAINAGE WORKS
A6.5.1 Scope
This method covers the determination of the leakage of water from pressure
pipelines for drainage works by means of a pressure test.
A6.5.2 Equipment
(1)
blank flanges or caps;
(2)
struts and wedges;
(3)
temporary concrete blocks or other anchors;
(4)
force pump;
(5)
pressure gauge, readable and accurate to 0.01 m head of water. The gauge
shall be either a conventional circular type of at least 300 mm diameter or
shall be a digital indicator type; and
(6)
measuring vessel, readable and accurate to 0.01 litre.
A6.5.3 Procedure
(1)
pipes and valves shall be cleaned and the operation of valves shall be
checked. Air valves shall be isolated.
(2)
blank flanges or caps shall be fixed to the ends of the pipeline, or part of the
pipeline, to be tested. Tests shall not be made against closed valves.
(3)
the blank flanges and caps and closed valves against which tests are made
shall be secured with struts and wedges against temporary concrete blocks or
other anchors. The blocks shall be completed and shall have hardened
sufficiently before testing starts. Thrust and anchor blocks, pipe straps and
other devices required to prevent movement of pipes and fittings shall be
completed before testing starts.
(4)
the pipeline shall be filled with water and all air shall be removed; measures
shall be taken during filling to provide free outlets for air and to prevent water
hammer.
(5)
the pressure in the pipeline shall be increased to working pressure and the
pipeline shall remain filled at this pressure for 2 hours to allow absorption to
take place and to achieve conditions which are as stable as practicable.
(6)
the pressure in the pipeline shall be increased slowly by pumping water into
the pipeline using a force pump until the specified test pressure is reached at
the lowest part of the pipeline being tested.

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(7)
the pressure in the pipeline shall be maintained at the specified test pressure,
using the force pump if necessary, for a period of at least 1 hour.
(8)
at the end of the 1 hour period the pressure shall be increased, if necessary,
to the specified test pressure and pumps and water supply points shall be
disconnected.
(9)
the pipeline shall be left in this condition for a test period of 1 hour; no water
shall be allowed to enter the pipeline during the test period.
(10) at the end of the test period the pressure in the pipeline shall be recorded.
(11) the pumps and water supply points shall be reconnected and the pressure
shall be increased to the specified test pressure.
(12) water shall be drawn off from the pipeline until the pressure in the pipeline is
the same as at the end of the test period. The leakage of water from the
pipeline shall be measured as the amount of water drawn off.
A6.5.4 Calculation
(1)
The average test pressure (P) shall be calculated as the average of the
specified test Pressure and the pressure at the end of the test period.
(2)
The permitted leakage of water from the pipeline during the pressure test shall
be calculated from the equation:
Permitted leakage = d x 1 x
t
12
x P litre
where:
-
d is the nominal internal diameter of the pipe (m),
l is the length of pipeline tested (km),
t is the test period (hr),
P is the average test pressure (m).

(1)
the nominal internal diameter of the pipe;
(2)
the location and length of pipeline tested to the nearest 0.3 m;
(3)
the test period to the nearest one minute;
(4)
the specified test pressure to the nearest 0.01 m head of water;
(5)
the pressure at the end of the test period to the nearest 0.01 m head of water;
(6)
the average test pressure to the nearest 0.01 m head of water;

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(7)
leakage and permitted leakage to the nearest 0.1 litre;
(8)
details of any discernable leakage of water from the pipeline during the test;
and
(9)
that the test method used was in accordance with this General Materials and

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APPENDIX A6.6
SPECIFICATION FOR POLYETHYLENE PIPES AND FITTINGS
1.
2.
3.
General
1.1
The manufacturer for the supply of polyethylene pipes and fittings shall
operate a quality system relating to the relevant part(s) of the specification
stated hereunder in accordance with BS EN ISO 9002 or similar equivalent
standard. The manufacturer's quality assurance certificates issued by an
independent third party certification body shall be submitted to the Project
Manager for review without objection. Such certificates shall be valid at the
time the pipes and fittings are manufactured.
1.2
Polyethylene pipes and fittings shall be used aboveground for the

conveyance of sewage discharge.
Definitions
2.1
Nominal outside diameter of a polyethylene pipe shall mean the minimum

mean outside diameter of the pipe as described in Clause 3.1 of IS0 16 1-1.
2.2
Nominal wall thickness of a polyethylene pipe shall mean the minimum wall
thickness of the pipe as described in Clause 3.4.5 of BS IS0 11922-1.
2.3
The Standard Dimension Ratio (SDR) of a polyethylene pipe shall mean the
ratio of its nominal outside diameter to its nominal wall thickness as described
in Clause 3.8 of IS0 161-1.
2.4
WIS shall mean the Water Industry Specification produced and published by
WRc.
Polyethylene Pipes
3.1
PE80 and PE 100 pipes with nominal outside diameter from 90mm to
1000mm inclusive shall conform to IS0 4427.
3.2
PE80 and PE100 pipes shall have a SDR of 17.6 and have nominal pressure
rating as follows:
PEl00 - 10 bar (PNl0)
3.3
The colour for polyethylene pipes shall be black within the range below:
3.4
Nominal Outside
Diameter
Colour Range
90mm 1000mm
20D44 to 20D45 or 20E53 to 20E56 of BS

5252
The tolerance on the nominal outside diameter of polyethylene pipes shall be

in accordance with Grade B of BS ISO 11922-1.

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January 2011
3.5
The end of the pipe shall be cut cleanly and square to the axis of the pipe to
within the tolerances given below:
Nominal Outside
Diameter
4.
Maximum Tolerance (mm)
125mm
180mm or above
3.6
Standard length of polyethylene pipes shall be 5m. No reduction in the

specified length shall be allowed unless reviewed without objection by the
Project Manager.
3.7
Melt flow rate of PE80 and PE 100 pipes tested at a temperature of 190C
under a nominal load of 5kg shall be within the range of 0.2g/10 min to
1.3g/10 min.
Fittings for Polyethylene pipes

4.1
All fittings for polyethylene pipes shall have a pressure rating the same as or
higher than the nominal pressure rating of the pipes. The fittings shall be
supplied with complete set of accessories including insert, liners, joint rings,
flange gaskets, studs, bolts and nuts, etc. whatever appropriate.
4.2
The flanges of all fittings shall be constructed in such a way that they may be
attached to flanges designated PN16 whose dimensions conform to Table 9
of BS EN 1092-2. One complete set of bolts and nuts and one gasket shall
be supplied with each flange of flanged fittings. The strength of bolts shall be
Grade 4.8 and the strength of nuts shall be Grade 4 complying with BS 4190.
The bolts and nuts shall be hot dip galvanized or have other protective
coatings reviewed without objection by the Project Manager.
4.3
Polyethylene Electrofusion Fittings
4.3.1
Polyethylene electrofusion fittings including couplers, reducers, socket ends

tees, caps and elbows, self tapping tee saddles and other electrofusion
fittings shall comply with WIS 4-32-14. Polyethylene spigot fittings for
electrofusion jointing including the spigot stub flange assembly shall comply
with WIS 4-32-15. Stub flanges shall comply with WIS 4-24-01.
4.3.2
Melt flow rate of PE80 and PE100 electrofusion fittings tested at a

temperature of 190C under a nominal load of 5kg shall be within the range of
0.2g/10 min to 1.3g/10 min.
4.3.3
Notwithstanding Clause 5.1.6 of WIS 4-32-14, the fittings shall be capable of

being fused in the tropics.
4.3.4
The design of fitting terminals and shrouds shall be similar to that stated in
Clause 5.2.3 of WIS 4-32-14. Other designs of terminals will only be
considered if the Contractor can demonstrate that the appropriate lead
adaptor is readily available such that electrofusion of their fittings can be
conducted using common electrofusion control units available in the market.
4.3.5
All electrofusion fittings shall be black in colour within the range as specified
in Clause 3.3 of this Appendix A6.6.

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5.
6.
7.
4.4
Compression Fittings for Polyethylene Pipes
4.4.1
Compression fittings with external and/or internal threads shall be compatible

with pipes and fittings threaded to BS 21.
4.5
Mechanical Fittings for Polyethylene Pipes
4.5.1
Mechanical fittings for polyethylene pipes of nominal outside diameter 90mm

and above shall be Type 1 fittings conforming to WIS 4-24-01.
4.5.2
Mechanical fittings shall be coated with a minimum thickness of 250 microns

of epoxy or plastic based coating complying with the performance
requirement of WIS 4-52-01.
Samples and Submissions

5.1
A sample for each of the polyethylene pipes and fittings supplied shall be
submitted to the Project Manager for review without objection before placing
material order.
5.2
If required, a copy of the latest Manufacturer's type test reports required

under each of the above ISO and WIS shall be submitted to the Project
Manager for information.
5.3
For all non-metallic components of the polyethylene pipes and fittings

including coatings, certificates issued by an independent testing
laboratory/inspection authority showing compliance with BS 6920 shall be
Markings
6.1
Markings on the polyethylene pipes and fittings shall be in accordance with

the relevant clauses in the ISO or WIS appropriate to the pipes and fittings
supplied.
6.2
Notwithstanding Clause 8 of ISO 4427, the pipes series in SDR shall be

marked on the pipes.
6.3
Notwithstanding Clause 10 of ISO 14236, the designation of the material

(PE80 or PE100) and the number "ISO 14236" shall also be marked on the
compression fittings.
Packaging of Fittings
7.1
All fittings (including electrofusion fittings) shall be delivered ex-factory

together with all accessories such as bolts, ,nuts, washers, inserts,
compression rings, gaskets and other things necessary for the completion of
the joint in a complete set inside a separate polythene bag or equivalent
packaging.

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January 2011
8.
Testing and Inspection

8.1
The quality control tests listed in the following clauses of WIS shall be subject
to inspection by an independent inspection agent:
(a)
(b)
(c)
8.2
Clause 5 of WIS 4-24-01

Clause 7 of WIS 4-32-15
Clauses 5.1.2 and 8 of WIS 4-32-14
For quality control on manufacturing of the pipes, the following tests listed in
ISO 4427 shall be subject to inspection by an independent inspection agent:
(a)
(b)
(c)
(d)
(e)
Clause 3.3
Clause 3.7 - melt flow rate test only
Clauses 4.1 and 4.2
Clause 5.1 - 100 hour at 20C and 165 hour at 80C only
Clause 6.3 b)
In addition, the internal and external surfaces of the pipes shall be smooth
and free from defects which might otherwise impair their performance in
service.
8.3
For quality control on manufacturing of the compression fittings, the following

tests listed in ISO 14236 shall be subject to inspection by an independent
inspection agent:
(a)
(b)
8.4
Clause 6.1
Clauses 8.3.4.2 and 8.3.4.3
Polyethylene materials for both PE80 and PE100 shall be tested in

accordance with the Chlorine Water Test specified in Clause 9.8 of the
Japanese Industrial Standard (JIS) K6762 and the performance of the
polyethylene materials shall comply with the chlorine-water resistance for
single wall pipe specified in Clause 5 of the JIS K6762. Test certificates shall
be submitted to the Project Manager for review without objection.

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SECTION 7
EARTHWORKS
7.1
7.1.1
Areas of Fill
Areas of fill are areas within the Site, including areas in embankments, platforms
and slopes and in excavations for structures, pits and trenches, in which fill material
is deposited and compacted as part of the Permanent Works.
7.1.2
Earthworks Final Surface and Formation

Earthworks final surface is the surface to which the work included in Section 7 is
finished. Formation is that part of the earthworks final surface on which a
pavement, structure or utility, is constructed, or on which the blinding or bedding for
a pavement, structure or utility is placed.
7.1.3
Earthworks Material
Earthworks material may consist of soil, rock, crushed concrete or crushed inert
demolition material which is on or below the Site at the commencement of the
Contract, or which is imported to the Site to carry out the Works.
7.1.4
Topsoil
Topsoil shall mean the surface material which contains humus and supports
vegetation.
7.1.5
Rock, Boulders and Materials other than Rock

Rock shall mean all naturally occurring hard strata which would normally be
removed by blasting, by ripping, by chemical, gas or mechanical bursting agents, by
hydraulic breaker, by pneumatic drills or by wedges and sledge hammers if
removed by hand.
Boulders are isolated volumes of Rock which exceed 0.2m and are contained in a
matrix of Material other than Rock.
Material other than Rock shall mean material which cannot be classified as
Topsoil or Rock.
7.1.6
Public Fill
Public fill shall mean the inert material arising from construction and demolition
activities such as site clearance, excavation, construction, refurbishment,
renovation, demolition and roadworks. Public fill comprises material including stone,
rock, masonry, brick, concrete, soil and other inert material. There is no size
limitation on the public fill, and a small amount of timber mixed with otherwise
suitable material is permissible. The public fill may also consist of wet soil.

Section 7 - Earthworks
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January 2011
7.2
MATERIALS
7.2.1
Fill Material
(a)
Fill material, other than public fill, shall consist of naturally occurring or
processed material which at the time of deposition is capable of being
compacted in accordance with the specified requirements to form stable areas
of fill.
(b)
Fill material shall not contain any of the following:

(i)
material susceptible to volume change, including marine mud soil with a

liquid limit exceeding 65% or a plasiticity index exceeding 35%, swelling
clays and collapsible soils;
(ii)
peat, vegetation, timber, organic, soluble or perishable material;
(iii)
dangerous or toxic material or material susceptible to combustion;
(iv)
metal, rubber, plastic or synthetic material;
(v)
material susceptible to volume change, marine mud or material from

swamps; or
(vi)
other environmentally unacceptable contaminants.
(c)
The different types of fill material shall have the particle size distributions
within the ranges stated in Table 7.1.
(d)
Special fill material shall consist of material which has a liquid limit not
exceeding 45%, a plasticity index not exceeding 20% and a coefficient of
uniformity exceeding 50.
(e)
Granular fill material shall consist of clean, hard, durable material.
(f)
Rock fill material shall consist of pieces of hard, durable rock of which not
more than 30% by mass is discoloured or shows other evidence of
decomposition. Crushed rock or crushed concrete may be permitted subject
to review without objection by the Project Manager.
(g)
The Contractor will not be permitted to erect a crushing plant under the Contact.
(h)
The soluble sulphate content of fill material placed within 500 mm of concrete,
cement bound material or cementitious material shall not exceed 1.9 grams of
sulphate, expressed as SO3, per litre.
(i)
The total sulphate content, expressed as SO3, of fill material placed within
500 mm of metalwork shall not exceed 0.5% by mass.
(j)
The use of public fill as fill material for earthworks shall only be permitted if the
fill material complies with the particular requirements stated in the Contract
and is reviewed without objection by the Project Manager.

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January 2011
(k)
Well-graded material shall consist of material which has a coefficient of

uniformity exceeding 10.
(l)
Uniform-graded material shall consist of material which has a coefficient of

uniformity of 10 or less.
Table 7.1:
Particle Size Distributions of Fill Material

Type of fill material
Size
400 mm 200 mm
BS test sieve
75 mm
20 mm
600 mm
63 mm
Fine fill material
100
General fill material
100
75 - 100
Special fill material
100
0 - 45
Granular fill material
100
0-5
Rock fill material (Grade 200)
100
20 - 75
0 - 50
Rock fill material (Grade 400)
100
20 - 75
10 - 30
0 - 25
7.3
SUBMISSIONS
7.3.1
Particulars of Earthworks
(a)
The following particulars of the proposed materials and methods of

construction for earthworks shall be submitted to the Project Manager for
(i)
details of Contractor's Equipment and haulage vehicles;
(ii)
methods of excavation and of deposition and compaction of fill material;
(iii)
use of different types of excavated material and sources of imported fill

material;
(iv)
arrangements for stockpiling excavated material and fill material and for
disposing of earthworks material;
(v)
methods of controlling the moisture content of fill material;
(vi)
methods of controlling surface water and groundwater and of protecting

earthworks and earthworks material from damage due to water and
from weather conditions which may affect the earthworks or earthworks
material;
(vii) types of instrumentation and methods of monitoring groundwater levels;

(viii) types of instrumentation and methods of monitoring the ground and
structures for movements;

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January 2011
(b)
(ix)
methods of dealing with existing water courses so as to maintain

existing drainage path; and
(x)
any special methods/sequence of work for earthworks adjacent to

structures.
Where the Contractor proposes to form temporary slopes or proposes any

form of temporary support to earthworks, then he shall submit full supporting
calculations and the provisions of Section 2 of this General Materials and
Workmanship Specification shall apply.
7.4
WORKMANSHIP
7.4.1
Ownership of Earthworks Material
7.4.2
(a)
Earthworks material within the Site at the commencement of the Contract

shall remain the property of the Employer except as stated in Clause 7.4.1(b).
(b)
Earthworks material which is required to be disposed of by the Contractor

shall become the property of the Contractor when it is removed from the Site
and shall be disposed of in accordance with the Employers guidelines for
disposal of construction waste and Section 7 of the General Specification.
Temporary Works for Earthworks

The Contractor shall be fully responsible for the design, installation, dismantling and
removal of all temporary supporting systems for earthworks. The Contractor shall
submit to the Project Manager for review without objection the full supporting
calculations for any proposed temporary slopes or any form of temporary support to
earthworks and the provisions of Section 2 of this General Materials and
Workmanship Specification shall apply.
7.4.3
Temporary Access and Drainage

The Contractor shall provide and maintain temporary access roads and temporary
drainage and shall divert and reinstate permanent drainage systems. Temporary
access roads shall be provided with drainage ditches over their full length. Details of
any such temporary works shall be submitted to the Project Manager and his
consent in writing shall be obtained before construction commences.
7.4.4
Handling and Storage of Earthworks Material

(a)
Earthworks material shall not be handled or stored in a manner which will

result in segregation, deterioration, erosion or instability of the material.
(b)
Different types of earthworks material shall be kept separate from each other.
Earthworks material which is suitable for use as fill material shall be
maintained in a suitable condition and shall not be contaminated.

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7.4.5
Protection from Water and Weather and Protection of Existing Instruments

(a)
Earthworks after site clearance, excavation or filling and earthworks material

after excavation shall be kept free from water and shall be protected from
damage due to water and from exposure to weather conditions which may
affect the earthworks or earthworks material. The measures to be taken shall
include the following:
(i)
all safety measures stated in the Contract;
(ii)
surfaces shall be maintained in a stable condition and shall be formed to

falls to shed water and to prevent ponding;
(iii)
the area of exposed surfaces shall be kept to a minimum;
(iv)
surface water flowing into the Site and within the Site shall be
intercepted and diverted from the Site to a suitable discharge point;
(v)
at each intersection and abrupt change of direction of surface drainage

channels an accessible catchpit shall be provided;
(vi)
all drainage works shall be kept clear of debris and silt; and
(vii) where partially completed drainage works discharge within the Site a
temporary conduit shall be provided to the discharge point.
(b)
Excavations for structures, pits and trenches shall not be carried out on or
adjacent to slopes unless measures are taken to drain the excavation and to
prevent water from the excavation entering the slope.
(c)
Geotechnical Instrumentation
(i)
The Contractor shall note the existence of any instrumentation, for

example, piezometers, inclinometers and surface movement
monuments, and shall install a prominent marker post at each such
instrument.
(ii)
Instruments shall not be removed or disturbed in any way except in

accordance with sub-clauses (iii) and (iv) below. Any instrument
damaged by the Contractor shall be reinstated by him immediately.
(iii)
Certain instruments shall be maintained as the Works proceed around

them. Working methods shall take account of this requirement and
piezometer / settlement marker / inclinometer tubes shall be shortened
or lengthened as necessary. When the adjacent works have reached
their final level, a protective concrete box or other surface structure shall
be constructed and a prominent marker post shall be installed.
(iv)
Certain instruments shall be removed as the Works proceed but not

until the Project Manager has confirmed that it is necessary for the
progress of the Works in each case.

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7.4.6
7.4.7
Earthworks Material Allowed to become Unsuitable or to Deteriorate

(a)
Earthworks material which has been used, or is required for use, in the
Permanent Works and which is allowed to become unsuitable such that in the
opinion of the Project Manager it no longer complies with the specified
requirements for that type of material shall be replaced or dealt with by
(b)
Earthworks material which is not stated in the Contract to be excavated and

which the Contractor causes or allows to deteriorate such that in the opinion
of the Project Manager the Permanent Works will be affected shall be
replaced or dealt with by methods reviewed without objection by the Project
Manager.
(c)
Material provided to replace earthworks material which has been allowed to

become unsuitable or which the Contractor causes or allows to deteriorate
shall be an equivalent material reviewed without objection by the Project
Manager. The replacement material shall have the same volume after
compaction as the material replaced.
(d)
The material which is to be replaced shall be disposed of by the Contractor.
Additional Excavation and Stabilisation

(a)
Earthworks material which is not stated in the Contract to be excavated but

which in the opinion of the Project Manager has inadequate strength,
durability or stability shall be dealt with by additional excavation and filling as
stated in Clause 7.4.7(b) or by stabilisation as stated in Clause 7.4.7(c).
(b)
Additional excavation shall be carried out and the resulting voids shall be
dealt with as follows:
(i)
general fill material, fine fill material or special fill material shall be
deposited and compacted below areas of fill and below formations other
than in rock;
(ii)
Grade 15 concrete shall be placed and compacted below formations in

rock; and
(iii)
granular fill material shall be deposited below standing water.
(c)
Stabilisation shall be carried out using rock fill material (Grade 400) deposited
directly into the original unstable material and compacted to form a stable
foundation on which to construct the subsequent work.
(d)
During the wet season where temporary bare earth slope faces are
unavoidable they shall be protected with impermeable sheeting well secured
against the wind. Where slope faces steeper than 50 and higher than 5 m are
to be temporarily exposed for more than two weeks temporary hard surfacing,
such as chunam, shall be provided and temporary drains shall be installed.

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January 2011
7.4.8
Removal of Earthworks Material

Earthworks material which is required for use in the Permanent Works as fill
material shall not be removed from the Site. The Contractor shall notify the Project
Manager before any earthworks material is removed from the Site.
7.4.9
Disposal of Excavated Material

(a)
(b)
7.4.10
7.4.11
Excavated material which cannot be selected, processed or mixed in a

practical manner to make it suitable for use in the Permanent Works as fill
material shall be disposed of by the Contractor unless otherwise stated in the
Contract.
The Contractor shall not dispose of any materials of any type obtained from
within the Site without the permission of the Project Manager.
Disposal of Surplus Fill and Fill Containing Materials as Defined in Clause

7.2.1(b)
(a)
Pursuant to Clause 7.4.10(b), excavated or imported materials (other than

those dredged), surplus to the requirements of or unsuitable for use in the
Works as defined in Clause 7.2.1(b) shall be disposed of by the Contractor as
defined below. The Contractor shall, prior to disposal, screen the surplus
materials to yield general fill materials and rock fill material.
(b)
Rock fill material which cannot be incorporated in the Works shall be deposited
in the stockpiles designated by the Project Manager.
(c)
Fill materials other than rock fill material and materials as defined in Clause
7.2.1(b)(i) to (vi) which cannot be incorporated in the Works shall be deposited
and compacted in accordance with Clause 7.4.26 in the stockpiles designated
(d)
Materials as defined in Clause 7.2.1(b)(i) to (vi) shall become the property of

the Contractor who shall dispose of such materials off-Site.
Use of Excavated Material

(a)
Excavated material required for use in the Permanent Works which is capable
of being selected, processed and mixed to make it suitable for use as fill
material shall not be used for any other purposes.
(b)
Such excavated materials shall be selected and/or processed by using a

suitable screening system. If necessary, the Contractor shall blend materials to
obtain fill materials to meet the various requirements.
(c)
Excavated material which is required for use in the Permanent Works as fill
material and which the Project Manager permits to be removed from the Site
or used for other purposes shall be replaced by an equivalent material
reviewed without objection by the Project Manager. The replacement material
shall have the same volume after compaction as the material which is
replaced.

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January 2011
7.4.12
Boulders in Excavations
Boulders which project through the earthworks final surface or formation shall be
dealt with as excavation proceeds by methods reviewed without objection by the
Project Manager. Boulders shall not be left protruding.
7.4.13
7.4.14
7.4.15
Excavation
(a)
Temporary supports or other methods shall be used to maintain excavations

in a stable condition and to prevent settlement of structures or utilities due to
excavation or dewatering.
(b)
Contractor's Equipment or other vehicles shall not be operated or parked

adjacent to excavations. Earthworks material or other materials shall not be
placed adjacent to excavations unless this has been allowed for in the design
of the Temporary Works for the support of the excavation.
(c)
Temporary groundwater control of excavation shall be carried out in

accordance with the requirements stated in Clause 8.18.9 and Clauses
8.19.16 to 8.19.19 inclusively.
Excavations Adjacent to Structures and Utilities

(a)
Excavations shall be carried out by hand adjacent to, and around utilities that
are known, proven or suspected to exist.
(b)
Excavations adjacent to existing structures shall be carried out by hand.
Excavations for Structures, Pits and Trenches

(a)
Excavations for structures, pits and trenches shall be the minimum size
necessary to construct the Permanent Works.
(b)
The length of trench excavation left open at any one time shall not exceed
that permitted by the Project Manager.
(c)
Trenches for utilities in areas of fill shall not be excavated until the fill material
has been deposited and compacted up to the earthworks final surface or
formation or up to 1 m above the top of the utility, whichever is lower.
(d)
The sides of pits and trenches shall be adequately supported at all times.
Alternatively except where the Contract expressly requires otherwise they may
be suitably battered.
(e)
The bottom of all excavations shall be levelled carefully and stepped or

benched horizontally as shown on the Employers Drawings. Any pockets of
soft material or loose rock in the bottoms of pits and trenches shall be removed
and the resulting cavities and any large fissures filled with Grade 10 concrete.
After the placing of any blinding concrete required by the Contract, no trimming
of the side faces shall be carried out for 24 hours.

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January 2011
(f)
7.4.16
The Contractor shall make good with fill material as defined in Clause 7.2.1 or
concrete as directed by the Project Manager:
(i)
Any excavation greater than the net volume required for the works as
described in the Contract.
(ii)
Any additional excavation at or below the bottom of foundations to

remove material which the Contractor allows to become unsuitable.
Rock Splitting Using a Special Technique

(a)
Where shown on the Employers Drawings or directed by the Project

Manager, non-explosive rock-splitting techniques shall be used to form the
finished rock face. Such techniques include expanding chemical grout and
uncharged drillholes.
(b)
Parallel holes shall be drilled in the final excavation face. The spacing of the
holes shall be determined in relation to the diameter of the drillhole and shall
be within the range of 400-1000 mm.
(c)
Before starting splitting along the final excavation face in any given type and
condition of rock, trials shall be carried out at least 6 m away from the final
face to produce results acceptable to the Project Manager, with a minimum
trial length of 4 m. The following details of the procedures used shall be
submitted to the Project Manager at least 24 hours before starting to drill in
the final excavation face:(i)
diameter, spacing, depth and subdrill of rock-splitting holes; and
(ii)
when using expanding chemical grout, chemical composition of the

grout and mix ratio of chemical (kg): water (kg).
(d)
After review without objection by the Project Manager of the trial results, the
procedures used shall be the same in all respects as in the trial. Drilling a set
of rock-splitting holes in the plane of the final rock-face shall not proceed until
at least 50% of the face formed by the previous adjacent splitting has been
exposed and the results assessed.
(e)
If the rock-splitting results deteriorate because of changes in the jointing or

degree of weathering of the rock mass, without a major change necessitating
new trials as sub-clause (c) hereof, procedures shall be modified as
necessary, with the agreement of the Project Manager, and rock splitting shall
continue in lengths of not more than 6 m until fully satisfactory results are
again achieved. If necessary in the opinion of the Project Manager, new
proposals shall be submitted in accordance with Clause 7.4.16(c) and this
Clause, before continuing.
(f)
Chemical grout holes shall not be charged until the rock broken by previous
operations has been mucked out.
(g)
When the chemical grout has expanded fully, the rock in front of the plane of
the drillholes shall be broken out and all traces of the solidified chemical
removed.
(h)
After drilling the rock-splitting holes, (for uncharged drillholes) the rock in front
of the plane of the drillholes shall be broken out by a mechanical rock breaker.

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January 2011
7.4.17
Surface Preparation for Fill Material

Surfaces on which fill material is to be deposited shall be prepared after site
clearance in accordance with the following requirements:
7.4.18
(a)
topsoil, grass, and other organic matter shall be removed;
(b)
soft spots, boulders and other materials which are unsuitable or unstable shall
be removed;
(c)
watercourses shall be diverted in accordance with methods reviewed without

objection by the Project Manager;
(d)
benches shall be cut and sub-soil drainage systems installed as stated in the
Contract;
(e)
voids shall be dealt with as stated in the Contract or instructed by the Project
Manager; and
(f)
topsoil, soil, material other than rock and all material which is capable of being
scarified, shall be scarified to a depth of 200 mm and compacted to the same
standard as the fill material which is to be deposited.
Commencement of Deposition of Fill Material

The Contractor shall notify the Project Manager before deposition of fill material
starts in any area of fill.
7.4.19
Haulage of Fill Material

Haulage of fill material to an area of fill shall commence only when the specified
requirements for relative compaction of the fill material have been achieved.
7.4.20
Deposition of Fill Material

(a)
Fill material obtained from excavations within the Site shall be deposited in its
final location as soon as practicable after it has been excavated.
(b)
Fill material shall be deposited in layers of a thickness appropriate to the

compaction method to be used.
(c)
Layers of fill material shall be horizontal, except for any gradient required for
drainage, and the thickness of each layer shall be uniform over the area to be
filled.
(d)
Except in excavations for structures, pits and trenches, if the difference in

level between adjacent areas to be filled exceeds 1 m the edge of the higher
area shall be benched before fill material is placed against it.
(e)
The construction of the Works shall be controlled in such a manner that any
compaction of the fill material, including that resulting from the passage of
Contractor's Equipment or haulage vehicles is uniform.

10/37
January 2011
(f)
Fill material shall not be deposited by end-tipping, by pushing loose material

down slope faces or by other methods which may result in segregation or
inadequate compaction of the fill material.
(g)
Isolated boulders each within the range 0.015 cu m to 0.10 cu m in size may be
incorporated in embankments not of rockfill at the discretion of the Project
Manager provided that the specified compaction requirements are met and no
stone exceeding 0.015 cu m shall be placed less than 2 m below formation
level of carriageways or hardshoulders.
(h)
In reclamation, before any other material is dumped within 90 m of any seawall,

material shall first be dumped immediately behind the wall to a width of 15 m to
30 m by working outwards from the wall unless the Project Manager directs
otherwise. If directed, the Contractor shall also dump material in bunds to form
self-contained areas before filling the remaining area.
An accurate and up-to-date record showing dates, weather conditions,
approximate elevations, source of materials, compactive effort etc shall be kept
by the Contractor showing when fill is placed in various locations within the Site.
This record shall be available for inspection by the Project Manager. The
Contractor shall also record the results of all compaction and in-situ density
tests and shall identify these results with the various locations and elevations at
which fill material has been placed and the location from which the fill material
was obtained.
(i)
7.4.21
Overfilling
In areas of fill formed of fill material other than rock fill material, earthworks final
surfaces sloping at a gradient exceeding 1 vertical to 3 horizontal shall be formed
by overfilling and cutting back after compaction. Over-filling shall extend beyond the
earthworks final surface by a horizontal distance of 0.5 m or two times the thickness
of the compacted layer, whichever is greater.
7.4.22
Deposition of Fill Material Adjacent to Structures and Utilities

(a)
Except as stated in Clause 7.4.22(d), fill material deposited within 0.5 m of a

structure or utility shall be fine fill material unless otherwise stated in the
Contract. In addition, the material may contain up to 5% by weight of fresh,
slightly decomposed or moderately decomposed rock fragments of up to 200
mm provided that these do not cause any damage to structures, nor do they
interfere with the compaction requirements.
(b)
Fill material shall not be deposited adjacent to or above structures or utilities

until the construction of the structure or utility is sufficiently advanced to
accept the imposed forces without disturbance or damage.
(c)
Fill material shall be deposited evenly on all sides of structures and utilities
and in such a manner that the structure or utility is not disturbed or damaged.
(d)
Unless otherwise stated in the Contract, fill material around water, sewage
and drainage pipes which are constructed as part of the Permanent Works
shall be special fill material as defined in Clause 7.2. Fill material shall be
deposited in layers not exceeding 100 mm thick to a level of 300 mm above
the top of the pipe. Fill material shall be deposited in such a manner that the
layer on one side of the pipe is not more than 100 mm higher than the layer
on the other side.

11/37
January 2011
7.4.23
7.4.24
(e)
Backfill material more than 300 mm above the top of the pipe should be
general fill material compacted in layers not exceeding 250 mm thick.
(f)
Fill material shall be brought up to original ground level or the earthworks final
level or as directed by the Project Manager.
Deposition of Rock Fill Material

(a)
The final compacted thickness of each layer of rock fill material shall exceed
1.5 times and shall not exceed twice the nominal grade size of the rock fill
material.
(b)
The surface voids of each layer of rock fill material shall be filled with
fragments of rock before the next layer is deposited. The final surface of rock
fill material shall also be blinded with fine fill material.
Deposition of Fill Material in Excavations for Structures, Pits and Trenches

If sheet piling, timbering or other temporary supports to excavations for structures,
pits and trenches are not to be left in place, the sheet piling, timbering or supports
shall be removed as deposition of fill material proceeds. The supports shall be
removed in such a manner that the stability of the adjacent ground is maintained
and the compacted fill material is not disturbed.
7.4.25
7.4.26
Deposition Compaction of Materials in Trenches and Pits in Carriageways and

Footways
(a)
Trenches and pits cut in carriageways and footways, which are to remain
open to traffic only during the term of the Contract, shall be backfilled and
compacted, to the underside of the adjacent pavement construction or to a
level 260 mm below the surface, whichever is the lower. The next layer of
backfilling shall be sub-base to a level 60-100 mm, as directed by the Project
Manager, below the surface of adjacent construction.
(b)
A tack coat of bituminous emulsion shall be applied to the surface of the

compacted sub-base and the edges of the existing pavement except the
edges of the friction course exposed by the excavation. Tack coating shall be
applied as specified in Clause 9.5.6(d).
(c)
The backfilling shall be completed with 60-120 mm of bituminous roadbase,

as specified in Clause 9.3.2.
Compaction of Fill Material

(a)
Fill material in areas of fill shall be compacted in layers to a stable condition

as soon as practicable after deposition and in a manner appropriate to the
location and to the material to be compacted.
(b)
The Contractor shall notify the Project Manager before the next layer is
deposited on each layer of compacted fill material.

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January 2011
(c)
7.4.27
Except as stated in Clauses 7.4.27(a), 7.4.29(b) and 7.4.32(b), fill material

shall be compacted to obtain a relative compaction as determined by the
modified Proctor test as defined in BS 1377-4;1990 and tests defined in
Geospec 3 of at least:
(i)
95% throughout;
(ii)
98% within 200 mm of formations.
Compaction of General Fill Material with a Large Portion of Coarse Material

(a)
General fill material with material of which less than 90% passes a 20 mm BS
test sieve, where it is not possible to determine the moisture content and
maximum dry density according to the testing methods stated in Appendices
A7.1 to A7.5, shall be compacted to the requirements of Sub-Clauses (b), and
(c), or (d) of this clause.
(b)
Spread and level each horizontal layer of general fill material with a thickness
not less than 1.5 times of the maximum size of the general fill material and not
exceeding the maximum depth of compacted layer in accordance with Table
7.2. If this criterion is not met due to the presence of over-sized coarse
material in the general fill, the over-sized coarse material shall be removed or
broken down to sizes acceptable to the Project Manager. Each layer shall be
systematically compacted by a vibratory roller with the stipulated minimum
number of passes corresponding to the minimum static load per 100 mm
width of the roller.
(c)
The number of passes of the roller shall only be counted when the roller has
travelled on the material to be compacted at a speed of not more than 2 km
per hour with full vibration. Plant other than a vibratory roller used to carry out
material spreading or to provide some preliminary compaction only to assist
the use of heavier plant shall be disregarded in counting the number of
passes.
(d)
Variation from the method or the use of plant different from that specified in
Sub-Clause (b) of this Clause will be permitted only if the Contractor
demonstrates by Site trials that equivalent compaction is achieved by the
alternative method. The procedure to be adopted for these Site trials shall be
agreed with and reviewed without objection by the Project Manager.
(e)
Without prejudice to the General Conditions and in order that the Project
Manager may make proper provision for the supervision of compaction in the
permanent work, the Contractor shall, not less than 48 hours before he
proposes to carry out compaction processes, apply in writing to the Project
Manager for permission to do so.
(f)
When materials of widely divergent characteristics are used in embankments

and fill areas they shall be spread and compacted in separate clearly defined
areas.
(g)
If more than one class of material is being used in such a way that it is not
practicable to define the areas in which each class occurs, compaction plant
shall be operated as if only the material which requires the greatest
compactive effort is being compacted.

13/37
January 2011
Table 7.2: Compaction Requirement for General Fill Material with a Large
Portion of Coarse Material
Force per 100mm
width
(kN)
Well-graded material
Maximum
depth of
compacted
layer
(mm)
0.25-0.45
0.46-0.70
0.71-1.25
1.26-1.75
1.76-2.30
2.31-2.80
2.81-3.50
3.51-4.20
4.21-4.90
7.4.28
Minimum no.
of passes
125
150
150
175
200
225
250
12
8
4
4
4
4
4
Uniform-graded material
Maximum
depth of
compacted
layer
(mm)
150
150
150
200
225
250
275
300
300
Minimum no.
of passes
16
12
6
10
12
10
8
8
8
Moisture Content of Fill Material

Fill material other than rock fill material and material as stated in Clause 7.4.27(a)
shall be at optimum moisture content during compaction. Fill material at a moisture
content within 3% of the optimum moisture content, may be acceptable provided
that it is capable of compaction, in accordance with the specified requirements, to
form stable areas of fill.
7.4.29
7.4.30
Compaction of Fill Material Adjacent to Structures and Utilities

(a)
Fill material shall be compacted in such a manner that structures or utilities

are not disturbed or damaged.
(b)
Fill material around water, sewage and drainage pipes which are constructed
as part of the Permanent Works shall be compacted by hand-rammers or
manually operated power equipment. Fill material within 300 mm above the
top of sewage and drainage pipes shall be compacted to obtain a relative
compaction of at least 85% throughout.
Compaction of Rock Fill Material

(a)
Every layer of rock fill material shall be compacted by at least eight passes of
a vibrating roller or by other equivalent compaction method reviewed without
objection by the Project Manager. The final surface of rock fill material shall
be compacted by at least two additional passes of a vibrating roller or by other
equivalent compaction method reviewed without objection by the Project
Manager.
(b)
Vibratory rollers used for the compaction of rock fill material shall have a static
load per 100 mm width of roll of at least 2 kN for layers with a compacted
thickness not exceeding 500 mm and at least 4 kN for layers with a
compacted thickness exceeding 500 mm.

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January 2011
7.4.31
7.4.32
7.4.33
Completion of Earthworks Final Surfaces

(a)
Earthworks final surfaces shall be completed to a stable condition as soon as

practicable after excavation or after deposition and compaction of fill material
has been completed. The subsequent Permanent Works or surface protection
shall be carried out as soon as practicable after the earthworks final surface
has been completed.
(b)
Earthworks final surfaces shall be completed to smooth alignments without

abrupt irregularities unless otherwise stated in the Contract.
Completion of Formations
(a)
Formations above structures or utilities shall be completed after construction

of the structure or utility.
(b)
Except in excavations in rock and in areas of fill formed of rock fill material or
fill material as stated in Clause 7.4.27(a), formations shall be compacted to
obtain a relative compaction of at least 98% to a depth of 200 mm below the
formation.
(c)
Proof rolling shall be carried out on formations unless otherwise reviewed

without objection by the Project Manager. The Project Manager shall be
notified prior to commencement of proof rolling. The formation shall be rolled
by at least two passes of a non-vibrating rubber tyred roller. The roller shall
have a static load per 100 mm width of roll of at least 4 kN and shall travel at
a speed not exceeding 2 km/h. Any defect in the formation which is revealed
during proof rolling by deformation of the formation which in the opinion of the
Project Manager is excessive shall be made good as directed by the Project
Manager.
(d)
After all other formation work and testing have been completed and damage
caused by testing reinstated, formations for pavements shall be rolled with
one pass of a smooth steel-wheeled non-vibrating roller. The roller shall have
a load per 100 mm width of roll of at least 2 kN.
(e)
Formations which will not be immediately covered shall be protected by

(f)
Surface irregularities in formation after trimming of the rock excavation shall be

regulated to the requirements of this Section with granular fill material, no-fines
concrete or lean concrete as determined by the Project Manager.
Protection of Earthworks Final Surfaces and Formations

(a)
Earthworks final surfaces and formations shall be maintained in a stable

condition and shall be protected from damage due to water or other causes
and from exposure to conditions which may adversely affect the surface.
(b)
Formations shall not be used by Contractor's Equipment or vehicles other

than those which are essential to construct the subsequent work.

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January 2011
7.4.34
(c)
If the Contractor wishes to continue to use the surface of embankments for

construction traffic before trimming to formation level he shall bring up and
maintain the area between the extremities of the carriageway(s), including (if
any) central reserve and hardshoulders to a level not less than 150 mm above
formation level whereupon construction traffic will be allowed to use the surface
so formed but any damage to the earthworks final surface caused by the use of
such surface shall be made good by the Contractor.
(d)
In areas of shallow filling where after removal of topsoil the ground level is
within 300 mm of the earthworks final surface level, construction traffic shall not
use the surface unless the Contractor brings up and maintains the surface level
at least 300 mm above the earthworks final surface level. Any damage to the
subgrade arising from such use shall be made good by the Contractor with
material having the same characteristics as the damaged material.
Tolerances: Earthworks Final Surfaces and Formations

(a)
Earthworks final surfaces and formations shall be within the tolerances stated
in Table 7.3 of the specified lines and levels. The tolerances for formations do
not apply for pipes or preformed structures which require support over their
complete length or area.
(b)
In excavation, a positive tolerance refers to insufficient excavation and a

negative tolerance refers to excess excavation. In areas of fill, a positive
tolerance refers to excess fill material and a negative tolerance refers to
insufficient fill material.
Table 7.3: Tolerances for Earthworks Final Surfaces and Formations
Type of surface
Method of forming surface
Excavation except in rock

Formations for structures and
Excavation in rock
utilities
Deposition and compaction of fill
material
Formations for pavements
including carriageways, footways, Excavation in rock
cycletracks, paved areas, aircraft Deposition and compaction of fill
pavements and railway trackbeds. material
Earthworks final surfaces other
than formations, with a gradient
Excavation in rock
not exceeding 1 vertical to 10
horizontal
material
Excavation in rock
Other earthworks final surfaces
material

16/37
Tolerance (mm)
+
0
0
25
150
25
0
0
50
150
50
0
0
100
200
100
100
100
100
200
100
100
January 2011
7.4.35
General Ground Treatment: Vibrocompaction

Where treatment of the ground is to be carried out using methods of vibrocompaction and/or vibro-replacement, the Contractor shall submit to the Project
Manager for his review without objection details of the method, Contractor's
Equipment and materials he intends to use and, notwithstanding any other
requirements of the Contract, the testing he intends to carry out to demonstrate that
he has achieved the degree of ground improvement as specified. The Contractor
shall demonstrate to the Project Manager's satisfaction that the persons carrying
out the work are suitably experienced.
7.4.36
7.4.37
Existing Instrumentation
(a)
The Contractor shall note the existence of any instrumentation (e.g.

piezometers, inclinometers and surface movement monuments) shown on the
Employers Drawings and shall install a prominent marker post at each such
instrument.
(b)
Instruments shall not be removed or disturbed in any way except in

accordance with Sub-Clauses (c) and (d) below. Any instrument damaged by
the Contractor shall be reinstated by him immediately and at his own
expense.
(c)
Certain instruments, if so shown on the Employers Drawings, shall be

maintained as the Works proceed around them. Working methods shall take
account of this requirement and piezometer/settlement marker/inclinometer
tubes shall be shortened or lengthened as necessary. When the adjacent
works have reached their final level, a protective concrete box (or other
surface structure as shown on the Employers Drawings) shall be constructed
and a prominent marker post shall be installed.
(d)
Certain instruments, if so shown on the Employers Drawings, shall be

removed as the Works proceed but not until the Project Manager has
confirmed that it is necessary for the progress of the Works in each case.
Excavation for Utilities Trenches in Hard Materials

The Contractor shall form trenches for the installation of utilities at locations where
excavation is in hard materials. He shall programme the trench excavation so that it
is completed in advance of the work by the utility undertaking. He shall backfill the
trenches with fine fill material in horizontal layers and compact as directed by the
Project Manager.
7.5
7.5.1
Batch: Fill Material

A batch of fill material is any quantity of fill material of the same type and which has
similar properties throughout. For the purpose of testing for moisture content and
relative compaction a batch shall, in addition to the above, be fill material which is
deposited in a single layer in any area of fill presented by the Contractor for testing
on one occasion.

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January 2011
7.5.2
7.5.3
Samples: Fill Material

(a)
Each sample of fill material shall consist of at least four increments taken from
different parts of the batch. The increments shall be combined and thoroughly
mixed and shall then be divided by quartering or by using a riffle box to obtain
specimens of an appropriate size to carry out the individual tests.
(b)
The size of samples of fill material other than rock fill material shall be in
accordance with Section 2.5 in Geospec 3. Each sample of rock fill material
of grade size not exceeding 200 shall have a mass of at least 250 kg and
each sample of rock fill material of grade size exceeding 200 shall have a
mass of at least 1000 kg.
Test Fill Material General

All tests as required by the Project Manager shall be carried out by a HOKLAS
accredited laboratory reviewed without objection by the Project Manager.
7.5.4
Samples: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient

of Uniformity, Sulphate Content
Samples of fill material to be tested for particle size distribution, liquid limit, plasticity
index, coefficient of uniformity and sulphate content shall be delivered at least 14
days, before deposition of the fill material starts. The number of samples to be
provided from each batch shall be as stated in Table 7.4.
Table 7.4: Number of Samples to be Tested for Particle Size Distribution,
Liquid Limit, Plasticity Index, Coefficient of Uniformity, Sulphate
Content, Optimum Moisture Content and Maximum Dry Density
Description
Special fill material
Fill material other than
special fill material
7.5.5
Size of batch
No. of samples per batch
0 - 3,000 m
exceeding 3,000 m
1 for each 1,000 m or part thereof
0 - 15,000 m
exceeding 15,000 m
1 for each 5,000 m or part thereof
Testing: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient of

Uniformity, Sulphate Content
(a)
Each sample of fill material taken as stated in Clause 7.5.4 shall be tested to
determine the particle size distribution. In the case of special fill material
testing shall include calculation of the coefficient of uniformity as stated in
Clause 7.5.5(d). Each sample of fill material other than rock fill material shall
be tested to determine the liquid limit and the plasticity index of that portion of
the fill material passing a 425m BS test sieve. Each sample of fill material
which will be deposited within 500 mm of concrete, cement bound material,
cementitious material or metalwork shall be tested to determine the soluble
sulphate content.

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January 2011
(b)
The method of testing shall be in accordance with the following tests as

stipulated in Geospec 3:
Particle size distribution
: Clause 7.5.5(c)
Liquid limit
: test method 6.1
Plasticity index
: test method 6.1
Soluble sulphate
: test method 9.3
Total sulphate
: test method 9.3
(c)
The particle size distribution of fill material passing a 75mm BS test sieve
shall be determined in accordance with a test specified in Section 3 in
Geospec 3, whichever as instructed by the Project Manager. The size of
particles of fill material which do not pass a 75 mm BS test sieve shall be
taken as the largest dimension measured in any plane.
(d)
The coefficient of uniformity (Cu) shall be calculated from the equation:

Cu
D60/D10
Where:
-
7.5.6
7.5.7
D60 and D10 are the equivalent sieve sizes in millimetres, interpolated
from the particle size distribution curve, through which 60% and 10% of
the fill material would pass respectively.
Non-compliance: Particle Size Distribution, Liquid Limit, Plasticity Index,

Coefficient of Uniformity, Sulphate Content
(a)
If the result of any test for soluble sulphate content of fill material does not
comply with the specified requirements for soluble sulphate content, each
sample shall be tested to determine the total sulphate content.
(b)
If the result of any test for particle size distribution, liquid limit, plasticity index,
coefficient of uniformity or total sulphate content of fill material does not
comply with the specified requirements for the property, additional samples
shall be provided from the same batch and additional tests for the property
shall be carried out. The number of additional samples shall be as stated in
Table 7.4.
Samples: Optimum Moisture Content, Maximum Dry Density

(a)
Samples of fill material to be tested for optimum moisture content and

maximum dry density shall be delivered at least 72 hours before deposition of
the fill material starts. The number of samples to be provided from each batch
shall be stated in Table 7.4
(b)
The Contractor shall notify the Project Manager of the exact location in which
the fill material from which each sample is taken is to be deposited.

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7.5.8
7.5.9
(c)
Samples to be tested for optimum moisture content and maximum dry density
shall also be taken after the fill material has been deposited in its final
position, at intervals of not more than 28 days.
(d)
Samples shall not be provided from fill material including rock fill material
which contains an insufficient proportion of particles passing a 20 mm BS test
sieve to permit determination of the moisture content and maximum dry
density.
Testing: Optimum Moisture Content, Maximum Dry Density

(a)
determine the optimum moisture content and the maximum dry density.
(b)

Optimum moisture content:
Geospec 3 test method 10
Maximum dry density
Geospec 3 test method 10 adjusted in

accordance with Appendix A7.5 where
appropriate.
(c)
If permitted by the Project Manager, the Hilf method stated in Appendix A7.4
may be used instead of the methods stipulated in Clause 7.5.8(b) to
determine the optimum moisture content and maximum dry density.
(d)
If in the opinion of the Project Manager there is any undue discrepancy

between the results of tests for optimum moisture content of fill material using
methods stipulated in Clause 7.5.8(b) and the results of tests using the Hilf
method, the results of tests using methods stipulated in Clause 7.5.8(b) shall
prevail.
Consistency: Optimum Moisture Content, Maximum Dry Density

If the result of any test for optimum moisture content or maximum dry density of fill
material indicates that the batch contains material which differs to such an extent
that subsequent tests for relative compaction may be affected, the batch shall be
divided into smaller batches; each of the smaller batches shall comprise material
with similar properties throughout. Additional samples shall be provided from each
of the smaller batches and additional tests for optimum moisture content and
maximum dry density shall be carried out. The number of additional samples shall
be as stated in Table 7.4.
7.5.10
Samples: Moisture Content

(a)
Samples of fill material to be tested for moisture content shall be taken during
deposition and compaction of fill material and shall be delivered to the
laboratory not more than 1 hour after the fill material has been deposited in its
final position.
(b)
The number of samples to be provided from each batch shall be as stated in

Table 7.5. Samples shall not be provided if, in accordance with Clause 7.5.7
d(i) or (ii), the optimum moisture content has not been determined.

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7.5.11
Testing: Moisture Content

(a)
determine the moisture content.
(b)
The method of testing shall be in accordance with one of the following

methods:
(i)
Method 1: Geospec 3 Test Methods 5.1, 5.2 or 5.3, whichever as

instructed by the Project Manager; or
(ii)
Method 2: Microwave oven drying method as stated in Appendix A7.2.
Method 1 shall be used unless otherwise permitted by the Project Manager.

7.5.12
Compliance Criteria: Moisture Content

If in the opinion of the Project Manager there is any undue discrepancy between the
results of tests for moisture content of fill material using Method 1 and the results of
tests using Method 2 in Clause 7.5.11, the results of tests using Method 1 shall
prevail.
7.5.13
Non-compliance: Moisture Content

If the result of any test for moisture content of fill material differs from the optimum
moisture content by more than the specified amount, the moisture content of the
whole of the batch of fill material shall be adjusted. Additional samples shall be
provided from the same batch and additional tests for moisture content shall be
carried out. The number of additional samples shall be as stated in Table 7.5.
Table 7.5: Number of Samples to be Tested for Moisture Content and Number
of Tests for Relative Compaction
Description
Areas of fill in
excavations for
Structures, pits and
trenches and on
Formations
Size of area of fill in

batch
0 - 100 m
100 - 500 m
No. of samples/No. of tests per

batch
3
2 for each 100 m or part thereof
exceeding 500 m
0 - 1 ha
2 - 10 ha
exceeding 10 ha

Other areas of fill
7.4.14
Testing: Relative Compaction

(a)
Each batch of fill material shall be tested to determine the relative compaction.
Tests shall be carried out after the fill material has been deposited and
compacted in its final position. The number of tests on each batch shall be as
stated in Table 7.5. Tests shall not be carried out on fill material including
rock fill material which contains an insufficient proportion of particles passing
a 20 mm BS test sieve to permit determination of the relative compaction.

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(b)
Tests shall be carried out at positions which in the opinion of the Project
Manager are representative of the batch of compacted fill material as a whole.
(c)
Testing shall be carried out by the Contractor.
(d)
The relative compaction of fill material shall be determined in accordance with

one of the following methods:
(i)
Method 1:
The relative compaction (RC) shall be calculated from the

equation:
RC =
IDD/MDD x 100%
where:
- IDD is the in-situ dry density, determined as stated in Clause
7.5.14(e)
- MDD is the maximum dry density, determined as stated in Clause
7.5.8(b)
Method 2:
The relative compaction (RC) shall be calculated from the

equation:
RC =
IBD/MCBD x 100%
where:
-
IBD is the in-situ bulk density determined as stated in Clause

7.5.14(e)
MCBD is the maximum converted bulk density determined by the
Hilf method as stated in Appendix A7.4

(e)
The in-situ bulk density and the in-situ dry density of fill material shall be
determined in accordance with one of the following methods:
(i)
Method 1:
GEO Report No. 36, Test 9.2.1or 9.2.2 as appropriate to

the grain size of the fill material; or
(ii)
Method 2:
Nuclear densometer method as stated in Appendix A7.3.

(f)
7.5.15
The maximum converted bulk density of fill material of which more than 5% is
retained on a BS 20 mm test sieve shall be adjusted as stated in Appendix
A7.5.
Compliance Criteria: Relative Compaction

If in the opinion of the Project Manager there is any undue discrepancy between the
results of tests for relative compaction of fill material using Method 1 and the results
of tests using Method 2 in Clause 7.5.14, the results of tests using Method 1 shall
prevail.

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7.5.16
Non-compliance: Relative Compaction

If the result of any test for relative compaction of fill material does not comply with
the specified requirements for relative compaction, additional tests for relative
compaction shall be carried out on the same batch. The number of additional tests
shall be as stated in Table 7.5.

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APPENDIX A7.1
TEST METHODS FOR FILL MATERIAL
A7.1.1 General
The definitions, terms, abbreviations, symbols, and grouping of materials stated in
BS 1377: 1975 shall apply except as stated in Clauses A7.1.2 and A7.1.3.
A7.1.2 Terms and Symbols
Terms used in the Specification, and in BS 1377: 1975 are identified by the
abbreviations and symbols stated in Table A7.1.1.
Table A7.1.1: Abbreviations and Symobls
Abbreviation/Symbol
Term
BD
bulk density
CBD
Converted bulk density
DD
dry density
IBD
In-situ bulk density
IDD
in-situ dry density
MDD
Maximum dry density
MCBD
Maximum converted bulk density
RC
Relative compaction
moisture content
wi
in-situ moisture content
wo
Optimum moisture content
A7.1.3 Grouping of Material

(1)
Fine grained material is material of which at least 90% passes a 2 mm BS test

sieve.
(2)
Medium grained material is material of which at least 90% passes a 20 mm

BS test sieve and more than 10% is retained on a 2 mm BS test sieve.

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APPENDIX A7.2
DETERMINATION OF THE MOISTURE CONTENT
OF FINE GRAINED AND MEDIUM GRAINED MATERIAL
BY THE MICROWAVE OVEN DRYING METHOD
A7.2.1 Scope
This method covers the determination of the moisture content of fine grained and
medium grained material as a percentage of the mass of the dry material.
A7.2.2 Apparatus
The following apparatus is required:
(1)
A microwave oven with a timer and an adjustable power setting.
(2)
An airtight container of microwave safe and non-reflective material.
(3)
A balance readable and accurate to 0.01 g.
(4)
A desiccator containing anhydrous silica gel.
A7.2.3 Procedure
(1)
The container shall be cleaned, dried and weighed to the nearest 0.01 g (m1).
(2)
A specimen shall be crumbled and placed loosely in the container and the lid
shall be replaced. Each specimen of fine grained material shall be at least 30
g and each specimen of medium grained material shall be at least 300 g.
Specimens of medium grained material may be tested in several parts each
less than 300 g and the results aggregated.
(3)
The container and contents shall be weighed to the nearest 0.01 g (m2).
(4)
The lid of the specimen container shall be removed and the container with its
lid and contents shall be placed in the microwave oven and dried. The
specimen shall be considered to be dry when, after an initial drying period,
successive weighings at intervals of 1 minute produce results which are the
same to the nearest 0.01 g. Alternatively, the oven may be set to an
appropriate time and power setting to dry the specimen as determined by
calibration of the oven on soil of a similar type.
(5)
After drying, the container and contents shall be removed from the microwave
oven and placed in the desiccator to cool.
(6)
The lid shall be replaced and the container and contents shall be weighed to
the nearest 0.01 g (m3).

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A7.2.4 Calculation
The moisture content of the material (w) shall be calculated as a percentage of the
dry mass of the material from the equation:
w = (m2 - m3)/(m3 - m1) x 100%
where:
- m1 is the mass of the container (g)
- m2 is the mass of the container and contents before drying (g)
- m3 is the mass of the container and contents after drying (g)
The following shall be reported:
(1)
source and identification of the soil;
(2)
the moisture content of the material to the nearest 0.1%; and
(3)

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APPENDIX A7.3
DETERMINATION OF THE IN-SITU BULK DENSITY
AND THE IN-SITU DRY DENSITY OF FINE GRAINED
AND MEDIUM GRAINED MATERIAL
BY THE NUCLEAR DENSOMETER METHOD
A7.3.1 Scope
This method covers the determination of the in-situ bulk density of fine grained and
medium grained material by the attenuation of gamma rays and calculation of the
in-situ dry density using a moisture content determined in accordance with either
GEO Report No. 36, Test 2.3.2A or 2.3.2B or Appendix A7.2, whichever as
instructed by the Project Manager.
A7.3.2 Apparatus
(1)
A nuclear device for the measurement of density (densometer). The details of

construction of the densometer may vary but the following general
requirements shall apply:
- The probe shall be an adjustable probe containing a gamma source which
can be readily positioned in a preformed hole. The probe assembly shall
be graduated in increments not exceeding 50 mm and shall be constructed
in such a manner that it will be securely held in the test depth position.
- The instrumentation shall display the results directly in metric units.
(2)
A reference standard of uniform and constant density to establish the

background count and count reproducibility.
(3)
Site preparation equipment, such as spades, straight-edges, scoops and

brushes, required to prepare a suitably cleared and level surface to
accommodate the densometer.
(4)
A hole forming device, such as an auger or steel pin, to form a hole to

accommodate the probe. The device shall have a nominal diameter which
exceeds the probe diameter by not more than 3 mm and shall be graduated to
indicate the depth of the hole. The device shall have a guide which will
ensure that the hole is formed normal to the prepared surface.
(5)
Sampling equipment, such as augers, spades, picks, small digging tools,

scoops, airtight containers and bags, to obtain samples of the material.
(6)
Apparatus for the determination of the moisture content in accordance with

either GEO Report No. 36, Test 2.3.2A or 2.3.2B or Appendix A7.2, whichever
as instructed by the Project Manager.

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A7.3.3 Procedure: Comparability of Test Methods

(1)
Before using the densometer on material for which it has not previously been
used, the results of determinations of in-situ bulk density using the
densometer shall be compared with the results of determinations of in-situ
bulk density in accordance with GEO Report No. 36, Test 9.2.2. The location
of each determination in accordance with GEO Report No. 36, Test 9.2.2 shall
correspond to the midpoint of the densometer probe and the gamma sensor.
A minimum of ten pairs of determinations shall be carried out.
(2)
If the difference between any pair of results does not exceed 0.08 Mg/m and
if the densometer produces results which are both higher and lower than
those produced in accordance with GEO Report No. 36, Test 9.2.2, the
densometer may be used without correction.
(3)
If either of the criteria stated in Clause A7.3.3(2) is not met, the densometer
shall not be used.
A7.3.4 Procedure: Routine Denosometer Check

The procedure for carrying out a routine densometer check shall be as follows:
(1)
The densometer shall be warmed up in accordance with the manufacturer's

recommendations.
(2)
A standard count shall be carried out in accordance with the manufacturer's

recommendations. The standard count shall be carried out by placing the
reference standard on a hard, level surface consisting of material with a
density of at least 1.6 Mg/m. The reference standard shall be placed at a
distance of at least 10 m from any other nuclear device and at least 3 m from
any large object. At least three count readings shall be taken and the mean of
the three readings shall be determined. The mean shall be the standard
count reading for the day.
(3)
The standard count reading for the day shall be compared with the mean of
the standard count readings for the previous 4 days. If the difference is
greater than that recommended by the manufacturer or if no recommendation
is made and the difference is greater than 1%, the densometer shall not be
used.
(4)
The densometer shall be left switched on with the probe in the locked
position. If the densometer is switched off a further standard count shall be
carried out in accordance with Clause A7.3.4(2) and (3).
A7.3.5 Procedure: Determination of In-Situ Bulk Density

The procedure for determination of the in-situ bulk density shall be as follows:
(1)
A level surface of sufficient size to accommodate the densometer shall be

prepared and cleared of all disturbed and loose material. The depth of any
depression below the densometer shall not exceed 3 mm. Depressions
exceeding 3 mm in depth shall be filled using fine sand or material taken from
the adjacent soil which passes a 600 m BS test sieve.

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(2)
(3)
A suitable hole for the probe shall be prepared using the hole forming device.
The hole shall be normal to the prepared test area and at least 50 mm deeper
than the intended test depth. If a driven pin is used to form the hole, the pin
shall be rotated every two or three blows to facilitate its removal.
The test depth shall be the same as the maximum depth required for
determination of the in-situ bulk density in accordance with GEO Report No.
36, Test 9.2.1 or 9.2.2 as appropriate to the grain size of the material.
(4)
The probe shall be positioned and inserted into the hole in such a manner that
the gamma source is shielded at all times. The probe shall be seated firmly
against the side of the hole nearest to the back of the densometer by gently
pulling the densometer backwards until contact is achieved. The operator
shall ensure that the densometer is correctly seated and the depth setting on
the control panel is the same as the probe depth.
(5)
The operator shall ensure that there are no other radioactive sources within
10 m of the densometer.
(6)
Three readings of the in-situ bulk density shall be taken in accordance with
the manufacturer's recommendations and the mean determined. If any one
reading differs from any other reading by more than 0.015 Mg/m, additional
readings shall be taken until three consecutive readings which do not differ by
more than 0.015 Mg/m are obtained and the mean determined. The mean of
the three readings shall be taken as the in-situ bulk density (IBD). If the
above criterion is not met after six readings, the densometer shall not be
used.
(7)
The densometer shall be removed and a minimum 500 g sample of the

material directly beneath the densometer position shall be taken for
determination of the moisture content. The sample shall be obtained by
augering or digging to the test depth. The sample shall be placed in a
moisture tight container and the lid replaced. The moisture content (w) shall
be determined in accordance with either GEO Report No. 36, Test 2.3.2A or
2.3.2B or Appendix A7.2, whichever as instructed by the Project Manager.
(8)
If a sample of material at the same location as the densometer test is required

for determination of the maximum dry density or the maximum converted bulk
density, the sample shall be obtained by digging to the test depth, keeping the
sides of the excavation vertical and the bottom flat and level. The appropriate
quantity of material required for the test shall be taken, placed in a moisture
tight container and the container sealed.
A7.3.6 Calculation
The in-situ dry density of the material (IDD) shall be calculated from the equation:
IDD = IBD/(1 + w ) Mg/m
100
where:
-
IBD is the in-situ bulk density of the material (Mg/m)
w is the moisture content of the material (%)

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January 2011

(1)
the location of the test;
(2)
the in-situ dry density to the nearest 0.01 Mg/m;
(3)
the moisture content to the nearest 0.1%; and
(4)

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January 2011
APPENDIX A7.4
DETERMINATION OF THE MAXIMUM CONVERTED BULK
DENSITY BY THE HILF METHOD
A7.4.1 Scope
This method covers the determination of the maximum converted bulk density and
the difference between the optimum moisture content and the in-situ moisture
content of a material by relating the converted bulk density and the moisture added.
A7.4.2 Apparatus
(1)
Apparatus in accordance with GEO Report No. 36, Test 4.3.3A or 4.3.3B,
whichever as instructed by the Project Manager.
(2)
Apparatus for determination of the moisture content in accordance with either

GEO Report No. 36, Test 2.3.2A or 2.3.2B or Appendix A7.2, whichever as
instructed by the Project Manager.
(3)
Apparatus to extract specimens from the mould.
(4)
Apparatus, such as a warm air blower, for rapid drying of the material.
A7.4.3 Procedure
(1)
A sample of material shall be taken immediately after completing the in-situ

bulk density test at the same location as the test. The sample shall be
obtained by digging to the same depth as that of the in-situ bulk density test,
keeping the sides of the excavation vertical and the bottom flat and level. The
size of the sample shall be sufficient to yield a minimum of 10 kg after
screening over a 20 mm BS test sieve.
(2)
The sample shall be weighed to the nearest 0.01 g.
(3)
The sample shall be screened over a 20 mm BS test sieve, ensuring that

moisture loss is kept to a minimum and that any free moisture appearing in
the containers is worked back into the sample.
(4)
The amount retained on the sieve shall be weighed to the nearest 0.01g and
expressed as a percentage of the mass of the sample. If the percentage
exceeds 5%, an adjustment for coarse material shall be made in accordance
with Appendix A7.5. If the percentage does not exceed 5%, no adjustment is
required.
(5)
The material to be tested shall be thoroughly mixed and divided by quartering

or by using a riffle box to obtain a minimum of four specimens of at least
2500g each, ensuring that moisture loss is kept to a minimum. Alternatively,
if it has previously been ascertained that the material is not susceptible to
crushing, a single specimen of at least 2500 g may be used for repeat testing.

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January 2011
(6)
Each specimen shall be weighed to the nearest 0.01g and the result shall be
taken as the mass of the specimen at the in-situ moisture content.
(7)
Each specimen and any remaining material shall be placed in separate

moisture-tight containers and the containers sealed.
(8)
The converted bulk density of at least three specimens shall be plotted

against the amount of water added or removed as a percentage of the mass
of the specimen at the in-situ moisture content (z) on a graph as shown in the
Hong Kong Government Civil Engineering Department Standard Drawing No.
C2006, in accordance with the procedure stated in Clause A7.4.3(9) to (15).
(9)
The first point on the graph shall be obtained as follows:

-
A specimen shall be compacted at its in-situ moisture content in

accordance with GEO Report No. 36, Test 4.3.3A, Clause 4.3.3A.4 or
Test 4.3.3B, Clause 4.3.3B.4, whichever as instructed by the Project
Manager.
A diametrical slice of approximately 400 g to 500 g shall be cut from the

specimen along its entire length. The in-situ moisture content of the
slice (wi) shall be determined in accordance with either GEO Report No.
36, Test 2.3.2A or 2.3.2B or Appendix 7.2, whichever as instructed by
The bulk density (BD1) shall be calculated as stated in Clause A7.4.4(1)

and plotted on the 0% ordinate of the graph as the converted bulk
density (CBD1).
(10) The second point on the graph shall be obtained as follows:

-
A second specimen shall be examined and, if the in-situ moisture

content obviously exceeds the optimum moisture content, the procedure
stated in Clause A7.4.3(11) shall be followed.
The moisture content of the specimen shall be increased by adding an

amount of water equal to 2% of the mass of the specimen. The
specimen shall be thoroughly mixed and compacted in accordance with
the method stipulated in Clause A7.4.3(9).
The bulk density (BD2) shall be calculated as stated in Clause

A7.4.4(1), adjusted to converted bulk density (CBD2) as stated in
Clause A7.4.4(2) and plotted on the +2% ordinate of the graph.
(11) If the in-situ moisture content of the second specimen obviously exceeds the
optimum moisture content, the specimen shall be dried until the amount of
water removed is approximately 2% of the mass of the specimen and cooled.
The specimen shall be thoroughly mixed and compacted in accordance with
the method stipulated in Clause 7.4.3(9). The amount of water removed shall
be determined. The bulk density (BD2) shall be calculated as stated
in Clause A7.4.4(1), adjusted to converted bulk density (CBD2) as stated in
Clause A7.4.4(2) and plotted on the negative ordinate of the graph at a point
which corresponds to the amount of water removed.
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(12) The third point on the graph shall be obtained as follows:

-
If the plotted value of CBD2 is equal to or greater than the plotted-value

of CBD1, the moisture content of a third specimen shall be increased by
adding an amount of water equal to 4% of the mass of the specimens.
Alternatively, if the procedure stated in Clause A7.4.3(11) has been
followed, the specimen shall be dried until the amount of water removed
is approximately 4% of the mass of the specimen after cooling.
If the plotted value of CBD2 is less than the plotted value of CBD1, the
third specimen shall be dried until the amount of water removed is
approximately 2% of the mass of the specimen after cooling.
Alternatively, if the procedure stated in Clause A7.4.3(11) has been
followed, the moisture content shall be increased by adding an amount
of water equal to 2% of the mass of the specimen.
The specimen shall be thoroughly mixed and compacted in accordance

with the method stipulated in Clause A7.4.3(9). The amount of water
removed shall be determined.
The bulk density (BD3) shall be calculated as stated in Clause

A7.4.4(1), adjusted to converted bulk density (CBD3) as stated in
Clause A7.4.4(2) and plotted on the graph at a point which corresponds
to the amount of water added or removed.
(13) If the centre point of the three points plotted is lower than one of the other two
points, or is higher than one point and equal to the other, an additional point
or points shall be obtained by proceeding in 2% increments or decrements as
appropriate.
(14) If it is apparent that the moisture condition of the material is such that a total
of five points will not result in the determination of the optimum moisture
content, increments and decrements of 3% moisture content may be adopted
for the entire procedure.
(15) A smooth approximately parabolic curve shall be drawn to the plotted points.
The peak value of the curve shall be determined as the maximum converted
bulk density (MCBD).
(16) The amount of water added or removed as a percentage of the mass of the
specimen at the in-situ moisture content corresponding to the maximum
converted bulk density shall be determined (zm).
(17) The value of the moisture correction curve passing through the peak value of
the plotted parabolic curve shall be determined (zc). If there is no moisture
correction curve passing through the peak value of the curve, a moisture
correction curve shall be drawn through the peak by interpolating to the
nearest 0.1%.

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A7.4.4 Calculation
(1)
The bulk density (BD) shall be calculated from the equation:

BD = (m2 - m1)/V Mg/m
where:
(2)
m1 is the mass of the mould and base (g)
m2 is the mass of the mould, base and wet material (g)
V is the volume of the mould (mL)
The converted bulk density (CBD) shall be calculated from the equation:
CBD = BD/(1+z/100) Mg/m
where:
(3)
z is the amount of water added or removed as a percentage of the mass

of the specimen at the in-situ moisture content
z is negative for values below the in-situ moisture content
The difference between the optimum moisture content (wo) and the in-situ
moisture content (wi) of the material shall be calculated from the equation:
wo - wi = zm + zc %
where:
(4)
zm is the amount of water added or removed as a percentage of the

mass of the specimen at the in-situ moisture content corresponding to
the maximum converted bulk density (%)
zc is the value of the moisture correction curve passing through the

peak value of the plotted parabolic curve (%)
The optimum moisture content (wo) shall be calculated from the equation:
wo = wi + (1 + wi/100) zm %
where:
-
(5)
wi is the in-situ moisture content of the material (%)
The maximum dry density (MDD) shall be calculated from the equation:
MDD = MCBD/(1 + wi/100) Mg/m
where:
-
MCBD is the maximum converted bulk density of the material (Mg/m)

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January 2011
(6)
The relative compaction (RC), if required, shall be calculated from the

equation:
RC = IBD/MCBD x 100%
where:
-
IBD is the in-situ bulk density of the material determined in accordance

with GEO Report No. 36, Test 9.2.1 or 9.2.2 as appropriate to the grain
size of the material or in accordance with Appendix A7.3

The following shall be reported;
(1)
source and identification of the soil;
(2)
the graph showing the plotted points and the parabolic curve passing through
them;
(3)
the maximum converted bulk density to the nearest 0.01 Mg/m;
(4)
the optimum moisture content to the nearest 0.1%;
(5)
the maximum dry density to the nearest 0.01 Mg/m;
(6)
the relative compaction to the nearest 0.1%, if determined;
(7)
the percentage retained on the 20 mm BS test sieve and the percentage

retained on the 37.5 mm BS test sieve to the nearest 1%, if applicable;
(8)
whether the test was carried out using individual specimens or repeat testing
of a single specimen;
(9)
whether a manual or an automatic compaction rammer was used; and
(10) that the test method used was in accordance with this General Materials and

35/37
January 2011
APPENDIX A7.5
ADJUSTMENT OF THE MAXIMUM CONVERTED BULK DENSITY
FOR THE DETERMINATION OF THE RELATIVE COMPACTION
A7.5.1 Scope
This method covers the adjustment of the maximum converted bulk density
determined in accordance with Appendix A7.4 for the determination of the relative
compaction of a material containing more than 5% of the mass of the material at the
in-situ moisture content retained on a 20 mm BS test sieve.
A7.5.2 Apparatus
(1)
Apparatus in accordance with Appendix A7.4.
(2)
A 20 mm and a 37.5 mm BS test sieve.
(3)
A mould with collar as used for determination of the California Bearing Ratio
(CBR mould).
(4)
An extrusion device as used for determination of the California Bearing Ratio.
A7.5.3 Procedure
(1)
If the amount of material retained on the 20 mm BS test sieve exceeds 5%

and does not exceed 20%, the material passing the sieve shall be compacted
in accordance with Appendix A7.4. The maximum converted bulk density
(MCBD20) shall be determined and adjusted as stated in Clause A7.5.4.
(2)
If the amount of material retained on the 20 mm BS test sieve exceeds 20%,

the retained material shall be screened over the 37.5 mm BS test sieve. The
procedure stated in either Clause A7.5.3(3) or Clause A7.5.3(4) as
appropriate shall be followed.
(3)
If the amount of material retained on the 37.5 mm BS test sieve does not
exceed 5%, the procedure stated in Clause A7.5.3(5) shall be followed.
(4)
If the amount of material retained on the 37.5 mm BS test sieve exceeds 5%

and does not exceed 20%, the retained material shall be replaced with an
equal mass of material which is of a similar nature and which is retained on a
20 mm BS test sieve but passes a 37.5 mm BS test sieve. The procedure
stated in Clause A7.5.3(5) shall be followed.
(5)
The procedure stated in Appendix A7.4 shall be followed except that the
material shall be compacted into the CBR mould and each layer shall be
subjected to 62 blows of the rammer.

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January 2011
A7.5.4 Calculation
The maximum converted bulk density (MCBD) shall be calculated from the
equation:
MCBD = MCBD20 [1 +
m
1+ z
100
(1 - MCBD20)] Mg/m
Gs
where:
-
MCBD20 is the maximum converted bulk density of the material passing the
20 mm BS test sieve (Mg/m)
z is the amount of water added as a percentage of the mass of the specimen

at the in-situ moisture content corresponding to the maximum converted bulk
density (%)

(1)
the source and identification of the soil;
(2)
the results in accordance with Appendix A7.4;
(3)
the mass of the original material not passing the 20 mm and 37.5 mm BS test
sieve as a percentage of the mass of the material at the in-situ moisture
content to the nearest 0.1%;
(4)
the type of mould used;
(5)
the number of blows per layer;
(6)
whether the specific gravity was measured or assumed and, if measured, the
method used; and
(7)
Workmanship Specification, and the results have been adjusted in
accordance with this Appendix.

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January 2011
SECTION 8
8.1
GEOTECHNICAL WORKS
GENERAL REQUIREMENTS
stated, unless otherwise stated in this Section:
8.2
(a)
Site clearance shall comply with Section 3.
(b)
Drainage works shall comply with Section 6.
(c)
(d)
TRIALS FOR GEOTECHNICAL WORKS

(a)
Details of trials to be carried out for geotechnical works shall be as stated in

the Contract.
(b)
The trials shall be carried out to demonstrate that the proposed materials and
methods of construction will produce work which complies with the specified
requirements.
(c)
Trials shall be carried out in sufficient time before commencement of the

relevant Permanent Works starts to allow the Project Manager a sufficient
period to determine if the trial complies with the specified requirements.
(d)
The Contractor shall notify the Project Manager before the trial starts.
(e)
Trials shall be carried out using the materials and methods of construction
submitted to the Project Manager for review. Trials shall be carried out at
locations reviewed without objection by the Project Manager.
(f)
If work which complies with the specified requirements has not been produced
in the trial, particulars of proposed changes to the material or methods of
construction shall be submitted to the Project Manager for review; further trials
shall be carried out until work which complies with the specified requirements
has been produced in the trial.
(g)
Geotechnical works for which trials are required shall not commence until
work which complies with the specified requirements has been produced in
the trial.
(h)
The material and methods of construction used to produce work which

complies with the specified requirements in a trial shall not be changed.

Section 8 Geotechnical Works
1/75
January 2011
8.3
DEFINITIONS AND ABBREVIATIONS - GROUND INVESTIGATION
8.3.1
Block sample
Block sample is an undisturbed sample recovered by in-situ hand trimming of a
block of material from the surrounding soil.
8.3.2
Bulk sample
Bulk sample is a sample of at least 10 kg mass which is representative of the
grading of the material at the point of sampling.
8.3.3
Inspection pit
Inspection pit is a pit for locating and identifying underground utilities and structures.
8.3.4
Jar sample
Jar sample is a disturbed sample of at least 0.7 kg mass contained in a transparent
airtight jar which has a screw cap with an airtight sealing ring.
8.3.5
Mazier sample
Mazier sample is an undisturbed sample recovered by rotary drilling using a Mazier
triple tube core barrel which has inner tubes protruding proud of the outer tube to
protect the material being sampled from disturbance.
8.3.6
Sample
Sample is any quantity of material obtained from the ground for the purposes of
inspection, logging or testing.
8.3.7
Slope surface stripping

Slope surface stripping is the removal of surface protection and vegetation from
existing slopes to expose underlying soil or rock for inspection.
8.3.8
Trial pit
Trial pit is a pit for inspecting and logging the ground and in which to carry out insitu testing and sampling.
8.3.9
U 100 and U 76 samples

U 100 and U 76 samples are undisturbed samples recovered by advancing a
thin-walled tube with a cutting edge into the soil.
8.3.10
Undisturbed soil sample

Undisturbed soil sample is a sample complying with Class 1 or Class 2 of BS 5930.

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January 2011
8.4
SUBMISSIONS GROUND INVESTIGATION
8.4.1
Particulars of ground investigation

The following particulars of proposed materials and methods for ground
investigation shall be submitted to the Project Manager for review:
(a)
details of drilling and in-situ testing equipment;
(b)
details of sampling equipment; and
(c)
details of filter materials and fill materials for drilling and testing,
8.5
WORKMANSHIP - GROUND INVESTIGATION
8.5.1
Inspection pits
Inspection pits shall be formed by manual methods.
8.5.2
8.5.3
8.5.4
Trial pits
(a)
The plan dimensions at the bottom of a trial pit shall be at least 1.2 m x 1.2 m
and the sides of trial pits shall be vertical.
(b)
The sides of trial pits shall be trimmed by manual methods to remove all
disturbed material. Supports to the sides of trial pits shall be such that the cut
surface is clearly visible throughout the height of each face.
(c)
The Project Manager shall be notified before fill material is deposited in trial
pits.
Slope surface stripping

(a)
Slope surface stripping shall start at the top of the slope and shall proceed
downwards. All loose material remaining on the slope after stripping shall be
removed.
(b)
Access shall be provided for inspection by the Project Manager.
(c)
Stripped areas shall be covered up at the end of each working day and during
rainstorms to prevent the ingress of water into the slope.
(d)
Stripped areas shall be reinstated in form, colour and conditions similar to the
original. The Project Manager shall be notified before reinstatement starts.
Records of inspection pits

Records of inspection pits shall be kept by the Contractor on Site and a report shall
be submitted to the Project Manager for review within 3 days after each inspection
pit has been excavated. The report shall contain details of the positions, depths
and dimensions of all utilities and structures encountered in each inspection pit.

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January 2011
8.5.5
Records of trial pits and slope surface stripping

(a)
(b)
(c)
8.5.6
Each trial pit shall be photographed as soon as excavation is complete. The

full face of each of the sides and the bottom of the trial pit shall be
photographed individually. One copy of specimen prints of 127 mm x 76 mm
size shall be submitted to the Project Manager for review before fill material is
deposited in the trial pit. The photographs shall contain the following
information:
(i)
number of trial pit and site reference;
(ii)
measuring scale bar; and
(iii)
a suitable colour comparison chart placed alongside the trial pit face.
Records of trial pits shall be kept by the Contractor on Site and a report shall
be submitted to the Project Manager for review within 24 hours after each trial
pit has been excavated. The report shall contain the following:
(i)
details shown, and in the format shown in Figure 7 of `Geoguide 2 :

Guide to Site Investigation', Hong Kong Government 1987;
(ii)
details of depths and rate of groundwater seepage;
(iii)
details of water levels, including dates and details of fluctuation; and
(iv)
four sets of photographs or composite photographs as stated in Clause

8.5.5(a); the photograph of each face shall occupy the full height of an
A4 size page.
Records of slope surface stripping shall be kept by the Contractor on Site and
a report shall be submitted to the Project Manager for information within 24
hours of the surface stripping. The report shall contain a detailed geological
description of the materials exposed, and details and locations of groundwater
seepage.
Drilling rigs for ground investigation

(a)
Drilling rigs for ground investigation shall be the hydraulic feed type and shall
have a rating of at least 26.5 kW to drive a rotary tool tipped with diamonds or
tungsten carbide. Drilling rigs shall be capable of drilling in the specified sizes
and to the specified depths without excessive vibration.
(b)
The weight of each rig shall be such that a force of 12 kN can be applied to
the drilling bit without movement of the rig.
(c)
Drilling rigs shall be capable of providing stable drill-string rotation at speeds

of between 50 rpm and 1250 rpm and have a ram stroke length of at least 600
mm. The rigs shall be fitted with a tachometer and a hydraulic feed pressure
gauge, both of appropriate scales, and a device for measuring the rate of
penetration of the drill strings.

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January 2011
(d)
8.5.7
8.5.8
Triplex or similar type pumps shall be used when the flushing medium is
water; the pumps shall be equipped with a gear box and shall be capable of
delivering up to 2 L/s. The pumps shall incorporate a surge bottle to reduce
fluctuations in water pressure and the suction hose shall be fitted with a
suitable filter. The pumps shall have a by-pass system allowing full control of
water flow at all pump delivery rates.
Drilling equipment for ground investigation

(a)
Spare drill bits shall be available for use during drilling.
(b)
The size of casings shall be appropriate to the drilling, coring, sampling,

testing and other installation requirements.
(c)
Core barrels for sampling soil shall be equipped with a sediment catcher tube.
The tube shall have the same external diameter as the core barrel and shall
be approximately 0.75 m long.
(d)
Casings shall be used to stabilize caving ground. The size of casing and drill
rod in use shall be appropriate to the size of core barrel in use. Casings and
drill rods shall be straight and shall be clean at the time of drilling and free
from scale, dirt and other loose material.
(e)
Only regular lengths of casings and drill rods shall be used and imperial and
metric lengths shall not be mixed.
(f)
Short lengths of drill rods shall be used to enable continuous coring to be

carried out in such a manner that each core run can be completed within one
ram stroke.
(g)
Short lengths of casing not exceeding the ram stroke length shall be used to
enable casings to be advanced after each core run where necessary.
(h)
Core barrels and drill rods shall be stored on steel frame trestles.
Drilling for ground investigation

(a)
Drillholes for ground investigation shall be sunk by rotary methods.

methods and equipment used shall be such that:
The
(i)
the overall hole alignment is within 2% for vertical drillholes and is within
5% of the specified alignment for non-vertical drillholes;
(ii)
the soil encountered and the levels at which changes in ground

conditions occur can be accurately identified;
(iii)
the specified sampling requirements can be achieved;
(iv)
in-situ tests can be carried out and field installations can be

incorporated at any depth in the drillhole; and
(v)
consistency of measurement and minimal disturbance of the ground is

achieved.

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January 2011
8.5.9
8.5.10
8.5.11
(b)
Casings shall be advanced concurrently with the removal of material in such a

manner that loss of ground is avoided.
(c)
Larger casings shall be set concentric with drillholes which are being reamed.
(d)
The flushing medium for drilling shall be clean water, air, air mist or air foam;
other substances or materials shall not be introduced into drillholes. The
flushing medium for drilling shall be passed through a sedimentation basin
and shall either be reused or be discharged to surface drains or natural
stream courses. Measures shall be taken to prevent flushing mediums
seeping through the ground.
(e)
The flushing medium for drilling shall not be discharged to stream courses
which are used as a supply of drinking water.
Sampling from drillholes

(a)
Jar samples from drillholes shall be taken from the cutting shoe of each
undisturbed sample, from any anomalous material, from each standard
penetration test and at other locations as directed by the Project Manager.
(b)
All loose material and material disturbed by drilling or in-situ tests shall be
removed from the sides and bottom of the drillhole before each undisturbed
sample is taken.
Filling drillholes
(a)
Granular fill material of a type reviewed without objection by the Project

Manager, or 4:1 cement bentonite grout where directed by the Project
Manager, shall be deposited in drillholes for ground investigation and
compacted to the same relative compaction as the surrounding ground. The
casing shall be gradually withdrawn; the fill material shall be kept above the
bottom of the casing during withdrawal. Subsequent depressions in the
ground surface shall be filled and reinstated. The drillhole position shall be
marked with a metal marker and flag or a 300 mm x 300 mm x 150 mm thick
concrete block; the hole number shall be inscribed on the surface and
highlighted in red paint.
(b)
The Project Manager shall be notified before fill material is deposited in

drillholes and before the casing is withdrawn. The ground surface around
drillholes shall be reinstated as soon as practicable after the fill material has
deposited and compacted in each drillhole.
Records of drillholes
(a)
Records of drillholes for ground investigation shall be kept by the Contractor

on Site and two copies of a preliminary drillhole log, stamped PRELIMINARY,
shall be submitted to the Project Manager for review within 24 hours after
completion of each drillhole. Drillhole logs shall be comprehensive and shall
be in a form similar to that shown in Figure 44 of 'Geoguide 2 : Guide to Site
Investigation', Hong Kong Government, 1987; soil and rock descriptions shall
comply with those stated in the insert titled 'Checklist for Soil Descriptions'
and 'Checklist for Rock Descriptions' in 'Geoguide 3 : Guide to Rock and Soil
Descriptions', Hong Kong Government, 1988.

6/75
January 2011
(b)
8.5.12
Drillhole logs shall be drawn to a constant vertical scale of 1:50 and shall
contain the following details:
(i)
information shown and in the format in Figure 44 and Paragraphs 40.2.6

(2), (4) and (5) of 'Geoguide 2 : Guide to Site Investigation', Hong Kong
Government, 1987;
(ii)
reduced levels of groundwater strike, observation well bases,

piezometer tips, and sand filter layers; and
(iii)
details of utilities identified in the inspection pit excavated at the drillhole

location.
Sampling equipment for ground investigation

Sampling equipment and containers for ground investigation shall comply with
BS5930 and the following :
(a)
For general purpose open tube samples and thin-walled samples, the sample
tube and cutting shoe shall be free from rust, pitting, burring or any other
defect. The use of oil inside the sampler shall be limited to the minimum
practical. Each sample tube shall have a unique reference number and the
word 'TOP' engraved on its exterior at one end. The sample tube shall be
driven with the end marked 'TOP' uppermost. The dimensions, construction
and condition of each sample tube, cutting shoe and adaptor head shall be
reviewed by the Project Manager prior to sampling. The adaptor head shall be
fitted with a ball valve to permit the exit of air or water during driving and to
assist in retaining the sample during withdrawal, and it shall have an
allowance for over-driving. In soil of low cohesion such as silts and silty fine
sands the sampler shall be equipped with a basket core retainer to enhance
core recovery.
(b)
U100, U76 and U40 thin-walled samplers shall be 102 mm (for U100), 78 mm
(for U76) and 42 mm (for U40) diameter open drive sample tubes made from
thin-walled seamless cadmium plated or stainless steel not less than 450 mm
(for U100), 350 mm (for U76) and 200 mm (for U40) in length fitted with a
cutting shoe tapered at an angle not exceeding 20. The area ratio of the
sampler as defined in Figure 13 of 'Geoguide 2 : Guide to Site Investigation',
Hong Kong Government, 1987 shall not exceed 30%.
(c)
Piston samplers shall be a thin-walled fixed piston sampler. The piston

sampler shall be capable of operating to a depth of at least 20 m below
ground level with no lateral movement during the actual sampling operation.
The design and maintenance of the sampler shall be such that a partial
vacuum is formed over the retained sample in the tube. The minimum
recovered sample length shall be 900 mm. The thin-walled tube shall have an
external diameter of 75 mm or 100 mm as directed by the Project Manager.
The area ratio of the sampler as defined in Figure 13 of 'Geoguide 2 : Guide
to Site Investigation', Hong Kong Government, 1987 shall not exceed 10%.

7/75
January 2011
(d)
Mazier samplers shall be a Mazier triple-tube core barrel fitted with a

detachable rigid PVC inner tube, 2 mm thick, 74 mm internal diameter by
1000 mm long having a detachable projecting cutting shoe which perforates
the soil and insulates the core sample from the drilling fluid. The internal
diameter of the projecting shoe should not differ by more than 2 mm. The
dimensions of the sampler shall not differ by more than 0.50 mm from those
shown in Table 8.1 basket core retainer shall be fitted at the bottom of the
PVC inner tube to assist in recovery of the core. The length of the sample
recovered shall not be less than 750 mm. A triple-tube core barrel of
alternative design shall be submitted for the Project Manager's review.
(e)
Split spoon samplers for the standard penetration test shall be provided with a
thin smooth stainless steel.
Table 8.1: Dimensions of Mazier Core Barrel Sampler

Item
Inner Barrel Cutting Shoe
Core bit
Liner tube
Inner tube barrel
Outer tube barrel
8.5.13
Dimension (mm)
72.0
77.2
101.1
74.0
78.0
88.5
98.5
ID
OD
OD
ID
ID
OD
OD
Sampling for ground investigation

(a)
A reference number shall be assigned to each soil sample taken from a

drillhole or trial pit. The number shall be unique for that drillhole or trial pit and
shall be in order of depth below ground level.
(b)
The visible ends of each undisturbed sample shall be trimmed of any

disturbed material immediately after recovery from the ground. The sides of
the tube or box shall be cleaned and the ends of the sample shall be coated
with three successive thin films of just-molten microcrystalline wax. A metal
foil disc or plate shall be added and followed by more molten wax to give a
total thickness of at least 20 mm. Any space remaining in the ends of the
sample tube or box shall be solidly filled with damp sawdust and the ends of
the sample tube shall be covered with tight fitting rubber caps.
(c)
Each sample shall be identified by a label. The label shall be written with
permanent ink and protected from moisture, damage and loss. The minimum
labelling requirements shall be as follows:
(i)
All labels shall contain the following information:

name of Contract;
name or reference number of the site;
reference number, location and angle of borehole;
reference number of sample;
date of sampling;
brief description of the sample;
depth of the top and the bottom of the sample below ground level;
and
location and orientation of the sample if taken from a trial pit.

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January 2011
8.5.14
8.5.15
(ii)
For jar samples, a stick-on label covered with a transparent plastic

cover shall be secured with adhesive tape to the body of the jar.
(iii)
For undisturbed and bulk samples, a permanent or stick-on label

covered with a transparent plastic sheet shall be secured with adhesive
tape to the body of the container. An additional label giving the sample
reference number and depth of sample shall be sealed in with the
sample.
(iv)
For core samples stored in core boxes, a stapled card, stick-on label or
permanent ink shall be used externally on the front of the box and
repeated inside. The hole reference number shall be written in
permanent ink or paint on each end of the core box.
Storage and delivery of samples for ground investigation

(a)
Samples for ground investigation shall be delivered to, and stored at, a core
store at a location reviewed without objection by the Project Manager.
Samples shall be delivered to the testing laboratory at a time reviewed without
(b)
Undisturbed soil samples shall be stored and delivered in a wooden crate of

appropriate dimensions. The samples shall be kept in an upright position with
a separate compartment for each sample. The compartment shall be properly
padded and the lower end of the sample shall be placed in the bottom of the
compartment.
(c)
The samples shall not be disturbed during transportation, handling and

storage.
Bulk samples
Bulk samples shall be obtained from undisturbed ground. Each bulk sample shall
be sealed into a metal or plastic container immediately after it has been taken.
8.5.16
Mazier samples
Mazier samples shall be taken by a Mazier sampler and in accordance with Clause
8.5.12.
8.5.17
U100 and U76 samples

(a)
Sample tubes shall be advanced by jacking action. The jack shall be arranged
to align with the sampler. Measures shall be taken to prevent lateral
movement during the sampling operation.
(b)
Each U100 sample shall contain at least 300 mm net length of undisturbed
material and each U 76 sample shall contain at least 200 mm net length of
undisturbed sample.

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January 2011
8.5.18
8.5.19
8.5.20
Block samples
(a)
Block samples shall be taken from the sides or bottom of trial pits at locations
and orientations determined by the Project Manager.
(b)
Each block sample shall be at least 230 mm x 230 mm x 230 mm and shall be
excavated, trimmed, cut, wrapped, waxed and packed in metal or wooden
boxes in accordance with the procedure stated in Part A of Des. E-2 of the
United States Bureau of Reclamation Earth Manual.
Rock cores
(a)
Rock cores obtained from drillholes shall be removed from the core barrel
without damage by gentle hammering with a wooden mallet on the side of the
core barrel to free wedges pieces; other methods shall not be used.
(b)
As the rock core is extruded, it shall be arranged in the box in sequence

starting with the shallowest core on the left side of the box against the hinge
and working along the slat and subsequently outwards towards the staple.
The depths at which each core run started and finished shall be recorded
within the box by painting on wooden blocks which fit between the dividing
slats. Fractured rock core shall be spread throughout its length and packed
securely. Rock core losses shall be shown by wooden blocks or polystyrene
of a square cross section to fill the core box; the length of the wooden block or
polystyrene shall be equal to the length of core lost.
Standard penetration tests

(a)
The apparatus and procedure for standard penetration tests shall comply with
BS1377:1975, Test 19. The drive hammer shall be a type incorporating an
automatic trip mechanism to ensure free fall. The 60 solid core shoe shall be
used in soil containing coarse gravel.
(b)
A thin smooth stainless steel or aluminum liner of 35 mm internal diameter

shall be fitted in the split-spoon sampler during the standard penetration test.
After the sampler has been withdrawn from the drillhole, the liner and the
retained soil shall be treated in the same manner as an undisturbed sample.
(c)
Standard penetration tests shall be carried out below the level of the casing.
The base of the drillhole shall be fully cleaned before the test starts. Jar
samples shall be taken from the split-barrel shoe after each test.
(d)
The number of blows of the drive hammer required to achieve each 75 mm of

shoe penetration until a total penetration of 450 mm has been achieved shall
be recorded. The N-value shall be recorded as the sum of the number of
blows of the drive hammer required to achieve the last 300 mm of shoe
penetration. The number of blows recorded for the initial 150 mm of shoe
penetration shall not be included in the N-value calculation. If any increment
of 75 mm of shoe penetration is not achieved after 100 blows of the drive
hammer, the number of blows and the penetration achieved shall be recorded
and the test shall be terminated.

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January 2011
8.5.21
GEO probe tests

GEO probe tests shall be carried out in accordance with Appendix A8.1. The GEO
probe hole shall be sealed with cement grout on completion of the test for at least
the top 600 mm of the hole. The grout shall consist of cement and water in the
proportions 0.4:1 by mass.
8.5.22
8.5.23
In-situ density tests

(a)
In-situ density tests shall be carried out by the sand replacement method in
accordance with Clause 7.5.14 (e) and (f).
(b)
A jar sample shall be taken at each location where an in-situ density test is
carried out.
Rising and falling head permeability tests

(a)
Rising and falling head permeability tests shall be carried out using the
apparatus described in Figure 27 of 'Geoguide 2: Guide to Site Investigation',
Hong Kong Government, 1987. The method of testing shall be in accordance
with Figure 30 of 'Geoguide 2: Guide to Site Investigation', the method of
flushing of the bottom of the drillhole stated in Clause 8.5.23(d) shall be used.
The type of filter material and sand to be used shall be in accordance with
Clause 8.24.10(b), and shall be placed in the drillhole using a tremie pipe.
(b)
Rising head permeability tests shall be carried out by lowering the water level
in the standpipe by approximately 3 m. The water level in the standpipe shall
be allowed to rise to equalise with the ground water level and the time for
each 0.2 m rise in water level shall be recorded.
(c)
Falling head permeability tests shall be carried out by raising the water level in
the standpipe by approximately 3 m. The water level in the standpipe shall be
allowed to fall to equalise with the ground water level and the time for each
0.2 m drop in water level shall be recorded.
(d)
The method of flushing of the bottom of the hole for field permeability tests
shall be as follows:
(i)
Clean water shall be introduced to the cased hole through a 38 mm

diameter pipe fed from a storage tank. The feed pipe shall contain a
perforated section 480 mm in length consisting of 20 rings of holes, at
25 mm centres, each containing 4 holes of 6 mm diameter. The
complete perforated section shall be positioned such that it is just below
the existing ground water level in the borehole. The end of the
perforated section of pipe shall be capped.
(ii)
The flushing water shall be withdrawn from the casing through a 38mm
diameter pipe positioned with its open end between 150 mm and 200
mm above the base of the borehole. The discharge shall be by means
of a pump of sufficient capacity to extract the flushing water from the
base of the borehole. Control of the flow of clean water and discharge
water shall be by means of valves positioned on the inflow pipe and the
discharge pipe.

11/75
January 2011
8.5.24
Constant head permeability tests

(a)
Constant head permeability tests shall be carried out using the apparatus
described in Clause 8.5.23(a). Clean water shall be fed into the standpipe at
a constant rate and the time for each 0.2 m rise in water level shall be
recorded until either a constant water level is established or until the water
level is 0.3 m below the top of the casing. The constant rate of inflow which is
required to maintain a constant head shall be recorded.
(b)
After a constant water level has been achieved as stated by Clause 8.5.24(a),
the cumulative inflow readings required to maintain the constant head shall be
recorded in the following sequence:
(i)
4 readings at 15 second intervals;
(ii)
9 readings at 1 minute intervals;
(iii)
4 readings at 5 minute intervals; and
(iv)
readings at 10 minute intervals until two consecutive readings differ by

less than 0.5 litre.
8.6
INSPECTION, TESTING AND COMMISSIONING GROUND INVESTIGATION
8.6.1
Records of in-situ testing

(a)
Records of each in-situ test shall be kept by the Contractor on Site. The
Project Manager shall be notified before test apparatus is dismantled.
(b)
The results of standard penetration tests shall be recorded on drillhole logs as

stated in Clauses 8.5.11 and 8.6.2.
(c)
The results of GEO probe tests shall be recorded as stated in Clause 8.5.21
and shall be submitted to the Project Manager for review within 24 hours after
the test.
(d)
The results of in-situ density tests shall be recorded in a form reviewed

without objection by the Project Manager and shall be submitted to the Project
Manager for review within 24 hours after the test.
(e)
The results of rising, falling and constant head permeability tests shall be
recorded as stated in Clauses 8.5.23 and 8.5.24 and shall be submitted to the
Project Manager for review within 24 hours after the test. The results of the
rising and falling head permeability tests shall be recorded in the format
shown in Figure 30 of 'Geoguide 2 : Guide to Site Investigation', Hong Kong
Government, 1987.

12/75
January 2011
8.6.2
Reports for ground investigation

(a)
(b)
Daily records of ground investigation operations shall be kept by the

Contractor on Site and two copies of the records shall be submitted to the
Project Manager for review within 3 days after the ground investigation
operation to which they refer. The daily records shall contain the following
information in a form reviewed without objection by the Project Manager:
(i)
Contractor's name, and Contract number, borehole reference number

and inclination, site name, rig type and number, operator, hours worked
with times, date, weather, ground level at borehole and measured water
levels in the borehole at various times;
(ii)
for each sample, drilling or core run for each test, installation or strata
encountered, the following where applicable:
start and finish depths below ground level;
start and finish times;
casing diameter and depth;
bit number and type;
sample reference number and type;
SPT test result in number of blows recorded;
percentage water returns and core recovery;
a description of the soil and rock strata or sample; and
a description of field tests or instruments installed.
A final report on ground investigation operations shall be prepared by the

Contractor and shall be submitted to the Project Manager for review within 15
days after all comments on the preliminary drillhole logs have been received
from the Project Manager. The report shall contain the drillhole logs and test
records.
8.7
MATERIALS - SLOPE TREATMENT WORKS
8.7.1
Cement mortar
8.7.2
(a)
Cement mortar for in-filling joints in rock faces, for bedding rock for masonry
infilling and for surfacing slopes shall consist of OPC and sand in the
proportions 1:3 by volume.
(b)
OPC shall comply with BS 12.
(c)
Sand shall be natural sand or crushed natural stone complying with BS 1200.
Rock for masonry infilling

Rock for masonry infilling shall not exceed 300 mm in size and shall be obtained
from a source reviewed without objection by the Project Manager.

13/75
January 2011
8.7.3
Soil-cement
(a)
8.7.4
8.7.5
(b)
Soil-cement shall consist of OPC, sand and inorganic soil in the proportions
1:3:12 by mass.
(c)
Sand shall comply with BS 1200.
(d)
Inorganic soil shall be free from organic matter and shall contain not more
than 30% of soil particles passing a 63 m BS test sieve.
Chunam
(a)
Chunam for surfacing shall consist of OPC, hydrated lime and inorganic soil in
the proportions 1:3:20 by mass.
(b)
(c)
Hydrated lime shall comply with BS 890, Type 1.
(d)
Inorganic soil shall be as stated in Clause 8.7.3(d).
Aggregates for sprayed concrete

The nominal maximum aggregate size of aggregates for sprayed concrete shall not
exceed 10 mm.
8.7.6
Reinforcement for sprayed concrete

Fabric reinforcement for sprayed concrete shall comply with BS 4483.
8.7.7
Protective mesh and fixings

(a)
Protective mesh for slopes shall be PVC coated galvanized steel wire woven
into a double twist hexagonal mesh; each hexagon shall be 80 mm x 60 mm.
The steel wire shall be at least 2.2 mm diameter and the PVC coating shall be
at least 0.4 mm thick.
(b)
Tying wire for protective mesh shall be 2.2 mm diameter PVC coated
galvanized soft annealed steel wire.
(c)
Bolts for fastening protective mesh to rock shall be galvanized mild steel
hooks as stated in the Contract.
(d)
Bolts for permanent protective screens shall be galvanized to a minimum

average mass coating of 610 g/m.
(e)
Galvanizing shall comply with BS 729.

14/75
January 2011
8.7.8
8.7.9
Rock bolts
(a)
Rock bolts shall be a proprietary type reviewed without objection by the

Project Manager. Rock bolts shall comply with CS2 and shall be mild steel or
high yield deformed steel as stated in the Contract. Rock bolts shall be
galvanized to a minimum average mass coating of 610 g/m in accordance
with BS 729.
(b)
The rated working load of rock bolts shall not exceed 50% of the ultimate
tensile strength. A reduction of 4 mm in the diameter of the bolt shall be taken
into account for corrosion when calculating the ultimate tensile strength.
Grout for rock bolts

Grout for rock bolts shall be as stated in Clauses 8.11.2 and 8.14.5 except that the
water cement ratio shall not exceed 0.45.
8.7.10
Rock dowels
Rock dowels shall comply with CS2 and shall be high yield deformed steel as stated
in the Contract.
8.7.11
Grout for rock dowels

Grout for rock dowels shall be as stated in Clauses 8.11.2 and 8.14.5 with a water
cement ratio not greater than 0.45.
8.8
SUBMISSIONS SLOPE TREATMENT WORKS
8.8.1
Particulars of access
Particulars of the proposed means of access for slope treatment works, including
access structures and reinstatement, shall be submitted to the Project Manager for
review.
8.8.2
Particulars of sprayed concrete

(a)

construction shall be submitted to the Project Manager for review:
(i)
type and performance of mixing and spraying plant;
(ii)
details of water sprays and associated pumps for surface spraying;
(iii)
method of curing;
(iv)
details of trial panels and test panels;
(v)
methods of measuring surface temperature and moisture content of the

soil; and
(vi)
methods of achieving the specified thickness of sprayed concrete and

the specified cover to reinforcement and methods of measuring the
thickness and cover after spraying.

15/75
January 2011
8.8.3
Particulars of rock bolts

(a)
8.8.4
The following particulars of the materials and methods of construction for rock
bolts shall be submitted to the Project Manager for review:
(i)
details of rock bolts, anchorages and centralizers;
(ii)
methods of tensioning and grouting;
(iii)
proposed working loads;
(iv)
previous performance records; and
(v)
details of equipment for testing rock bolts, including test and calibration
certificates.
Representative samples of materials

A representative sample of a complete rock bolt shall be submitted to the Project
Manager for review of the source and type of rock bolt at the same time as
particulars of rock bolts are submitted.
8.9
WORKMANSHIP SLOPE TREATMENT WORKS
8.9.1
Access to slopes
(a)
Means of access consisting of materials reviewed without objection by the

Project Manager shall be installed to enable the Project Manager to examine
slope treatment works. The means shall allow access to within 0.8 m of the
slope face; hand and foot holds for climbing shall be provided by members at
centres not exceeding 0.5 m vertically and 0.8 m horizontally.
(b)
A system of safety ropes shall be installed on the means of access; safety

ropes shall be 12 mm diameter and shall have a breaking force of at least 22
kN. The system of safety ropes shall consist of:
(i)
vertical ropes at not more than 3 m centres horizontally securely

anchored to the crest of the slope; and
(ii)
horizontal ropes at not more than 3 m centres vertically.
The system of safety ropes shall be constructed in such a manner that the ropes
are tied at not more than 3 m spacings in both directions to form a net.
8.9.2
Protection fences and barriers

(a)
Protection fences and barriers for slope treatment works shall be constructed
as stated in the Contract before slope treatment work starts.
(b)
Damage to protection fences and barriers shall be repaired immediately. The

Contractor shall notify the Project Manager before protection fences and
barriers are dismantled.

16/75
January 2011
8.9.3
8.9.4
8.9.5
Preparation for slope treatment works

(a)
Vegetation shall be cleared and existing impermeable surfaces and topsoil

shall be removed from existing soil slopes before slope treatment works start.
(b)
Loose material shall be removed from the surface of new soil slopes and the
surface shall be trimmed and scarified before slope treatment works start.
The surface shall be moistened immediately before the slope surface
treatment works start.
(c)
Rock faces and joints, and the surface and joints of retaining walls shall be
cleaned of moss, vegetation and loose material, immediately before slope
treatment works start, and surplus water shall be removed by an air jet.
Water flowing from or across the rock face shall be diverted by relief drains
before the application of impermeable surfaces. All vegetation and loose
material shall be removed from rock joints. Moss and loose materials shall be
removed by wire brushing or scraping.
Scaling and trimming of rock slopes

(a)
Scaling and trimming of rock slopes shall be carried out in such a manner that
soil and rock is removed from the slope face without affecting the stability and
integrity of the slope. Measures shall be taken to prevent uncontrolled falls of
debris arising from scaling and trimming works. Scaling and trimming of rock
slopes shall be carried out using hand-held tools, pneumatic tools or feather
and wedge.
(b)
All material removed or excavated by scaling and trimming and loose

fragments of soil and rock shall be removed from the slope. Rock faces shall
be cleaned using a water jet coupled to compressed air after scaling and
trimming is complete.
Rock splitting
Rock splitting shall be carried out using percussive hammers, drills, hydraulic
splitters, chemical expanding agents or hand-tools. Explosive shall not be used.
8.9.6
Removal of boulders
Boulders which are to be removed from slopes shall be broken down by means of
line drilling, expansive grouts or rock breakers. Explosives shall not be used.
8.9.7
Sealing and infilling & rock joints

Joints in rock faces shall be sealed with Grade 20/20 concrete, cement mortar or
masonry. Rock for masonry infilling shall be bedded in cement mortar. Relief
drains directed by the Project Manager shall be installed before rock joints are
sealed or infilled.

17/75
January 2011
8.9.8
8.9.9
Concrete buttresses
(a)
Concrete for buttresses shall be Grade 20/20 unless otherwise stated in the
Contract.
(b)
Drainage which is required behind buttresses shall consist of relief drains

connected to 50 mm diameter PVC outlet pipes laid at a gradient of at least 1
in 50; the PVC pipes shall be securely fixed to the formwork before concreting
starts.
Mixing soil-cement
Soil-cement shall be thoroughly mixed in a concrete mixer; small quantities of soilcement shall not be hand mixed. The constituents of the mix shall be as reviewed
without objection by the Project Manager on the basis of the results of field trials.
8.9.10
8.9.11
Deposition and compaction of soil-cement fill

(a)
Soil-cement fill shall be deposited in its final position and compacted within 30
minutes after the cement has been added to the mix.
(b)
Soil-cement fill shall be compacted as stated in Clauses 7.4.26 and 7.4.29,

using the layer thickness and compactive effort successfully demonstrated in
the field trials and reviewed without objection by the Project Manager.
(c)
The moisture content of the soil cement mix shall not be less than the
optimum value as determined by the vibrating compaction method of BS 1924
: Part 2, nor more than 2% above this optimum value.
(d)
The relative compaction of the soil cement fill will be as reviewed without
objection by the Project Manager following review of the results of the field
trials, but in any case will not be less than 95% of the maximum dry density
for the agreed mix as determined by the vibrating compaction method of BS
1924 : Part 2.
(e)
The in-situ density of compacted soil cement fill shall be determined using the
sand replacement method of BS 1924 : Part 2.
Mixing chunam
The cement and lime for chunam shall be mixed dry before adding the soil. The
materials shall then be mixed thoroughly, with water sprinkled, until the colour and
consistency are uniform.
8.9.12
Placing and compacting chunam

(a)
Bamboo dowels shall be driven into the face of the slope on which chunam
will be placed at 1.5 m centres on a staggered pitch to leave a 25 mm
projection from the slope face to receive the chunam. Bamboo dowels shall
be at least 25 mm in diameter and shall be 150 mm long. Bamboo dowels
shall not be used on slopes less than 30 to the horizontal.
(b)
The chunam shall be laid to a total thickness of 50 mm in two equal layers;

the layers shall be well compacted by ramming. The bottom layer of chunam
shall be left with a rough finish to provide bonding for the top layer.

18/75
January 2011
(c)
8.9.13
The top layer of chunam shall be thoroughly wetted and rubbed with sacks to
fill any cracks immediately before the chunam hardens. The surface shall be
sprinkled with water and finished by trowelling to form a smooth uniform
surface.
Joints in chunam
Joints in chunam shall be neat and straight and panels shall be rectangular. Joints
in the top and bottom layers shall not coincide.
8.9.14
Weepholes in chunam
50 mm diameter PVC weepholes shall be constructed at 1.2 m staggered centres in
each direction before chunam is placed; the weepholes shall penetrate at least 50
mm into the soil.
8.9.15
Temporary chunam surfaces

Temporary chunam surfaces to the faces of slopes or excavations shall consist of a
single layer of chunam 20 mm thick, without bamboo dowels. Temporary chunam
drainage channels shall be constructed by building up the chunam to an appropriate
shape or by cutting a channel into the slope and lining with chunam. Temporary
chunam shall be removed in stages before deposition of fill material or slope
treatment works start.
8.9.16
8.9.17
Preparation of slope surfaces for sprayed concrete

(a)
Weak material along joints or seams in slope surfaces to which sprayed

concrete will be applied shall be removed to a depth equal to the width of the
weak zone.
(b)
When the soil surface temperature exceeds 25C or the moisture content is
less than 10%, the surface to be sprayed shall be watered using sprays.
Hoses without sprays shall not be used. Spraying of water onto the slope
surface shall be carried out not more than 1 hour before spraying of concrete
starts.
Fixing reinforcement
Fabric reinforcement for sprayed concrete shall be fixed securely to the slope by
steel nails or rawl bolts and shall be laid without sharp bends or creases. The cover
to the reinforcement shall be at least 20 mm and laps between adjacent sheets
shall be at least 150 mm.
8.9.18
Weepholes in sprayed concrete

50 mm diameter weepholes shall be constructed at 1.2 m staggered centres in each
direction; the weepholes shall extend to the full thickness of the sprayed concrete.
8.9.19
Equipment for spraying concrete

Equipment for spraying concrete shall be the dry mix delivery type with water added
at the nozzle. The equipment shall be fitted with weighbatching facilities. The
equipment shall be capable of projecting a mixture of cement, fine and coarse
aggregate and water at high velocity on to the surface of the slope to produce a
dense homogeneous cover.

19/75
January 2011
8.9.20
8.9.21
Spraying concrete
(a)
The surface temperature and moisture content of the soil shall be measured,
and the results submitted to the Project Manager for review, immediately
before sprayed concrete is applied.
(b)
The aggregate and sand for sprayed concrete shall be kept dry before mixing.
The water shall be added at the nozzle at the instant of application. The air
and water supply, the rate of application and all other factors affecting the
quality of the work shall be adjusted to produce dense concrete with no
sloughing. Rebound material shall not be reused and shall be removed within
8 hours after spraying.
(c)
Sprayed concrete shall be applied in layers not exceeding 50 mm thick to the

total thickness stated in the Contract. The maximum panel dimension shall not
exceed 15 m.
Curing sprayed concrete

Sprayed concrete shall be cured for at least 4 days after application by either
Method 1, Method 2 or Method 3 as stated in Clause 20.7.15.
8.9.22
Fixing protective mesh for slopes

Protective mesh for slopes shall be suspended down the rock face and bolted into
the slope face at 250 mm centres at the top and sides of the mesh and at 5 m
intervals at the toe of the slope. Laps in the mesh shall be at least 300 mm and
each side of the lap shall be tied at 125 mm centres with galvanised and PVC
coated binding wire.
8.9.23
Trials for rock bolts

The design bond length of rock bolts with bonded anchorages shall be determined
for each rock type by a pull-out trial. The proof load of a pull-out trial shall be twice
the working load. Pull-out trials shall be carried out on two bolts for each
combination of rock bolt and rock type. The bolts used in trials shall be discarded
and shall not form part of the Permanent Works, and the hole shall be sealed by
grouting.
8.9.24
Drilling, preparing and testing rock bolt holes

(a)
Holes for rock bolts shall be drilled at the locations and to depths directed by
the Project Manager. The diameter of the hole shall be at least 20 mm larger
than the diameter of the rock bolt or the outer diameter of the connectors,
whichever is larger. The method of drilling shall be rotary or rotary percussive
with water flush or air flush accompanied by the operation of an effective dust
extraction and filtering device. Holes shall be drilled to provide 50 mm cover
to the end of bolts for which cement grout is used to form the bond length.
(b)
Holes for rock bolt shall be flushed with clean water before rock bolt
installation starts until the return water runs clear. Standing water shall be
blown out from the hole using compressed air after flushing.
(c)
Holes for rock bolts shall be tested by the Packer test as stated in Clauses
8.10.11, 8.10.12 and 8.10.13 and the results of the tests shall be submitted to
the Project Manager for review, before installation of rock bolts starts.

20/75
January 2011
8.9.25
8.9.26
8.9.27
Fixing rock bolts

(a)
The Project Manager shall be notified before installation of rock bolts starts.
(b)
Rock bolts shall be installed in accordance with the manufacturer's

recommendations.
(c)
Rock bolts shall be fully grouted after stressing.
(d)
Installation of rock bolts, including grouting of the free length and installation
of head protection, shall be completed as soon as practicable and not more
than 14 days after completion of the drillhole.
(e)
Rock bolts with a grouted anchorage shall not be stressed until the grout
crushing strength has attained a value of 21 MPa when tested in accordance
with Clauses 8.15.9, 8.15.10 and 8.15.11.
Grouting rock bolts

(a)
Grouting for rock bolts shall be in accordance with the requirements stated in
Clauses 8.11 to 8.15 except as stated in Clause 8.9.26(b) and (c).
(b)
Grout shall be introduced at the lower end of drillholes with downward

inclinations and shall displace all air and water through the top of the drillhole.
(c)
Packers and return ducts which maintain a head on the grout until the grout
has set shall be used for drillholes with upward inclinations or with inadequate
downward inclinations. The packers and ducts shall be such that separate
grouting of the anchorage zone and free-length zone of the drillhole can be
carried out. The head to be maintained on the grout shall be as reviewed
Proving rock bolts

Each installed rock bolt shall be proved as stated in Clauses 8.10.14 to 8.10.16
Rock bolts shall be locked off at 1.1 times the working load after proving. The
complete bolt head assembly shall be encased by a concrete block after locking off.
8.9.28
Records of rock bolts

Records of installation of rock bolts shall be kept by the Contractor on Site and a
copy shall be submitted to the Project Manager for review within 7 days after each
installation operation. Records shall contain the following:
(a)
rock bolt identification number;
(b)
drilling details, including:

(i)
date and time drilling started and finished;
(ii)
machine and operator identification;
(iii)
location, level, inclination, bearing, length and diameter of drillhole; and
(iv)
rate of penetration at 0.5 m intervals;

21/75
January 2011
(c)
(d)
(e)
8.9.29
watertightness of drillhole, including:

(i)
date and time water test started and finished;
(ii)
details of any pre-grouting and redrilling;
(iii)
length of test zone;
(iv)
water pressure applied;
(v)
duration of test; and
(vi)
measured water absorption rate;
details of steel bolts, including:

(i)
type and diameter;
(ii)
bond length;
(iii)
overall length;
(iv)
number and type of centralising spacers; and
(v)
stressing record and lock-off load;
details of grouting, including:

(i)
date and time grouting started and finished;
(ii)
details of any packers used and length of grouted zones;
(iii)
head maintained on grout during setting;
(iv)
volume of grout accepted; and
(v)
identification marks of grout cubes.
Drilling and preparation of rock dowel holes

The drilling and preparation of holes for rock dowels shall be as stated in Clause
8.9.24(a) and (b).
8.9.30
Grouting rock dowels

(a)
Grouting for rock dowels shall be in accordance with the requirements stated
in Clauses 8.11 to 8.15 except as stated in Clause 8.9.30(b).
(b)
Rock dowels shall be grouted over the complete length of the drillhole in
which the dowel is installed. Centralisers shall be fitted to rock dowels before
grouting to ensure an even annulus of grout.

22/75
January 2011
8.9.31
Records of rock dowels

Records of installation of rock dowels shall be kept by the Contractor on Site and a
copy shall be submitted to the Project Manager for review within 7 days after each
installation operation. The records shall contain at least the following details:(a)
rock dowel identification number;
(b)
drilling details, including:
(c)
(d)
(e)
(i)
date and time drilling started and finished;
(ii)
machine and operator identification;
(iii)
location, level, inclination, bearing, length and diameter of drillhole; and
(iv)
rate of penetration at 0.5m intervals;
watertightness of drillhole, including:

(i)
date and time water test started and finished;
(ii)
details of any pre-grouting and redrilling;
(iii)
length of test zone;
(iv)
water pressure applied;
(v)
duration of test; and
(vi)
measured water absorption rate;
details of steel dowels, including:

(i)
type and diameter;
(ii)
bond length;
(iii)
overall length; and
(iv)
number and type of centralising spacers; and
details of grouting, including:

(i)
date and time grouting started and finished;
(ii)
details of any packers used and length of grouted zones;
(iii)
head maintained on grout during setting;
(iv)
volume of grout accepted;
(v)
identification marks of grout cubes; and
(vi)
results of cube tests on grout.

23/75
January 2011
8.10
INSPECTION, TESTING AND COMMISSIONING SLOPE TREATMENT WORKS
8.10.1
Chunam Surface Trial panel

A trial panel 50 mm thick and at least 3m x 3m shall be constructed for chunam
surfaces.
8.10.2
Trial panel
A trial panel at least 50 mm thick and at least 3m x 3m shall be constructed for
sprayed concrete on the surface to be treated. The average percentage rebound
shall be estimated for each trial panel and shall be used in the calculations of the
cement content of the applied concrete.
8.10.3
Inspection of sprayed concrete

Completed areas of sprayed concrete shall be sounded using a wooden mallet;
areas which in the opinion of the Project Manager are substandard or hollow shall
be removed and resprayed.
8.10.4
Records of sprayed concrete

Records of sprayed concrete operations shall be kept by the Contractor on Site and
shall be submitted daily to the Project Manager for review. The records shall contain
details of the quantities of all materials used at each location.
8.10.5
Testing: Optimum moisture content and maximum dry density of soil-cement

fill
The maximum dry density and optimum moisture content of soil-cement fill shall be
tested as stated in Clauses 7.5.7 to 7.5.13 except that the method of testing shall
be the Vibrating Hammer Test Method in accordance with BS 1924.
8.10.6
Testing: test panels for sprayed concrete

(a)
The strength of sprayed concrete shall be determined from concrete cores cut
from a test panel constructed at the same time as sprayed concrete is
applied.
(b)
One test panel shall be constructed for each area of sprayed concrete of
500m or part thereof.
(c)
The test panel shall be 250 mm thick and shall be at least 1 m x 1 m. The
mould shall be securely fixed in position at the same height and inclination as
the surface being sprayed. The panel shall be constructed by spraying
concrete into the mould at the same time as the concrete to be tested is
applied. The test panel shall be cured by the same method as the sprayed
concrete.

24/75
January 2011
8.10.7
8.10.8
8.10.9
Samples: concrete cores from sprayed concrete

(a)
Three concrete cores shall be provided from each test panel; cores shall not
be taken within 125 mm from the edges of the panel.
(b)
Concrete cores shall be 100 mm diameter and shall be the full depth of the
test panel.
(c)
The method of taking concrete cores shall be in accordance with CS 1.
Testing: concrete cores from sprayed concrete

(a)
Each concrete core shall be tested to determine the compressive strength and
density.
(b)
The method of preparing and testing the cores to determine the compressive
strength shall be in accordance with CS 1; the method of testing the cores to
determine the density shall be in accordance with CS 1. Three concrete cores
shall be tested at 28 days.
Compliance criteria: concrete cores from sprayed concrete

The results of tests for compressive strength of concrete cores shall be interpreted
in accordance with BS 6089. Adjustments to the measured strength in respect of
the age of the core when tested shall not be made. The minimum compressive
strength of concrete cores, converted to estimated in-situ cube strength in
accordance with BS 6089 shall be 20 MPa at 28 days.
8.10.10 Non-compliance: concrete cores from sprayed concrete

If the result of any test for compressive strength or density of concrete cores from
sprayed concrete does not comply with the specified requirements for the property,
particulars of proposed changes to the materials, mix design, methods of production
or methods of construction shall be submitted to the Project Manager for review;
further trial mixes shall be made and further trial panels shall be constructed.
8.10.11 Testing: Packer test
(a)
The water loss from drillholes for rock bolts shall be determined by the Packer
test. The number of drillholes to be tested will be directed by the Project
Manager.
(b)
The Packer test shall be carried out on the bond length of the drillhole at a
test pressure of 100 kPa. The method of testing shall be as stated in Clause
8.15.12.
8.10.12 Compliance criteria: Packer test

The water loss determined by the Packer test in the grouted hole shall not exceed 5
Lugeons when measured over a 10 minute period.

25/75
January 2011
8.10.13 Non-compliance: Packer test

If the result of any Packer test on drillholes for rock bolts does not comply with the
specified requirements for the test, the drillhole shall be grouted, re-drilled and
retested. Grouting, re-drilling and retesting shall be continued until the result of the
Packer test complies with the specified requirements for the test.
8.10.14 Testing: rock bolts
Each installed rock bolt shall be tested to determine the loss in stress by applying a
test load of 1.5 times the working load for 5 minutes.
8.10.15 Compliance criteria: rock bolts
The loss in stress in installed rock bolts shall not exceed 5% of the test load in 5
minutes.
8.10.16 Non-compliance: rock bolts
(a)
If the result of any test for loss in stress of installed rock bolts does not comply
with the specified requirements for the test, an additional test for loss of stress
shall be carried out on the rock bolt.
(b)
If the result of any additional test for loss of stress of installed rock bolts does
not comply with the specified requirements for the test, the rock bolt shall be
replaced.
8.11
DEFINITIONS AND ABBREVIATIONS - GROUTING FOR GEOTECHNICAL

WORKS
8.11.1
Ground
Ground, for the purpose of grouting for geotechnical works, is fill material, soil and
rock and the interfaces between fill material, soil and rock and any structures.
8.11.2
Grout
Grout, for the purpose of grouting for geotechnical works, is cement grout,
cement-sand grout, cement-bentonite grout and proprietary grout reviewed without
8.11.3
Grouting
Grouting, for the purpose of grouting for geotechnical works, is the mixing and
injection of grout through predrilled or preformed holes.
8.11.4
Grouting stage
Grouting stage, for the purpose of grouting for geotechnical works, is the discrete
length of drillhole into which grout is to be injected in a continuous operation.

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January 2011
8.11.5
Lugeon
Lugeon is a water loss of 1 litre per minute per metre length of hole tested at an
effective pressure of 1 MPa.
8.11.6
Batch: grout for geotechnical works

A batch of grout for geotechnical works is any quantity of grout used for grouting
geotechnical works in one continuous operation in one day.
8.12
MATERIALS GROUTING FOR GEOTECHNICAL WORKS
8.12.1
Materials for grout

Materials for grout shall comply with Section 20 except as stated in this Section.
8.12.2
8.12.3
Grout for geotechnical works

(a)
Cement grout for geotechnical works shall consist of OPC, sand and water.
Admixtures shall not be used.
(b)
Sand for grout shall be clean dry sand complying with BS 1200 and shall have
a particle size distribution such that 100% passes a 2 mm BS test sieve and
not more than 30% passes a 0.2 mm BS test sieve.
(c)
Water for grout shall be clean fresh water having a temperature not exceeding
30C or less than 5C.
(d)
Unless otherwise stated in the Contract, cement grout shall have a minimum
crushing strength of 30 MPa at 28 days.
(e)
The amount of bleeding of grout shall not exceed 0.5% by volume 3 hours
after mixing or 1.0% maximum when measured at 23 2C in a covered glass
or metal cylinder of 100 mm internal diameter and with a grout depth of
approximately 100mm. In addition, the water shall be reabsorbed by the grout
within 24 hours.
(f)
The flow cone efflux time of grout shall not be less than 15 seconds.
Standpipes
Standpipes for grouting shall be standard black metal pipe complying with BS 1387.

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January 2011
8.13
SUBMISSION GROUTING FOR GEOTECHNICAL WORKS
8.13.1
Particulars of grouting for geotechnical works

(a)

construction for grouting for geotechnical works shall be submitted to the
Project Manager for review:
(i)
details of drilling, grouting and testing equipment;
(ii)
details of grout mix, including admixtures;
(iii)
methods of storing, mixing and injecting grout;
(iv)
methods of drilling, cleaning, capping and sealing grout holes;
(v)
methods of grouting, including grouting stages, order of working and

regrouting methods; and
(vi)
methods of controlling surface water, groundwater, leakage and ground

movement, including methods of monitoring and instrumentation.
8.14
WORKMANSHIP GROUTING FOR GEOTECHNICAL WORKS
8.14.1
Drilling for grouting for geotechnical works

(a)
Holes in rock for grouting for geotechnical works shall be drilled using rotary
or percussion type drills. The tolerance for the holes shall be as stated in
Clause 8.5.8(a). Grease and other lubricants shall not be used in the flushing
medium or on the rods, except around the threads at the ends of the rods.
Drilling methods which result in drill cuttings causing blockages such that
grouting cannot be performed satisfactorily shall not be used.
(b)
The flushing medium for drilling shall be air, air mist, clean water or air
accompanied by the operation of an effective dust extraction and filtering
device.
(c)
The minimum size of hole for grouting in rock shall be 40 mm.
(d)
Holes in soil for grouting for geotechnical works shall be drilled by a method
which is suitable to the ground conditions and which is reviewed without
The location of all underground obstructions and utilities shall be determined
by the Contractor before drilling starts and the drilling pattern shall take
account of the location of obstructions and utilities.
Casings required to prevent the collapse of grout holes shall be as stated in
Clause 8.5.7. Casings shall be removed immediately before or simultaneously
with the grouting or sleeve grouting operation in such a manner that the grout
hole will not collapse and the injection of grout will not be hindered.
(e)
(f)
(g)
Grout holes shall be flushed clean with water or compressed air introduced at
the bottom of the hole after drilling is complete. The holes shall be protected
with capping pipes or standpipes to prevent subsequent collapse or clogging
after flushing.

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January 2011
(h)
8.14.2
8.14.3
8.14.4
Grout holes which have been drilled more than one day before grouting of the
hole starts shall be reflushed with water or compressed air immediately before
grouting is commenced and excess flushing water shall be removed by air jet.
Holes drilled in soft ground or in ground other than rock and in which sleeve
grouts are proposed as part of the grouting operation shall be sleeve grouted
as soon as practicable after drilling.
Standpipes and capping pipes

(a)
Grout holes shall be capped after drilling and before grouting. Capping shall
be by a suitably sealed grout connection, standpipe or packer. The cap shall
seal the hole to prevent contamination or clogging of the hole until grouting
operations start.
(b)
Standpipes, if stated in the Contract, shall be installed in holes after drilling.

The pipe shall be sealed into the hole using cement grout consisting of OPC
and water in the proportions 1:1 by volume.
Monitoring of grouting operations

(a)
Instrumentation shall be installed to monitor heave, bulging, settlement, lateral

movement, deformation or fracturing of the ground or structures due to
grouting operations. Records of monitoring shall be kept by the Contractor on
Site and a copy submitted to the Project Manager for review. Arrangements
for installing instruments and taking measurements inside and outside the Site
shall be made by the Contractor.
(b)
The accuracy of the instruments shall be checked before grouting starts and
at regular intervals reviewed without objection by the Project Manager.
Grouting equipment
(a)
Standby grouting equipment shall be available at all times and shall be

capable of being brought into operation immediately in the event of
breakdowns during grouting operations.
(b)
Grout mixers shall be high speed colloidal mixers having a rotor speed of at
least 1000 rpm and capable of producing a colloidal grout mix. Mixers shall
be fitted with a water volume measuring device for batching purposes.
(c)
Holding tanks shall be fitted with an agitator to provide continuous agitation of

the grout at 100 rpm. The tank shall be fitted with a dipstick to allow
continuous measurement of the volume of grout in the tank. A 2.36 mm
removable screen shall be provided between the tank and the pump or grout
lines.
(d)
Grout pumps shall be a positive displacement type. Pumps shall be fitted with
bypass valves to allow a standby pump to be brought into operation.

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January 2011
8.14.5
8.14.6
(e)
Working pressure gauges shall be accurate to within 3% and shall be

calibrated against a test gauge before grouting starts and at weekly intervals.
A test gauge with accompanying calibration certificates shall be kept on Site
for the purpose of calibrating working gauges. Working gauges shall be
numbered and a record shall be kept of gauge number, shifts worked,
calibration dates and repairs undertaken; records shall be kept on Site and
shall be available for inspection by the Project Manager at all times.
(f)
Packers shall be such that they seal holes in rock at the specified level and
shall be capable of withstanding the maximum grout or water pressure to be
used at that level without leakage. Packers shall be of the mechanical or
inflatable rubber type. A sufficient number of packers of a size to suit the
holes shall be available on Site.
(g)
Grout hoses shall be of sufficient length and shall be arranged in such a

manner to allow continuous circulation of the grout from the pump to the hole
and back to the agitator and holding tank. Circulation hose lengths shall be
kept to a minimum and sufficient spare hose shall be available in the event of
ruptures.
Mixing grout
(a)
Grout for geotechnical works shall be batched by weight. The mix proportions
may be adjusted if permitted by the Project Manager depending on the results
of the trial grouting, water tests in the hole or the results of previously grouted
holes.
(b)
Grout shall be mixed by adding approximately two-thirds of the cement to the

water adding any admixture and adding the remaining one-third of cement.
Other mixing procedures shall not be used.
(c)
The time for which grout shall be mixed in high speed mixers shall be suitable
for the type of mixer used. Grout shall be continuously agitated in a holding
tank after mixing and shall be screened before being circulated in the grout
lines. Mixed grout shall be continuously circulated in such a manner that
grout which is not taken in a hole can be returned to the holding tank.
(d)
Grout to which a retarding agent has not been added, and which is not used
within 2 hours after mixing, shall not be used for grouting.
Pressure grouting
(a)
Holes in rock shall be grouted in grouting stages not exceeding 3 m. Grouting

shall be carried out in either an upstage or a downstage sequence.
(b)
Ground other than rock shall be grouted in such a manner that grout can be
injected at various points along the grout hole in a multi-stage operation. The
grouting method shall employ perforated pipes with rubber sleeve valves.
(c)
Grouting pressures shall initially be 100 kPa per 4 metre depth of hole and
shall not exceed the overburden pressure.
(d)
Holes shall be grouted in a continuous operation at the grouting stages and

pressures stated in the Contract. Grouting shall be carried out by injecting the
grout under pressure into each grouting stage of the hole until the grouting
stage refuses to take further grout.

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January 2011
(e)
8.14.7
8.14.8
If grouting of any hole or grouting stage has not been completed due to
excessive grout takes, low pressures, excessive leakage or other causes, the
hole shall be redrilled or flushed out with water and re-injected with grout.
Loss or leakage of grout

(a)
If during the grouting of any hole, grout is found to flow from adjacent grout
holes in quantities which interfere with the grouting operation or to cause
appreciable loss of grout, the holes shall be temporarily capped. If capping is
not essential, ungrouted holes shall be left open to allow air and water to
escape.
(b)
If during the grouting of any hole grout is found to flow from joints in the
geological formation at the Site or any other location, the leaks shall be
plugged or caulked in a manner reviewed without objection by the Project
Manager.
(c)
If during the grouting of any hole the grout take increases suddenly by a
significant amount, the Project Manager shall be notified immediately.
Making good holes

(a)
Grout holes through concrete shall be made good using concrete reviewed
without objection by the Project Manager. The concrete shall be firmly
compacted and shall be finished to match the adjacent surface.
(b)
Uncapped holes in rock shall be topped up after grouting using cement grout
consisting of OPC and water in the proportions 1:1 by volume, or 1:3 cement
sand mortar.
8.15
INSPECTION, TESTING
GEOTECHNICAL WORKS
8.15.1
Trials for grouting
AND
COMMISSIONING
GROUTING
FOR
A grouting trial shall be carried out. The extent and depth of holes for grouting trials
and the tests to be carried out shall be as stated in the Contract or as directed by
8.15.2
Records of grouting for geotechnical works

(a)
Records of grouting for geotechnical works shall be kept by the Contractor on

Site and shall be available for inspection by the Project Manager at all times.
Records shall include the following details:
(i)
hole location and reference number;
(ii)
depth of hole;
(iii)
type of grout and grout mix proportions;
(iv)
volume of grout injected;

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January 2011
(b)
(c)
(v)
grouting pressures; and
(vi)
times and details of any interruptions, leakages and equipment

malfunctions.
A record of grouting for each hole shall be submitted to the Project Manager
for review within 24 hours after completion of grouting of the hole. The record
shall contain the following details:
(i)
(ii)
grouting stage numbers and lengths;
(iii)
collar level and hole inclination;
(iv)
details of grout injections including the information stated in Clause

8.25.7(a); and
(v)
details of the grouting procedure, including any stoppages, leaks to

other holes, surface leaks and ground movement.
A record of the testing for each hole, including test results, shall be submitted
to the Project Manager for review within 24 hours after completion of testing of
a hole. Records of Packer tests shall contain the following details:
(i)
(ii)
depth of packer in the hole;
(iii)
date and time of test;
(iv)
type of gauge or meter and identifying reference number;
(v)
test readings for each 5 minute period;
(vi)
calculated test results in Lugeons; and
(vii) details of any equipment malfunctions, sudden water losses or

blockages, surface leakage or other variations in test procedure.
(d)
8.15.3
A report of grouting for each part of the Works as stated in the Contract,
including record drawings and logs of holes, shall be submitted to the Project
Manager for review within one week after completion and testing of grouting
for that part of the Works. The form of records, logs and record drawings
shall be submitted to the Project Manager for review.
Samples: bleeding of grout

(a)
One sample of grout shall be provided from each batch of grout for
geotechnical works to determine the amount of bleeding of the grout.
(b)
Samples shall be provided not more than 30 minutes after the grout has been
mixed and shall be protected from moisture content changes before the tests
for amount of bleeding are carried out.

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January 2011
8.15.4
8.15.5
Testing: bleeding of grout

(a)
Each sample of grout taken as stated in Clause 8.15.3 shall be divided into
three specimens; each specimen shall be tested to determine the amount of
bleeding.
(b)
Grout for geotechnical works shall be tested for bleeding in accordance with
Clause 21.6.24.
Non-compliance: bleeding of grout

If the result of any test for amount of bleeding of grout for geotechnical works does
not comply with the specified requirements for amount of bleeding, particulars of
proposed changes to the materials, grout mix or methods of production shall be
submitted to the Project Manager for review; further grouting trials shall be carried
out.
8.15.6
Samples: flow cone efflux time of grout

One sample of grout shall be provided from each batch of grout for geotechnical
works to determine the flow cone efflux time of the grout.
8.15.7
Testing: flow cone efflux time of grout

Each sample of grout taken as stated in Clause 8.15.6 shall be tested to determine
the flow cone efflux time. The method of testing shall be in accordance with
Appendix A8.2.
8.15.8
Non-compliance: flow cone efflux time of grout

If the result of any test for flow cone efflux time of grout does not comply with the
specified requirements for flow cone efflux time, particulars of proposed changes to
the materials, grout mix or methods of production shall be submitted to the Project
Manager; further grouting trials shall be carried out.
8.15.9
Samples: crushing strength of grout

(a)
One sample of grout shall be provided from each batch of grout for
geotechnical works to determine the crushing strength of the grout.
(b)
Samples shall be provided not more than one hour after the grout has been
mixed and shall be protected from moisture content changes before test
cubes are made.
8.15.10 Testing: crushing strength of grout

(a)
Nine 100 mm test cubes shall be made from each sample of grout taken as
stated in Clause 8.15.9. Three test cubes shall be tested to determine the
crushing strength at 3 days, three test cubes shall be tested to determine the
crushing strength at 7 days and three test cubes shall be tested to determine
the crushing strength at 28 days.
(b)
The method of making, curing and testing the test cubes shall be as stated in
Clause 20.8.12(b), (c) and (d).

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8.15.11 Non-compliance : crushing strength of grout

If the result of any test for crushing strength of grout for geotechnical works does
not comply with the specified requirements for grout, particulars of proposed
changes to the materials, grout mix or method of production shall be submitted to
the Project Manager for review. Further trial mixes shall be made and further
grouting trials shall be carried out.
8.15.12 Testing: Packer tests
(a)
The water loss from drillholes for grouting and from grouted and regrouted
drillholes shall be determined by the Packer test.
(b)
The number of drillholes for grouting to be tested to determine the water loss
shall be proposed by the Contractor and reviewed without objection by the
Project Manager.
Every grouted drillhole and every regrouted drillhole shall be tested to
determine the water loss.
(c)
(d)
Packer tests shall be carried out in accordance with BS 5930, Chapter 21.5,
and Clauses 8.15.12(e) to (h).
(e)
Tests shall be carried out using clean water, in grouting stages not exceeding
3 m in length. The rate of flow of water in the test shall be determined to an
accuracy of 10% for flows exceeding 1 L/min.
(f)
The test pressure shall be equal to the overburden pressure and shall not
exceed the specified maximum grouting pressure for the grouting stage being
tested.
(g)
The test shall be carried out between a packer and the base of the hole for
grouting stages at the base of a hole and shall be carried out between two
packers in other cases.
(h)
The test shall be carried out by pumping water at the specified pressure into
the grouting stage being tested and measuring with a volume meter the water
loss over three consecutive 10 minute periods. The result shall be calculated
in Lugeons for each 10 minute period.
8.15.13 Compliance criteria : Packer tests

The water loss determined by the Packer test in the grouted hole shall not exceed 5
Lugeons when measured over a 10 minute period.
8.15.14 Non-compliance: Packer test on drillholes for grouting
If the result of any Packer test on drillholes for grouting does not comply with the
specified requirements for the test, the drillhole shall be grouted, re-drilled and
retested. Grouting, re-drilling and retesting shall continue until the result of the
Packer test complies with the specified requirements for the test.

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8.15.15 Non-compliance: Packer test on grouted and regrouted drillholes

If the result of any Packer test on grouted drillholes or regrouted drillholes does not
comply with the specified requirements for the test, the grout shall be removed and
the drillhole shall be regrouted and retested. Removal of grout, regrouting and
retesting shall continue until the result of the Packer test complies with the specified
requirements for the test.
8.16
DEFINITIONS AND ABBREVIATIONS - GROUNDWATER DRAINAGE AND

CONTROL
8.16.1
Caisson drain
Caisson drain is an excavated vertical shaft, with or without raking drains, to provide
drainage by intercepting and lowering the groundwater level in the vicinity.
8.16.2
Geotextile filter
Geotextile filter is a permeable sheet of synthetic material used like a granular filter
for filtration and in-plane drainage.
8.16.3
Filter pipe
Filter pipe is a perforated or non-perforated pipe used for draining groundwater.
8.16.4
Granular filter
Granular filter is a graded sand or gravel placed against soil to prevent the
migration of fine particles out of the soil caused by water flow, and graded such that
free discharge of water flowing into the filter is allowed.
8.16.5
Prefabricated band drain

Prefabricated band drain is a synthetic drain which, when installed in a soil strata,
acts as a drainage medium for dissipation of pore water pressure.
8.16.6
Raking drain
Raking drain is a drillhole, with or without perforated filter pipes and geotextile filter
sheath, installed generally at an upward inclination for groundwater lowering by
gravity flow.
8.16.7
Relief drain
Relief drain is a synthetic drain installed on slope surfaces or in excavations to
divert water seepage before applying sprayed concrete, chunam, masonry dentition
or other construction.
8.16.8
Trench drain
Trench drain is a trench wholly or partly filled with granular material or clean
crushed rock, with or without filter pipes and geotextile filter.

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8.17
MATERIALS GROUNDWATER DRAINAGE AND CONTROL
8.17.1
Granular filter material

Granular filter material for granular filter, trench drains and caisson drains shall
consist of durable, inert, natural material free from clay, organic material and other
impurities. Granular filter material shall have the particle size distribution stated in
the Contract.
8.17.2
Geotextile filter
Geotextile filter shall be a proprietary type reviewed without objection by the Project
Manager and unless otherwise stated in the Contract shall have the following
properties :
- Trapezoidal tear resistance (ASTM D4533-85)
: 0.225kN;
- CBR puncture resistance (DIN 54307)
: 1.0kN;
- Piping limit
: 090 D85 Soil; and
: non-cohesive soil
: 090 0.12mm; and
: cohesive soil
: 090 D15 Soil; and
- Permeability limit
: 090 0.05mm.
where :-
8.17.3
090
is the pore size below which lies 90% of the pore sizes in the geotextile;
D85, D15
is the particle sizes below which lie 85% and 15% by weight of the soil to be
filtered (only fraction smaller than 5mm to be considered)
Filter pipes
(a)
Filter pipes shall comply with the following:

Precast concrete pipes
: BS 5911
Vitrified clay pipes
: BS 65
DI pipes
: BS 4772
Steel pipes
: BS 534
Porous concrete pipes
: BS 1194
Perforated concrete pipes
: BS 5911
Pitch fibre pipes
: BS 2760
UPVC pipes
: BS 4660 or BS 3506
Corrugated polyethylene tubing
: AASHTO Designation M252

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January 2011
8.17.4
8.17.5
(b)
Class O UPVC pipes shall not be used.
(c)
The perforations in perforated pipes shall be cleanly cut and shall be uniformly
spaced along the length and circumference of the pipe.
(d)
UPVC plastic pipes shall be jointed by couplers.
Raking drains
(a)
Type O raking drains shall be unlined raking drains; drain holes shall be at
least 40 mm diameter.
(b)
Type 1 raking drains shall be single pipe raking drains consisting of a single
perforated pipe with a non-perforated invert.
(c)
Type 2 raking drains shall be single pipe raking drains consisting of a single
perforated pipe with a non-perforated invert and enclosed within a geotextile
filter sheath.
(d)
Type 3 raking drains shall be double pipe raking drains consisting of an outer
permanent pipe and an inner removable pipe enclosed within a geotextile filter
sheath; the outer and inner pipes shall be perforated pipes with a
non-perforated invert.
(e)
Pipes for raking drains shall be as stated in Clause 8.17.3 (a) and (b); the
openings and slots in pipes with non-perforated inverts shall cover
approximately two-thirds of the circumference of the pipe.
(f)
Geotextile filter sheaths for raking drains shall be formed of woven or

non-woven geotextile filter complying with Clause 8.17.2.
Fill material for trench drains

(a)
Fill material to be used with geotextile filter in trench drains shall be clean
crushed rock. Type A and Type B fill material shall have the particle size
distributions stated in Table 8.2.
(b)
Fill material passing a 425 m BS test sieve shall be non-plastic.
(c)
The D15 particle size of Type A fill material for use with perforated pipes shall
be at least 15% larger than twice the maximum dimension of the perforations,
where D15 is the equivalent sieve size in millimetres, interpolated from the
particle size distribution curve, through which 15% of the fill material would
pass.
(d)
The Contractor shall check if the fill material to be used as a filter medium is in
the following relationship with the base soil, including any necessary soil
testing:(i)
D15Fc shall be less than 5 x D85Sf.
(ii)
D15Ff shall be greater than 5 x D15Sc.
(iii)
Uniformity Coefficient (

D60F
) shall be greater than 4 and less than 20.
D10F
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January 2011
(iv)
Material shall not be gap graded.
(v)
All material shall be less than 50 mm in size.
(vi)
Not more than 5% of the material shall pass the 63 micron sieve and
that fraction shall be cohesionless.
(vii) Within 48 hours of completion of the checking and testing, the

Contractor shall submit to the Project Manager the results of these
checks and tests.
Legend
(e)
(I)
D15F is used to designate the fifteen percent size of the filter

material, that is, the size of the sieve that allows fifteen percent by
weight of the filter material to pass through. Similarly, D85S
designates the size of sieve that allows eighty-five percent by
weight of the base soil to pass through. The subscript c denotes
the coarse side of the envelope; the subscript `f' denotes the fine
side.
(II)
If the filter grading Type A or B in Table 8.2 does not satisfy

Clause 8.17.5(d), the Contractor shall design the filter material so
as to comply with this Clause. The Contractor shall submit the
relevant details to the Project Manager at least four weeks in
advance of the commencement of laying of filter material on Site.
(III)
The Contractor shall also design the filter so as to prevent filter

material being washed into the pipe as defined in Clause
8.17.5(c).
Filter material shall be placed and compacted in such a manner as to avoid

segregation of the various grain sizes.
Table 8.2: Particle Size Distribution of Fill Material for Trench Drains
Percentage by mass passing BS test sieve
Type of fill
material
8.17.6
63 mm
37.5 mm
20 mm
10 mm
3.35 mm
600 m
63 m
Type A
100
45-100
25-80
8-25
0 5
Type B
100
85-100
0-20
0-5
Caisson liners
Caisson liners shall be concrete tapered rings at least 100 mm thick and not
exceeding 1 m deep. The liners shall be constructed with well-compacted concrete
of Grade 20/20 or greater.
8.17.7
Prefabricated band drains

(a)
Prefabricated band drains shall consist of a core and a filter. The drains may
be manufactured as a single unit or the filter may be wrapped around the
core, and overlapped and sealed to contain the core. The drains shall be
made from chemically treated paper, polyethylene, polyester, polyolefine or
other synthetic material or combination of such materials.

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(b)
Prefabricated band drains shall be provided with an outer casing or mandrel

of rhomboidal or rectangular cross section for use during installation. The
drains shall also be provided with an anchor to ensure embedment of the
drain during extraction of the mandrel.
(c)
The strength of the materials in prefabricated band drains shall be such that
the drains will withstand all forces resulting from handling and installation.
(d)
The filter jacket for prefabricated band drains shall be a type which:
(i)
has been previously proved effective under similar soil and pressure
conditions,
(ii)
is in all cases able to prevent excessive migration of soil particles into

the core, and
(iii)
has a permeability not less than that of the surrounding soil.
(e)
Prefabricated band drains shall be able to conform to soil deformation without

buckling or crimping of the core.
(f)
Prior to the installation of the drains within the designated areas, the
Contractor shall demonstrate that his equipment, method and materials
produce a satisfactory installation in accordance with the Specification. The
Contractor shall install trial drains at locations designated by the Project
Manager.
(g)
The end of each drain shall be provided with a suitable disposable shoe of an
acceptable type to ensure that the drain is securely anchored at its base level.
8.18
SUBMISSIONS GROUNDWATER DRAINAGE AND CONTROL
8.18.1
Particulars of granular filters

(a)

construction for granular filters shall be submitted to the Project Manager for
review:
(i)
whether granular filter material is to be supplied ready mixed or is to be

mixed on the Site;
(ii)
source of supply, including name of supplier of ready mixed material;
(iii)
quantity of each constituent if the material is to be mixed on Site;
(iv)
Contractor's Equipment and methods of mixing for material mixed on

Site;
(v)
method of storage and location of storage areas on Site;
(vi)
methods of deposition and compaction of material; and
(vii) results of three tests for particle size distribution of the fill material
against which the granular filter is to be placed.
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8.18.2
Particulars of geotextile filter

(a)

construction for geotextile filter shall be submitted to the Project Manager for
review:
(i)
manufacturer's name and source of supply;
(ii)
details of geotextile filter including manufacturer's literature;
(iii)
a certificate for the geotextile filter showing the manufacturer's name,

the date and place of manufacture and showing that the geotextile filter
complies with the requirements stated in the Contract, and including
results of the following tests :
- particle size distribution of sub-grade (BS 1377 : 1975 : Part 3); and
- determination of pH of sub-grade and sub-ballast (BS 1377 : 1975 :
Part 2);
(iv)
calculations showing that the geotextile filter complies with the filtration
characteristics stated in the Contract;
(v)
details of previous uses of the geotextile filter;
(vi)
details of quantities to be supplied in each delivery;
(vii) method of storage;

(viii) methods of cutting and jointing geotextile filter;
8.18.3
(ix)
method of repairing small batches; and
(x)
methods of laying and holding in position.
Particulars of trench drains

(a)

construction for trench drains shall be submitted to the Project Manager for
review:
(i)
method of excavation of trench and installation of geotextile filter;
(ii)
details of granular fill material as stated in Clause 8.17.5; and
(iii)
details of geotextile filter as stated in Clause 8.18.2.

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8.18.4
Particulars of raking drains

(a)
8.18.5
method of connecting adjacent sections of pipes;
(ii)
proportions of sealant mix; and
(iii)
details of geotextile filter sheath.

construction for relief drains shall be submitted to the Project Manager for
review:
(i)
details of relief drains and outlets; and
(ii)
method of fixing relief drains to the slope face.
Particulars of caisson drains

(a)
8.18.7
(i)
Particulars of relief drains

(a)
8.18.6

construction for raking drains shall be submitted to the Project Manager for
review:

construction for caisson drains shall be submitted to the Project Manager for
review:
(i)
methods of excavation and installation and removal of caisson liners;
(ii)
method of compaction of fill material;
(iii)
details of granular filter material as stated in Clause 8.18.1; and
(iv)
details of geotextile filter as stated in Clause 8.18.2.
Particulars of prefabricated band drains

(a)

construction for prefabricated band drains shall be submitted to the Project
Manager for review:
(i)
details of type of drain, including manufacturer's literature;
(ii)
a certificate showing the manufacturer's name, the date and place of

manufacture and showing that the drains comply with the requirements
stated in the Contract;
(iii)
details of previous installations by the Contractor using similar drains;
(iv)
method of installation; and
(v)
details of installation mandrel, drain anchor, method of penetration and

method of recording depth of installation.

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January 2011
(b)
(c)
8.18.8
(i)
a detailed layout of drains with reference numbers, which shall comply

with the spacing requirements shown on the Employers Drawings. In
his proposed layout, the Contractor shall take into account all
foreseeable obstructions to the installation of drains (e.g. transition pile
caps, retaining wall etc) and shall include proposals to revise the area
limits of drains as necessary to avoid such obstructions;
(ii)
the base level of each vertical drain which shall comply with the
requirements shown on Employers Drawings; and
(iii)
the supporting calculations and ground investigation logs on which his

proposal is based.
The Contractor shall carry out confirmatory drilling before the installation of
pneumatic piezometer tips and drains.
Particulars of filter pipes

(a)
8.18.9
Subject to a satisfactory installation of trial drains the Contractor shall submit

to the Project Manager for review the following particulars of his proposal:-

construction for filter pipes shall be submitted to the Project Manager for
review:
(i)
details of type of pipes, including manufacturer's literature;
(ii)

manufacture and showing that the pipes comply with the requirements
stated in the Contract;
(iii)
details of previous installations by the Contractor using similar pipes;

and
(iv)
method of installation.
Particulars of groundwater control, drawdown and monitoring

(a)

construction for groundwater control, drawdown and monitoring shall be
submitted to the Project Manager for review :(i)
Contractor's Equipment and materials for dewatering;
(ii)
timing and sequence of dewatering operations;
(iii)
details of silt traps;
(iv)
methods of monitoring flow rates and volumes of silt, including

monitoring intervals; and
(v)
methods and locations for discharging groundwater.

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8.18.10 Representative samples of materials

Representative samples of the following proposed materials shall be submitted to
the Project Manager for review at the same time as particulars of the material
(Clause 8.18.9) are submitted:
(a)
granular filter material;
(b)
geotextile filter and two pieces of geotextile filter joined in accordance with the
manufacturer's recommendations for each type of joint; and
(c)
relief drains.
8.18.11 Handling and storage of granular filter material

(a)
Granular filter material shall not be handled or stored in a manner which will
result in mixing of the different types and sizes or in segregation,
contamination, deterioration or erosion of the material.
(b)
Stockpiles of granular filter material shall be placed on well-drained, prepared

areas and shall be separated by dividing walls of sufficient height to keep the
different materials separate.
8.18.12 Delivery and storage of geotextile filter

(a)
Geotextile filter shall be delivered in secure wrappings to ensure that the

geotextile filter is dry and protected from damage, contamination and
exposure to conditions which may adversely affect it.
(b)
Geotextile filter shall be stored on a level surface and shall be kept in a secure
and dry condition, which will not result in damage to the fabric or in
contamination of the fabric.
(c)
Geotextile filter which is damaged shall not be used in the Permanent Works.
8.18.13 Storage of filter pipes

Coils of plastic tubing for filter pipes shall be stored flat.
8.18.14 Delivery and storage of prefabricated band drains
(a)
Prefabricated band drains shall be supplied in rolls, securely packed in lightproof wrappings.
(b)
Prefabricated band drains shall be stored in a clean, dry environment.
8.19
WORKMANSHIP GROUNDWATER DRAINAGE AND CONTROL
8.19.1
Mixing granular filter material

Granular filter material shall be thoroughly mixed by the method reviewed without
objection by the Project Manager. Material which has been stockpiled shall be
remixed before deposition.

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8.19.2
8.19.3
8.19.4
8.19.5
Deposition and compaction of granular filter material

(a)
Granular filter material shall be deposited and compacted as stated in

Clauses 7.4.20 to 7.4.29.
(b)
Granular filter material shall be deposited in a manner which will not result in
segregation or contamination of the material.
(c)
Granular filter material shall be deposited in such a manner that a continuous

free draining zone is formed. The surface of each layer shall be cleaned and
scarified before the next layer is deposited.
Damage to geotextile filter

(a)
The total period for which geotextile filter is exposed to daylight or other
sources of ultra-violet radiation during handling, delivery, storage and
installation shall not exceed 7 days.
(b)
Geotextile filter which has been damaged or exposed to daylight or other

sources of ultra-violet radiation for longer than the period stated in Clause
8.19.3(a) shall not be used in the Permanent Works.
(c)
Repairs to geotextile filter which has been torn or damaged during installation
shall be carried out using a patch of the same material extending at least 300
mm beyond the edge of the damaged area. Repairs shall not be carried out
on geotextile filter which has been damaged during storage or storage before
installation.
Laying geotextile filter

(a)
Geotextile filter shall be installed in such a manner that the individual yarns,
webs or layers of the fabric retain their intended orientation and relative
positions with respect to each another.
(b)
Geotextile filter shall be installed, cut and jointed in accordance with the
(c)
Fabric reinforcement stated in the Contract not to be jointed shall be lapped

by at least 300 mm.
Protection of geotextile filter

Contractor's Equipment and other vehicles shall not operate on installed geotextile
filter unless it is adequately protected by a cover of fill material.
8.19.6
Installation of raking drains

(a)
The length of raking drains assembled before installation shall not exceed
12.5 m. Connections between adjacent pipes shall be secured in such a
manner that the cumulative longitudinal extension of a 12.5 m assembled
length of pipe does not exceed 5 mm when pulled by hand.

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(b)
8.19.7
8.19.8
Pipes for Type 2 and Type 3 raking drains which are to be wrapped in a
geotextile filter sheath shall be placed along the centre of a strip of geotextile
filter of sufficient width to allow a lap of at least 50 mm. The strip of geotextile
filter shall be drawn around the pipe and fixed to the pipe along the pipe invert
with non-metallic ties at 300mm centres to prevent dislocation during
installation. The ends of pipes shall be marked to ensure that the
impermeable invert is correctly positioned during installation.
Drilling for raking drains

(a)
Drilling lubricants other than clean air or fresh water shall not be used for
drilling holes for raking drains. Casings shall be used to prevent collapse of
the hole and to permit unobstructed insertion of the pipes and geotextile filter
sheath.
(b)
The drillhole entry point shall be positioned within a tolerance of 75 mm.

Deviation in alignment shall not exceed 1 in 20. Deviation from straight shall
not exceed 20 mm in any 3 m length of drillhole. A positive gradient shall be
maintained throughout the complete length of the hole. The inclination of
holes shall be measured by a method reviewed without objection by the
Project Manager.
(c)
Drilling and sampling for undisturbed soil samples and rock cores directed by
the Project Manager to be recovered from drillholes shall be as stated in
Clauses 8.5.6 to 8.5.19.
(d)
Drillholes shall be temporarily plugged or otherwise protected to prevent entry

of deleterious material after drilling.
Excavation for trench drains

The width of trench drains shall be at least 450 mm. The width of trench drains with
filter pipes not exceeding 150 mm diameter shall be at least four times the nominal
diameter of the pipe. The width of trench drains for pipes exceeding 150 mm
diameter shall be at least the same as the external diameter of the pipe plus 450
mm.
8.19.9
Geotextile filter surround for trench drains

Geotextile filter surround for trench drains shall be installed as stated in Clause
8.19.4.
8.19.10 Bed for trench drains

(a)
(b)
Concrete bed for filter pipes in trench drains shall be at least 75 mm thick and
shall be Grade 20/20 concrete.
Granular bed for filter pipes for trench drains shall have a thickness at least
the same as the diameter of the pipe or 150 mm, whichever is greater.

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January 2011
8.19.11 Deposition and compaction of fill material for trench drains

(a)
The material for granular bed for trench drains shall be deposited in the trench
in layers not exceeding 150 mm thick and for the complete width of the trench.
Each layer shall be compacted with six passes of a plate vibrator or by other
method reviewed without objection by the Project Manager.
Trench drains shall be backfilled with Type A or Type B material of Table 8.2.
Type A or Type B material shall consist of hard, clean, crushed rock, crushed
slag or gravel having a grading within the limits of Table 8.2. The aggregate
crushing value of the material shall not exceed 30 per cent. The material
passing the 425 m BS sieve shall be non-plastic when tested in accordance
with BS 1377.
(b)
Fill material around filter pipes in trench drains shall be deposited and
compacted as stated in Clauses 7.4.20(b) and (c) and 7.4.27. The Project
Manager shall be notified before fill material is deposited around filter pipes.
8.19.12 Fixing relief drains

Relief drains shall be fixed in position before surface protection or remedial
measures are applied. Fixing shall be carried out in a manner which will not affect
the serviceability of the relief drains or outlets. Water collected in relief drains shall
be discharged to outlets reviewed without objection by the Project Manager.
8.19.13 Construction of caisson drains
(a)
Excavation for caisson drains shall be carried out by manual methods in

stages not exceeding 1.0 m depth. Dewatering shall be carried out for
excavation below the groundwater level so that work shall be carried out, as
near as practicable in the circumstances, in dry conditions. Dewatering shall
be carried out as stated in Clauses 8.19.16 and 8.19.17.
(b)
The caisson drain shaft shall be supported at all times during construction
using concrete liners. Voids between liners and excavated faces shall be
filled with no fines concrete. Caisson liners for each 1.0 m stage shall be
installed on the same day as that stage is excavated.
(c)
Softened and loose material shall be removed from the base of the caisson
drain immediately before granular filter material is deposited in the caisson
drain.
(d)
Part or all of the concrete liner adjacent to the granular filter layer shall be
removed before granular filter material or fill material is deposited. Debris
from the concrete liner shall be removed from the caisson drain.
(e)
Granular filter material shall be deposited in layers not exceeding 500 mm and
shall be compacted by methods reviewed without objection by the Project
Manager.
8.19.14 Discharge of water from caisson drains

Water collected in caisson drains shall be discharged to the outlets stated in the
Contract or reviewed without objection by the Project Manager
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8.19.15 Installation of prefabricated band drains

(a)
The installed location of prefabricated band drains shall be within 300 mm of

the specified location in plan on the ground surface and the drain shall be
within 2% of the installed length to the vertical.
(b)
Each prefabricated band drain shall be installed in one continuous length

without joints.
(c)
The depth of penetration of prefabricated band drains shall be as stated in the

Contract, modified as directed by the Project Manager during installation
based on the resistance of the soil to penetration. The Contractor shall notify
the Project Manager immediately of any sudden change in the penetration
resistance to the mandrel.
(d)
Augering, hammering, vibration or other methods may be used to assist vertical

drain installation through the filter drains and the reclamation fill. Such
augering, hammering, vibration or other methods shall not extend into the
underlying marine clay stratum.
(e)
Where obstructions above the marine clay stratum are encountered which
cannot be penetrated using normal and accepted procedures mentioned
above, the Contractor shall complete the drain from the elevation of the
obstruction to its top level and notify the Project Manager. At the discretion of
the Project Manager, the Contractor shall then install a new drain at a location
as directed by him.
(f)
The Contractor shall keep daily records of the drains installed. Copies of these
shall be submitted to the Project Manager on the day following the installation.
The records shall give the date, the reference no. of each drain and the depth
of placement below its top level. Brief notes on any unexpected conditions or
problems encountered shall be included.
8.19.16 Drawdown of groundwater table

The groundwater table shall not be drawn down to more than 2 m below the
earthworks final surface as defined in Clause 7.1.2 for excavation.
8.19.17 Dewatering
(a)
Dewatering shall be carried out in such a manner that no loss of fines from the
ground occurs.
(b)
Silt traps shall be provided and shall be regularly maintained; all dewatering
pumps shall discharge into silt traps.
(c)
Pumped groundwater shall not be discharged onto roads, footpaths, kerb

channels or adjacent land. The Contractor shall make all arrangements with,
and obtain the necessary approvals and consents from the Relevant
Authorities and the Project Manager for discharging water to drainage
systems, watercourses or the sea. Dewatering shall not start until the
permitted arrangements for disposal of the water have been implemented.
Water entering the Site shall not be discharged into the same silt traps as are
used for dewatering.

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(d)
The total capacity of pumps available on the Site for dewatering shall be at
least equal to twice the rate of flow measured through the silt traps at any time
when the groundwater table is maintained at maximum drawdown.
(e)
Half of the total pump capacity shall be equipped with a secondary motive
power source in addition to the primary motive power. The secondary motive
power source shall commence operation automatically in the event of failure
of the primary motive power source or an effective alarm system shall be set
up which will warn of failure of the primary motive power source. The
maximum allowable delay between failure of the primary motive power source
and full operation of the secondary motive power source shall not exceed 15
minutes.
(f)
A full-time attendant shall be available on the Site at all times to execute the
changeover if manual operation of equipment is required to bring the
secondary motive power into operation.
(g)
The operation of the changeover of motive power equipment shall be

demonstrated before the relevant work starts.
8.19.18 Groundwater recharge

(a)
If groundwater recharge is to be carried out to maintain the specified

groundwater levels at any location, the groundwater recharge system shall
have the means to regulate and measure the rate of recharge and to provide
an adequate continuous supply of water for recharge. Only clean fresh water
shall be used.
(b)
The capacity of pumps and the power sources which are to be used for
groundwater recharge shall be as stated in Clause 8.19.17(d) except that the
rate of flow shall refer to the maximum rate of groundwater recharge required.
(c)
The groundwater table at any location shall not be raised above the
background groundwater table measured before the relevant work starts.
8.19.19 Monitoring of groundwater control and drawdown

(a)
Monitoring of groundwater levels shall be carried out at locations stated in the

Contract or instructed by the Project Manager at all times when groundwater
control and drawdown is carried out. Arrangements for installing instruments
and taking measurements both inside and outside the Site shall be made by
the Contractor.
(b)
The survey marks for monitoring shall be located in position and level to the
Hong Kong standard survey grid and to PD to within 10 mm in every direction.
(c)
Monitoring stations and monitoring shall be as stated in Clauses 8.21.1 to

8.24.11.
(d)
Groundwater levels shall be measured to an accuracy of 20 mm. Settlements

shall be measured to an accuracy of 3 mm.
(e)
The Contractor shall notify the Project Manager immediately if any increment
settlement reading exceeds 5 mm or if the accumulated settlement exceeds
the maximum allowable settlement stated in the Contract.

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8.20
INSPECTION, TESTING AND COMMISSIONING GROUNDWATER DRAINAGE

AND CONTROL
8.20.1
Records of geotextile filter

Records of installation of geotextile filter shall be kept by the Contractor on Site and
a copy shall be submitted to the Project Manager for review each day. Records
8.20.2
(a)
identification of structures and sections of work where geotextile filter is

installed;
(b)
type of geotextile filter, including identification of batch;
(c)
date of first exposure of geotextile filter to ultra-violet radiation before

installation;
(d)
type of joint, amount of overlap, method of holding in place and any repairs to
geotextile filter carried out during installation;
(e)
date of installation of geotextile filter; and
(f)
date of final covering of geotextile filter.
Records of drillholes for raking drains

Records of drillholes for raking drains shall be kept by the Contractor on Site and a
drillhole log for each drillhole shall be submitted to the Project Manager for review
before installation of the raking drain starts. The borehole log shall contain the
following details:
8.20.3
(a)
drain reference number;
(b)
location, inclination, bearings, diameter and length of hole;
(c)
details of drilling progress;
(d)
details of water seepage related to drilling progress; and
(e)
details of samples taken.
Trials for relief drains

A trial length of relief drains of at least 2 m shall be constructed.

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8.20.4
Records of caisson drains

(a)
(b)
8.20.5
Records of caisson drains shall be kept by the Contractor on Site and a copy
shall be submitted to the Project Manager for review within 14 days after
completion of construction of caisson drains. The records shall contain the
following details:
(i)
record of work carried out each day; and
(ii)
drawings showing the exact locations of caisson drains and the final
depths relative to PD.
Detailed face logs of caisson drains shall be kept by the Contractor on Site
and shall be available for inspection by the Project Manager at all times. The
logs shall contain the information required in Clause 8.5.5(b)(ii), (b)(iii) and
(b)(iv) and the format shall be as shown in Figure 10 of 'Geoguide 2: Guide to
Site Investigation', Hong Kong Government 1987.
Records of settlement, groundwater control and drawdown

Records of monitoring of settlement, groundwater control and drawdown shall be
kept by the Contractor on Site and a copy shall be submitted to the Project Manager
for review within 24 hours of taking readings.
8.20.6
Batch: granular filter material

A batch of granular filter material is any quantity of granular filter material of the
same type and grading delivered to Site at any one time.
8.20.7
8.20.8
Samples: granular filter material

(a)
One sample of granular filter material shall be provided from each 500 m3 or
part thereof of the material delivered to Site.
(b)
One sample of granular material shall be provided from each 500 m3 or part
thereof of granular filter material which has been deposited and compacted.
(c)
The size of each sample taken as stated in Clause 8.20.7(a) shall be 10 kg.
The method of sampling shall be in accordance with BS 812:Part 102.
(d)
Samples taken as stated in Clause 8.20.7(b), shall consist of material

excavated from the compacted layer to form a flat bottomed, steep sided hole
of approximately 0.13 m2 to the complete depth of the compacted layer; a
template shall be used to fix the edges of the hole if necessary. The sides
and bottom of the hole shall be at least 50 mm from other types of fill material.
Testing: granular filter material

(a)
Each sample of granular filter material shall be tested to determine the particle
size distribution.
(b)
The method of testing shall be in accordance with the wet sieving method
stated in Geospec 3, Test Method 8.1 or 8.2 as appropriate.

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8.20.9
Non-compliance: granular filter material

(a)
If the result of any test for particle size distribution on a sample of granular
filter material taken as stated in Clause 8.20.7(a) does not comply with the
specified requirements for particle size distribution, additional samples shall
be provided from the same batch and additional tests for particle size
distribution shall be carried out.
(b)

requirements for particle size distribution if the result of any additional test for
particle size distribution does not comply with the specified requirements for
particle size distribution.
(c)
If the result of any test for particle size distribution on a sample of granular
filter material taken as stated in Clause 8.20.7(b) does not comply with the
specified requirements for particle size distribution, additional samples shall
be provided from the same batch and additional tests for particle size
distribution shall be carried out.
(d)

requirements for particle size distribution if the result of any additional test for
particle size distribution does not comply with the specified requirements for
particle size distribution.
8.20.10 Batch: fill material for trench drains

A batch of fill material for trench drains is any quantity of fill material for trench
drains of the same type delivered to Site at any one time.
8.20.11 Samples: fill material for trench drains
(a)
One sample of fill material for trench drains shall be provided from each batch
of fill material for trench drains delivered to Site.
(b)
The size of each sample and the method of sampling shall be in accordance
with Clause 8.20.7(c).
8.20.12 Testing: fill material for trench drains

(a)
Each sample of fill material for trench drains shall be tested to determine the
particle size distribution; fill material passing a 425 m BS test sieve shall also
be tested to determine the plasticity index.
(b)
The method of testing to determine the particle size distribution shall be in

accordance with Geospec 3, Test Method 8.1 or 8.2 as appropriate. The
method of testing to determine the plasticity index shall be in accordance with
Geospec 3, Test Method 6.1.

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8.21
DEFINITIONS AND ABBREVIATIONS - GEOTECHNICAL INSTRUMENTATION
8.21.1
Datum station
Datum station is a mark for which horizontal or vertical values, or both, have been
fixed, and which is used as a datum for monitoring or control surveys.
8.21.2
Geotechnical instrumentation
Geotechnical instrumentation is the installation and monitoring of instruments in the
ground or structures to provide information on soil and rock parameters, and to
monitor specific variations in the condition of the ground or structures for the
purposes of geotechnical design, construction control and performance monitoring.
8.21.3
Monitoring mark
Monitoring mark is a mark, fixed or installed, on a structure to be monitored.
8.21.4
Reference point
Reference point is a mark placed close to another important survey mark to aid
recovery or replacement.
8.21.5
Survey station
Survey station is a mark on a stone, concrete, metal or wooden block, pipe, peg or
other item defining a surveyed position.
8.22
MATERIALS GEOTECHNICAL INSTRUMENTATION
8.22.1
Instruments for geotechnical instrumentation

(a)
Instruments for geotechnical instrumentation and their accessories shall be

provided complete with all appropriate tubing, connections, monitoring
equipment, read-out units and any other tools necessary for the installation,
calibration, setting to work and maintenance of the instruments.
(b)
Instruments shall be manufactured by companies with proven experience and

only instruments which are well proven and have been in successful use shall
be used.
(c)
Instruments shall be handled, stored, installed and used in accordance with

the manufacturer's recommendations and in such a manner that the
performance of the instruments will not be impaired.
(d)
Instruments shall be protected from damage and measures shall be taken to

ensure that the instruments suffer the minimum practicable amount of
disturbance.
(e)
Instruments shall be calibrated by a laboratory reviewed without objection by

Instruments shall be calibrated at intervals
recommended by the manufacturer and at other intervals directed by the
Project Manager. Calibration certificates shall be provided to the Project
Manager for review within 24 hours after calibration.

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(f)
8.22.2
Installation, testing and monitoring of the instruments shall be carried out

under the supervision of a suitably qualified geotechnical engineer who shall
have a minimum of five-years experience of the installation and monitoring of
field instrumentation. Particulars of the geotechnical engineer, including
qualifications and experience, shall be submitted to the Project Manager for
review.
Standpipe piezometers
Standpipe piezometer tips for geotechnical instrumentation shall be porous ceramic
or plastic material at least 200 mm long and with a bore of at least 19 mm.
-4
Permeability shall be at least 10 m/s. The piezometer tip shall be connected to
rigid PVC standpipes with a bore of at least 19 mm and with a wall thickness of at
least 3 mm. The standpipes shall be jointed together and to the porous tips in such
a manner that the joints remain leak-proof under the anticipated head of water.
The general layout of the apparatus shall conform to the details shown in Geoguide
2 Figures 19 and 21.
8.23
SUBMISSIONS GEOTECHNICAL INSTRUMENTATION
8.23.1
Particulars of geotechnical instrumentation

(a)
The following particulars of the proposed geotechnical instrumentation shall

be submitted to the Project Manager for review:
(i)
details of instruments ;
(ii)
manufacturer's specifications;
(iii)
test and calibration certificates;
(iv)
method of installation;
(v)
method of acceptance testing;
(vi)
details of ancillary measuring equipment;
(vii) schedule for installing instrumentation in relation to progress of the

Works;
(viii) documents showing that the instruments are capable of measuring
within the ranges and accuracies stated in the Contract;
(ix)
name and experience of persons responsible for installation, testing and

monitoring of instruments;
(x)
details of standpipe
specification; and
(xi)
details of the form of records.

piezometer
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8.24
WORKMANSHIP GEOTECHNICAL INSTRUMENTATION
8.24.1
Location and arrangement of instruments
8.24.2
8.24.3
(a)
The locations and arrangement of instruments for geotechnical

instrumentation shall be as stated in the Contract or as reviewed without
objection by the Project Manager before installation.
(b)
The positions and alignments of instruments shall be recorded after

installation and surveys shall be carried out at times and frequencies reviewed
without objection by the Project Manager to detect any displacement of the
instruments.
(c)
At least two reference points shall be established for each survey station or
monitoring mark.
(d)
The survey station which has the least chance of being disturbed shall be
selected as datum station. The datum station shall be stainless steel. At
least three reference points shall be established for each datum station.
(e)
The survey network shall be related to the master survey stations provided by
Installation of instruments
(a)
The Contractor shall notify the Project Manager before the installation of each
instrument for geotechnical instrumentation starts.
(b)
Tests shall be carried out after installation to demonstrate that the instruments
have been correctly installed and are functioning correctly. Instruments which
are not correctly installed or are not functioning correctly shall be reinstalled or
replaced as directed by the Project Manager.
(c)
All installed instruments, tubes and wires shall be clearly marked with a
unique and conspicuous identification number.
Tubes and cables for instruments

(a)
Tubes and cables attached to instruments for geotechnical instrumentation for

remote reading shall be impervious to air and water, and shall have sufficient
strength and stiffness to withstand the internal and external pressures. Tubes
and cables shall be protected from mechanical damage and from the harmful
effects of direct sunlight, heat and ultra violet radiation at all times.
(b)
Tubes and cables shall be marked with identification colours and numbers at
5 m intervals. The tubes and cables shall be wound onto reels in such a
manner that kinks are not formed and strain is not induced. Open ends of
tubes and cables shall be blocked with stop ends at all times.
(c)
Tubes and cables shall be buried at least 0.5 m below ground level.

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(d)
8.24.4
8.24.5
8.24.6
Tubes and cables shall be laid with sufficient slack, loops and bends to allow
for settlement and other ground movements. The routing of tubes and cables
shall be as reviewed without objection by the Project Manager. The radius of
bends shall be at least 300 mm. Each tube or cable shall be laid from the
measuring instrument to the terminal duct in one continuous length without
joints.
Maintenance of instruments
(a)
Instruments for geotechnical instrumentation shall be maintained in good

working order until the expiry of Defects Liability Period. Instruments, survey
marks and stations shall be protected by suitable barricades, notices, signs or
marker-buoys.
(b)
The Contractor shall notify the Project Manager immediately of any

instruments found damaged or instruments found not to be in working order.
Replacements shall be installed for read-out units which are faulty or under
repair.
Records of geotechnical instrumentation

(a)
Records of activities relating to installation of geotechnical instrumentation

shall be kept by the Contractor on Site and a copy shall be submitted to the
Project Manager for review within 24 hours after installation of the instrument
is complete.
(b)
Contractors Drawing showing the locations and identification of installed

instruments shall be submitted to the Project Manager for review within 24
hours after installation of the instrument is complete.
(c)
Contractors Drawing showing the locations and details of survey stations,

monitoring marks and reference points shall be submitted to the Project
Manager for review within 3 days after the survey network has been
established.
Recording readings
(a)
Instrument readings and processed data for geotechnical instrumentation

shall be recorded by the Contractor on agreed record sheets, and shall be
submitted to the Project Manager for review within 24 hours after recording.
The form of record sheets shall be as reviewed without objection by the
Project Manager. Readings shall be taken in the presence of the Project
Manager.
(b)
Initial readings shall be taken immediately after the instruments have been
installed and after the effects of installation have subsided. The initial
readings shall be submitted to the Project Manager for record and shall form
the basis of comparison of subsequent readings. The instruments and the
initial readings shall be replaced if the initial readings are not repeatable.
(c)
The frequencies for reading instruments shall be as reviewed without

objection by the Project Manager. The Contractor shall notify the Project
Manager immediately of sudden or significant changes in the readings.

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(d)
8.24.7
8.24.8
8.24.9
All installed instruments shall be left in correctly functioning condition after

final readings have been taken or at the end of the Defects Liability Period.
Keys for locks shall be tagged to identify the instrument number and shall be
handed over to the Project Manager.
Installation of settlement plates

(a)
Settlement plates for geotechnical instrumentation shall be securely founded

on level ground free from obstructions and shall be immediately surveyed for
level and position and plotted on a plan.
(b)
Settlement plates shall be protected from damage and shall be kept in

position by a 600 mm thick layer of granular fill material or bags of sand which
shall be placed by manual methods and shall extend 600 mm beyond the
edges of the plate. The initial survey of levels and positions shall be taken
immediately after the fill material or bags of sand have been placed.
(c)
The metal rod fixed to the centre of the plate shall be in an upright position,
and protected by a tubular sleeve. The sleeve and the metal rod shall be
extended as fill material is placed such that at any time the sleeve and rod are
at least 500 mm above the level of the surrounding fill material or high water
mark, and the metal rod is within 2% of the embedded length to the vertical.
(d)
The level of the top of the metal rod shall be recorded immediately before and
immediately after each extension piece is added. Marker-buoys shall be fixed
to the tops of tubular sleeves installed in water.
Installation of tiltmeter system

(a)
Tilt-plates for geotechnical instrumentation shall be orientated to correspond

with the specified direction of measurement and fixed in place on the rock or
structure. The installed direction shall be recorded to an accuracy of 3.
(b)
A protective cap or cover shall be fitted to protect the tilt-plates from damage.
(c)
Tilt-plates and the tiltmeter shall be cleaned and inspected for damage before
readings are taken. The tiltmeter shall be accurately located on the tilt-plate
and a reading taken. The tiltmeter shall then be removed and the contact
surface recleaned. The procedure shall be repeated until consistent readings
are obtained. The tiltmeter shall then be rotated through 180 and the
procedures repeated.
(d)
The accuracy of the tiltmeter and its readout system shall be checked both
before and after the readings taken each day. Instrument errors shall be
investigated and immediately corrected; a record of calibrations and
adjustments shall be submitted to the Project Manager for review together
with the monitoring data.
Installation of telltales
Telltales for geotechnical instrumentation shall be as shown in Figure 10.5 of 'The
Geotechnical Manual for Slopes', Hong Kong Government, 1984. Telltales shall be
rigidly fixed across cracks to enable any movement across the cracks to be
determined. Telltales shall be labeled and marked with the date of installation.

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8.24.10 Installation of standpipe piezometers

(a)
Standpipe piezometers for geotechnical instrumentation shall be installed in

drillholes at the depths as stated in the Contract or as directed by the Project
Manager.
(b)
The sand filter surrounding the piezometer tip shall be between 1000 mm and
1500 mm long and shall consist of sand between the sizes of 200 m and
1210 m. Measurements shall be made to determine the actual location of
the sand filter column.
(c)
A seal shall be formed above the sand filter by placing 500 mm of bentonite
pellets of between 10 mm and 15 mm in size. The pellets shall be placed in
the hole and tamped with a suitably shaped tamper to form a homogeneous
plug to the hole.
(d)
If the depth of the completed hole is greater than the depth at which the
piezometer tip and sand filter are to be placed, the bottom of the drillhole shall
be grouted with grout consisting of cement and bentonite in the proportions
1:1 by mass together with sufficient water to achieve the required workability.
The drillhole above the plug shall be grouted with the same type of material.
(e)
The water level in the piezometer shall be measured after the standpipe
piezometer has been installed and the standpipe shall be topped up with
clean water. The rate of drop of water level or pressure head shall be
recorded at times of 0, 1/4, 1/2, 1, 2, 4, 8, 15, 30 minutes or until the water
has returned to its initial level.
(f)
The water level shall be measured by an electrical type water level probe
reviewed without objection by the Project Manager. The water may be salted
if necessary for response to the probe.
(g)
Measurements of the depth of piezometer tip and sand filter and the readings
taken as stated in Clause 8.24.10(f) shall be submitted to the Project Manager
for review within 24 hours after completion of installation of the piezometer
standpipe.
(h)
Surface boxes as shown in Geoguide 2 Fig 21 shall be constructed within 2

days of completion of the piezometer installation and backfilling of the hole.
(i)
The hole reference number shall be permanently inscribed on the surface box
either by welding a numbered steel plate to the box cover or by inscribing the
number in the concrete surround.

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8.24.11 Observation wells

(a)
Where shown on the Employers Drawings or as otherwise instructed by the

Project Manager, the Contractor shall provide and install an observation well.
(b)
The observation well shall consist of rigid PVC tubing to the dimensions and
installation details as described in Clause 8.24.10 except that the tube shall
be capped at its lower end and perforated with 6 mm diameter holes for a
minimum of 5% of its surface area over a length of 1.5 m or as instructed by
the Project Manager. The upper end of the tube shall be set in concrete and
fitted with a surface box as shown in Geoguide 2 Figure 21. The perforated
length shall be wrapped with two layers of nylon mesh. The granular surround
to the perforated length shall be 10 to 16 mm washed aggregate.
(c)
The elevation of the base and the top of the granular surround shall be
recorded on the log. The depth to the base of the observation well shall be
confirmed by dipping on completion of the installation.
8.25
GENERAL - LABORATORY WORK
8.25.1
General
8.25.2
(a)
The Contractor shall, when instructed by the Project Manager, carry out soil
tests specified in this Section at a HOKLAS accredited laboratory reviewed
(b)
The laboratory shall hold current HOKLAS accreditation for tests according to
Geospec 3.
(c)
The Laboratory Work shall be completed within four weeks of the completion
of the Field Works.
Work on General Holidays

No testing shall be carried out on general holidays without permission in writing by
8.25.3
Contractors supervision
Laboratory testing shall be carried out under the continuous supervision of a
competent engineer or senior technician who is experienced in soils testing
procedures. This person shall certify the accuracy, correctness and completeness
of the test results supplied to the Project Manager by the Contractor.
8.25.4
Staff - definitions
For laboratory testing the following definitions shall apply:Senior technician - a person with at least 10 years experience gained in a soil testing
laboratory and fully familiar with triaxial testing procedures.

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8.25.5
Results, samples and original sample containers property of the Employer

The results of the tests shall become the property of the Employer and shall not be
divulged by the Contractor except to the Employer or the Project Manager.
Samples and the original sample containers are the property of the Employer and
the Contractor shall not dispose of any samples, original sample containers or parts
thereof except as directed by the Project Manager.
8.26
WORKMANSHIP LABORATORY WORK
8.26.1
Extrusion of Mazier samples for testing

For testing purposes, 'Mazier' samples shall be cut to the appropriate length for
testing and then extruded in the direction of the top of the sample in a manner
reviewed by the Project Manager.
8.26.2
Retention of samples
When laboratory tests are carried out on only part of a soil sample, the remainder of
the soil in the sampler or container shall be resealed with wax as soon as possible
and retained. Soil on which laboratory tests have been carried out, including that
wasted during the preparation of test specimens, shall be retained in airtight
containers until the presentation of the Final Report.
8.26.3
Classification and chemical test procedures

The following laboratory soil classification tests shall where applicable be carried
out in accordance with the procedures described in Geospec 3 :(a)
determination of moisture content (Test Method 5.1 or 5.2 as appropriate);
(b)
determination of liquid limit (Test Method 6.1). The sample shall not be
completely dried before testing;
(c)
determination of plastic limit, plasticity index and liquidity index (Test Method
6.1 and 6.2). The soil shall not be completely dried before testing;
(d)
determination of particle density for soils containing gravel sized particles

(Test Method 7.1). Samples at natural moisture content of dry weight
approximately equal to that specified in BS 1377 shall be used. The sample
shall not be dried prior to testing but shall be oven dried and weighed on
completion of the test. The test shall be carried out using distilled water; and
(e)
determination of particle size distribution on:

(i)
essentially cohesionless soil down to the fine sand size (Test Method
8.1 or 8.2 as appropriate); and
(ii)
coarse sand to clay size (Test Method 8.3, 8.4, 8.5 or 8.6 as
appropriate).

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8.26.4
Triaxial test procedures

Triaxial Test Procedures as specified in Clauses 8.26.5, 8.26.21 and 8.26.22 shall
be based upon "The Measurement of Soil Properties in the Triaxial Test" (Second
edition, 1962) by A.W. Bishop and D.J. Henkel, unless otherwise instructed by the
Project Manager.
8.26.5
Use of ceramics
When necessary, as determined by the Project Manager, high air-entry ceramics
shall be used to separate the soil specimen from the base drain (Bishop and Henkel
p. 221). For any test where pore pressure is measured from the top of the
specimen, it shall be permissible to use low air-entry ceramics for separating the
specimen from the top cap. Porous ceramics shall be de-aired (Bishop and Henkel
p. 185).
8.26.6
Calibration of pressure gauges

Equipment capable of providing and maintaining steady cell pressures of up to 850
kPa shall be used. Pressure gauges (i.e. those used for cell pressure, pore
pressure and back pressure measurements) shall be calibrated against an accurate
dead load tester or alternative method agreed by the Project Manager unless
calibrated within the three months preceding the start of any test. The Contractor
shall provide the Project Manager with calibration charts showing the corresponding
values of the dead weight tester(s) and the pressure gauges. Results shall be
presented in increments of 50 kPa up to and including 850kPa. Calculations shall
be based on the pressure gauge readings reduced to their calibrated values.
8.26.7
De-aired water
De-aired water shall be used to saturate soil specimens and for cell water.
Adequate provision shall be made at any air/water interfaces in the pressure
application system to minimise air contamination of the water.
8.26.8
Specimen diameter
The size of specimen to be tested shall normally be 76 mm in diameter. Test
specimens shall be prepared from undisturbed samples (Bishop and Henkel p. 83),
or disturbed samples compacted or remoulded at a specified moisture content to a
specified density (Bishop and Henkel p. 87) in a manner reviewed by the Project
Manager.
8.26.9
Jacketing gritty soils

In the case of gritty soils two membranes shall be used for jacketing the soil
specimen, unless agreed otherwise with the Project Manager. Membranes shall be
checked for leakage before use.

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8.26.10 Saturation of specimens by back-pressure

Test specimens shall be saturated by the application of back-pressure before the
consolidation stage. The saturation procedure shall be as follows:(a)
application of an undrained 50 kPa increment in cell pressure (3). Adequate

time shall be allowed for pore-water pressure response (u) to stabilise. If the
ratio u/ 3 (hereafter called B) is less than 0.97 or as decided by the Project
Manager, then
(b)
the back-pressure shall be brought up to the value of the cell pressure minus
5 kPa with the drain closed. The drain shall then be opened and the volume
change shall be noted and adequate time shall be allowed for this change to
cease. Procedure (1) shall then be repeated.
If B exceeds 0.97, then

(c)
the cell pressure shall be taken up in undrained increments of 50 kPa or less

to the value of the test cell pressure allowing pore water stabilization at each
increment, and the pore water pressure shall be recorded immediately after
application of each additional increment of pressure.
8.26.11 Saturation by flooding

When instructed by the Project Manager samples shall be saturated by flooding.
The procedure for single-stage and for the first stage of multi-stage testing shall be
as follows:(a)
if saturation by back-pressure has been attempted, the cell pressure shall be

reduced to 50 kPa and simultaneously the back-pressure shall be reduced to
40 kPa. If saturation by back-pressure has not been attempted, cell pressure
shall be set at 50 kPa and back-pressure at 40 kPa; and
(b)
maintaining these pressures, the drain shall be opened from the sample top
cap to the atmosphere and de-aired water shall be allowed to flow through the
sample until bubbling ceases. The drain shall then be closed and the sample
saturated by back-pressure as specified in sub-clause (a) above.
8.26.12 Corrections to be applied to the value of deviator stress

The following corrections, where appropriate, shall be applied when calculating the
deviator stress and shall be indicated in the results:(a)
change in cross-sectional area (Bishop and Henkel, p. 28);
(b)
restraint from the rubber membrane and filter paper drains (Bishop and
Henkel, p. 167); and
(c)
friction on the loading ram (Bishop and Henkel, p. 174).

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8.26.13 Definition of shear failure

Shear failure for single stage triaxial tests shall be defined in terms of maximum
principal stress difference (1 - 3). Shear failure for multi-stage triaxial tests shall
normally be defined in terms of maximum principal effective stress ratio ( 1'/ 3')
unless otherwise instructed by the Project Manager.
8.26.14 Shear plane failure
For specimens which fail along a shear plane, the axial strain at which the shear
plane becomes apparent shall be recorded.
8.26.15 Required sketches of specimen failure
A sketch shall be made of the mode of specimen failure. The angle of any distinct
shear planes shall be measured with respect to the horizontal and noted both
before splitting and after splitting the specimen.
8.26.16 Consolidated-undrained single-stage triaxial tests
(a)
Consolidated-undrained Single-Stage Triaxial Tests (Bishop and Henkel

(1962) pp. 106 and 192) shall be carried out with pore-water pressure
measurement and using back-pressure for saturating the sample. At the end
of the consolidation stage a suitable rate of axial strain shall be agreed with
the Project Manager to ensure that the results obtained shall lead to a true
measure of the physical properties of the soil. The rate shall be sufficiently
low to ensure equalisation of pore-water pressure throughout the specimen
and shall not exceed 0.2 mm/min.
(b)
The report of each test shall include the following information:(i)
sample and specimen number;
(ii)
location and depth of the sample;
(iii)
description of the test specimen;
(iv)
method of preparation and dimensions of the specimen;
(v)
initial and final moisture content, volume and bulk density and specified
effective cell pressure;
(vi)
pore-pressure parameter B for each increment of back-pressure;
(vii) maximum pore-pressure parameter Bmax (being the maximum B value

calculated for the 50 kPa increments in cell pressure);
(viii) final back-pressure;
(ix)
standard increment of cell pressure (50 kPa, unless otherwise specified

by the Project Manager); and
(x)
final value of pore-water pressure generated by the final undrained

increment in cell pressure;

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Consolidation:
(xi)
volume change/square-root of time plot; and
(xii) computed coefficient of consolidation, coefficient of permeability and

coefficient of volume compressibility;
Shearing Stage:
(xiii) rate of axial strain;
(xiv) deviator stress/axial strain plot;
(xv) principal effective stress ratio/axial strain plot;
(xvi) pore water pressure/axial strain plot;
(xvii) maximum deviator stress and corresponding axial strain;
(xviii) maximum principal effective stress ratio and corresponding axial strain;
8.26.17 Consolidated-undrained multi-stage triaxial tests
Consolidated-Undrained Multi-Stage Triaxial Tests shall be carried out in 3 stages
with pore-water pressure measurement in accordance with procedures defined in
the Clause 8.26.16 relating to single-stage tests except that:(a)
B values recorded during saturation by back-pressure shall be determined as

described in Clauses 8.26.10 or 8.26.11 and in addition by measuring the
u/3 ratio as the cell pressure is increased between stages.
(b)
If failure has not occurred in a particular stage, shearing for that stage shall be
stopped at the following cumulative strains, subject to the Project Managers
agreement:
(i)
initial loading
15%;
(ii)
second loading 20%; and
(iii)
third loading
25%.
8.26.18 Consolidated-drained single-stage triaxial tests

(a)
Consolidated-Drained Single-Stage Triaxial Tests (Bishop and Henkel, pp.

124 and 204) shall be carried out as directed by the Project Manager. At the
end of the consolidation stage the Contractor shall calculate a suitable rate of
axial strain acceptable to the Project Manager. This rate shall be sufficiently
low as to ensure at least 95 per cent dissipation of excess pore-pressure at
failure.
(b)
The report of each test shall include the requirements

Clause 8.26.16(b) together with a volume change/axial strain plot.

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8.26.19 Unconsolidated-undrained triaxial tests

(a)
Unconsolidated-Undrained Single-Stage Triaxial Tests without the

measurement of pore-water pressure shall be carried out using back-pressure
for saturating the sample.
The tests shall be carried out in accordance with Part 7 Method 8 of BS 1377.
(b)
The report of each test shall include the following information:

(i)
sample and specimen number;
(ii)
(iii)
(iv)
method of preparation and dimensions of the specimen;
(v)
initial and final moisture content, volume and dry/bulk density;
(vi)
specified effective cell pressure;
(vii)
pore-pressure parameter B for each increment of back-pressure;
(viii) maximum pore-pressure parameter Bmax (being the maximum B value

calculated for the 50 kPa increments in cell pressure);
(ix)
final back-pressure;
(x)
standard increment of cell pressure (50 kPa, unless otherwise specified

by the Project Manager); and
(xi)
final value of pore-water pressure generated by the final undrained

increment in cell pressure; and
(xii) Shearing Stage:

(xiii) rate of axial strain;
(xiv) deviator stress/axial strain plot; and
(xv) maximum deviator stress and corresponding axial strain.
8.26.20 Plotting of results
A Mohr stress circle diagram shall be prepared for results of a series of tests on the
same sample or for results of one multi-stage test providing plastic failure has
occurred in each specimen or planar failure has been on planes included at
approximately (45 degrees +0/'/2) to the horizontal. The apparent cohesion (c') and
angle of shearing resistance (0/') with respect to changes in effective stress shall be
determined by the "least-squares" fitting technique. For failure of specimens on
planes not inclined at an angle of approximately (45 degrees +0/'/2) to the
horizontal, the Project Manager shall decide on the mode of presentation of the
results.

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8.26.21 Photographing of triaxial test specimens

(a)
A colour photographic record shall be kept of triaxial test specimens after

testing. The Contractor shall take all photographs required by the Project
Manager.
(b)
A reference label, scale and colour chart from the manufacturer applicable to
the type of film and paper used shall be placed together with the specimen in
the camera's field of view and a photograph shall be taken at a magnification
agreed with the Project Manager.
(c)
The photographs shall be processed so as to ensure accurate reproduction of

colours, as shown by the colour chart. One print of each photograph, and a
copy of the colour chart, shall be attached to each copy of the Draft Final
Report and to each copy of the Final Report. The set of negatives shall be
attached to the master copy of the Final Report.
8.26.22 Drained modulus tests

(a)
Drained Modulus Tests shall be carried out in a triaxial testing machine. The
test specimens shall be prepared, saturated and consolidated prior to the
application of axial strain in accordance with procedures relating to
Consolidated-Drained Single Stage Triaxial Tests (Clause 8.26.18). The
specimen shall then be loaded to a deviator stress as instructed by the Project
Manager before being unloaded. The rate of application of axial strain during
loading/unloading shall be sufficiently low to ensure at least 95 per cent
dissipation of excess pore-pressure. The above loading/unloading procedures
shall be repeated for four other cycles to different deviator stresses instructed
(b)
The report of each test shall include the requirements given in Clause
8.26.16(b) except that items (xiii) to (xviii) shall be replaced by:
Loading/Unloading Stage:
(i)
rate of axial strain;
(ii)
deviator stress/axial strain plot;
(iii)
volume change/axial strain plot; and
(iv)
pore-water pressure/axial strain plot.
8.26.23 Consolidated-drained shear box tests on soil

(a)
Consolidated-drained single-stage and multi-stage direct shear box tests shall

be carried out on samples of soil containing relict joints or discontinuities in
accordance with the requirements specified in this Clause. The Contractor
shall submit to the Project Manager for review:
(i)
the proposed testing equipment; and
(ii)
the proposed method of specimen preparation.

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(b)
Samples shall be handled with great care at all times. The jointed specimens
shall be prepared in such a way that shearing occurs along a continuous joint
surface.
(c)
After applying the initial normal pressure (30 kPa), water shall be added to the
carriage to a level such that the specimen is completely immersed. Then the
normal pressure shall be increased to the required value for shearing and
maintained for a minimum period of 12 hours for consolidation. Any
settlement of swelling taking place during the process shall be measured by
dial gauge at suitable time intervals. The specimen shall be maintained in a
soaked condition throughout the test.
(d)
The rate of testing shall be not greater than 0.1 mm/min, and the suitability of
the rate shall be checked from consolidation stage data. Shearing shall be
continued for the full travel of the shear box.
(e)
Colour photographs shall be taken of all specimens before and after testing.
A reference label, scale and colour chart from the manufacturer applicable to
the type of film and paper used shall be placed together with the specimen in
the camera's field of view and a photograph shall be taken at a magnification
agreed with the Project Manager. The photographs shall be processed so as
to ensure accurate reproduction of colours, as shown by the colour chart. One
print of each photograph, and a copy of the colour chart, shall be attached to
each copy of the Draft Final Report and to each copy of the Final Report.
The set of negatives shall be attached to the master copy of the Final
Report.
(f)
Testing shall otherwise be carried out in accordance with the procedure given
in "Laboratory Testing in Soil Engineering" by T.N.W. Akroyd.
(g)
Preparation of specimens for testing shall be carried out in the presence of an

experienced geotechnical engineer.
(h)
The report on each test shall include the following information:(i)
sample no.;
(ii)
description of the test specimen including sketches, with special

attention to features such as tightness, nature of joint surface, nature of
infilling material, waviness, asperities etc.;
(iii)
initial and final moisture content and bulk density;
(iv)
shear force/horizontal displacement plot;
(v)
shear force/vertical displacement plot;
(vi)
maximum shear force for each shear stage;
(vii) horizontal displacement corresponding to maximum shear force; and

(viii) when instructed by the Project Manager, a shear force/effective normal
load diagram shall be prepared corresponding to maximum shear force
determined on a number of test specimens or stages from one sample,
and the cohesion (c') and angle of shearing resistance (0/') with respect
to effective stresses shall be determined.
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8.26.24 Permeability tests

Falling head permeability tests (Akroyd p. 147) and constant head permeability
tests (Akroyd p. 154) shall be carried out on specimens of up to 110 mm in length
and diameter. The report of each test shall include the following information:(a)
sample no.;
(b)
(c)
(d)
method of preparation of the specimen;
(e)
moisture content and bulk density; and
(f)
coefficient of permeability.
8.26.25 California bearing ratio tests

(a)
California Bearing Ratio (CBR) Tests shall be carried out in accordance with
the procedures described in BS 1377 Part 4 Method 7. The test shall be
carried out on each sample over a range of moisture contents so that the
relationship of CBR to moisture content can be determined. The test shall
include at least 5 determinations with moisture contents chosen from the
results of the Soil Compaction Test and including optimum moisture content
and the values of moisture content corresponding to a dry density of 95 per
cent of the maximum.
(b)
The results shall be recorded on forms similar to Forms 4E to 4G, BS 1377

and acceptable to the Project Manager.
8.26.26 Soil compaction tests

(a)
Soil Compaction Tests shall be carried out in accordance with the procedures
described in BS 1377 Part 4 Method 3.3 or 3.4 as appropriate (2.5 Kg
rammer)(at least 5 determinations per test are required).
(b)
In the case of density determinations carried out at moisture contents less

than the natural moisture content in a compaction test, the soil shall not be
allowed to dry to a moisture content lower than the moisture content at which
the density determination is to be made.
(c)
The results shall be recorded on a form similar to Form 4A, BS 1377 and
acceptable to the Project Manager.
8.26.27 One dimensional consolidation tests

One Dimensional Consolidation Tests shall be carried out in accordance with the
procedures described in BS 1377 Part 5 Method 3. The results shall be recorded on
a form similar to Forms 5A to 5D, BS 1377 and acceptable to the Project Manager.
8.26.28 Rock Compression Tests
Uniaxial rock compression tests shall be conducted according to ASTM D2938-86.
Test results shall be presented according to relevant ASTM Standard, or according
to an alternative reviewed without objection by the Project Manager.
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8.26.29 Elastic Moduli and Poissons Ratio of Intact Rock

Elastic moduli of intact rock core specimens shall be determined according to
ASTM D3148-86. Test results shall be presented according to the relevant ASTM
Standard, or according to an alternative reviewed without objection by the Project
Manager. A plot of compressive stress versus axial diametral strain shall also be
presented.
8.26.30 Point Load Tests
(a)
Point load tests shall be conducted and reported according to the Suggested
Method of Determining Point Load Strength by ISRM (1985). Test results
shall be presented according to relevant ISRM figures, or according to an
alternative reviewed without objection by the Project Manager.
(b)
When testing core samples, each test specimen shall first be tested with the
direction of loading perpendicular to the axis of the core (i.e. the diametral
test), and secondly with the direction of loading either along the axis of the
core or perpendicular to observable planes of anisotropy (i.e. the axial test).
When testing irregular specimens that show anisotropy, one-half of the test
specimens shall be tested with the load perpendicular to the planes of
anisotropy, and the remaining half of the test specimens shall be tested with
the load parallel to the planes of anisotropy.
8.26.31 Rock Joint Shear Tests

Rock joint shear tests shall be conducted according to Suggested Methods for
Determining Shear Strength by ISRM (1974), as modified by the following:
(a)
rock joint shear tests shall be conducted using either a Golder or Roberston
Shear Box. The choice of shear box shall be as directed by the Project
Manager;
(b)
except as otherwise instructed, multi-stage tests shall be used;
(c)
the following items shall be included for rock joint shear tests, with test results
presented according to relevant ISRM figures, or according to alternatives
reviewed without objection by the Project Manager:
(i)
the dimensions of the top and bottom shear surfaces shall be

determined and recorded;
(ii)
the actual area of contact between the top and bottom shear surfaces
shall be estimated: areas that have regular shapes shall be calculated:
areas that have irregular shapes shall be estimated using graph paper;
(iii)
the roughness profile shall be recorded, before and after shear, with the
aid of a profilometer. A description of the rock joint shall also be made,
including colour, tightness and nature of joint infill materials, if any;
(iv)
photographs of top and bottom joint surfaces, before and after shear,
shall be taken according to Clause 8.26.21;

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January 2011
(d)
(e)
(f)
(v)
the horizontal displacements, vertical displacements, shear loads and

normal loads shall be recorded during the tests; and
(vi)
the specimen shall be soaked in water overnight before testing, unless

otherwise instructed by the Project Manager.
the following corrections shall be made when calculating stresses:

(i)
hydraulic ram springs: when hydraulic ram springs have been used a
correction shall be applied to gauge readings to account for the
resistance provided by the ram return springs;
(ii)
cross-sectional area: the reduction in cross-sectional area during the

shearing process shall be accounted for; and
(iii)
contributions to normal load, such as the self-weight of the loading

system and the weight of the upper box and sample shall be accounted
for.
the following plots shall be prepared according to the relevant ISRM, or

according to an alternative reviewed without objection by the Project
Manager:
(i)
shear stresses versus horizontal displacement;
(ii)
shear stresses and vertical displacement shall use the same abscissa
that represents the horizontal displacement; and
(iii)
peak shear stresses versus normal stress, uncorrected and corrected

for dilation; and
the variations to the above procedure for testing tight joints shall be as
8.26.32 Velocity of Sound in Rock

The determination of the velocity of sound in rock shall be made according to
Suggested Methods of Determining Sound Velocity Method 1 or 2 (for P-wave and
S-wave), by ISRM in Rock Characterisation Testing and Monitoring by E.T. Brown
(editor) (1981).
8.26.33 Porosity and Dry Density of Rock
The determination of porosity and dry density of rock shall be made according to
Suggested Method for Porosity/Density Determination Using Saturation and
Calliper Techniques Method 2, or Suggested Method for Porosity/Density
Determination Using Saturation and Buoyancy Techniques Method 3, by ISRM in
Rock Characterisation Testing and Monitoring by E.T. Brown (editor)(1981).

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8.27
INSPECTION, TESTING AND COMMISSIOINING LABORATORY WORK
8.27.1
Presentation of test results
8.27.2
(a)
The test results shall be presented in tabular and/or graphical form as

appropriate and on forms acceptable to the Project Manager. Examples of
suitable forms for presentation are given in BS 1377 and also in Manual of
Soil Laboratory Testing by K H Head Published by Pentech Press Limited,
Graham Lodge, Graham Road, London NW4 3DG, England.
(b)
Four preliminary copies of the results of each test complete with test data and
photographs shall be submitted to the Project Manager within two days of
completion of the test. The records shall be legible and intelligible and shall be
stamped PRELIMINARY.
Progress reports
Whilst laboratory testing is in progress, the Contractor shall inform the Project
Manager without delay of any unusual or irregular occurrences observed during any
of the laboratory tests ordered.
8.27.3
Draft final report

Within three days of completion of the Laboratory Work the Contractor shall
submit three copies of the Draft Final Report. The contents and standard of
presentation shall be as proposed for the Final Report. The presentation shall be
neat, clear and intelligible. Each page, and the cover, shall be stamped DRAFT.
The Project Manager will return one copy of the Draft Report to the Contractor
with his comments within three weeks of receipt of the report.
8.27.4
Final report
(a)
The Final Report shall contain the information described in the following
sub-clauses relevant to the Works. In preparing the Final Report, account
shall be taken of comments made by the Project Manager after examining the
Draft Final Report.
The information on the cover page shall include:
(i)
names of Employer, Contractor, Project Manager;
(ii)
title and number of Contract; and
(iii)
date of report (month and year).
The introductory text shall include:

(iv)
description of Site location;
(v)
dates of investigation;
(vi)
methods used in making holes, taking samples and carrying out in-situ
tests;

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January 2011
(vii) methods used in carrying out laboratory tests;

(viii) details of any bench marks and/or survey beacons to which the Field
Work is referenced; and
(ix)
any other relevant information.
(b)
The location of holes and tests shall be shown on a plan or plans of the Site.
(c)
Final logs and any photographs specified shall be appended. The master
copy of each final log together with the negatives of all photographs specified
shall be included with the master of the Final Report. Logs shall be ring
bound to facilitate photocopying.
(d)
The results of in-situ tests shall be presented on the logs of holes and/or in
tabular and/or graphical form, as appropriate. The information given shall
include that provided for by the relevant test procedure in accordance with
Clause 8.6.1
together with other information necessary for a full
understanding of the results.
(e)
The results of laboratory tests on earthworks materials shall be presented in

accordance with Section 7. The information given shall include that provided
for by the relevant test procedure and any other information necessary for a
full understanding of the results.
(f)
Page size shall be A4. (Tables and figures shall be A4 height but greater
width, folded in such a way that the essential titles can be read without
opening).
(g)
One master and ten bound copies of the Final Report shall be submitted.
(h)
The Final Report shall be submitted within 2 weeks of the return to the
Contractor of the Draft Report with the Project Managers comments.

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APPENDIX A8.1
"GEO" PROBE TEST
A8.1.1 Scope
This method covers the determination of the penetration resistance of soil using the
GEO probe.
A8.1.2 Apparatus
(1)
GEO Probe as shown in Figure 36 of 'Geoguide 2 : Guide to Site

Investigation,' Hong Kong Government 1987. The anvils shall be rigidly fixed
to the guide rod, the lower anvil shall also be rigidly fixed to the extension
rods. The mass of the lower anvil shall be between 1.5 kg and 1.8 kg. The
combined mass of the lower anvil, guide rod and upper anvil shall not exceed
5.0 kg.
(2)
Extension rods with a length of 1000 mm 10 mm. The rods shall be attached
to bear against each other by means of external couplers.
A8.1.3 Procedure
(1)
The lower end of the probe shall be rested against the ground at the test
location, with the first extension rod and guide rod in a vertical position.
(2)
The hammer shall be raised to bear against the upper anvil, and shall be
allowed to fall freely. It shall not be connected to objects which may influence
its acceleration and deceleration, and shall be stationary when released in the
upper position. The fall shall be 300 mm 5 mm.
(3)
The hammer shall be used to drive the probe into the ground, with a rate of
driving between 20 and 60 blows per minute.
(4)
Additional extension rods shall be added as necessary. The rods shall be

rotated clockwise one full turn each time a rod is added to ensure that screw
joints are tight.
(5)
The blow count for every 100 mm of penetration shall be recorded, or at

refusal the penetration distance for 50 blows of the hammer. Interruptions
exceeding 5 minutes shall be recorded.

(1)
Blow count for every 100 mm penetration or at refusal the penetration

distance for 50 blows of the hammer.
(2)
Interruptions exceeding 5 minutes.

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(3)
GEO probe record as shown in Figure 37 of 'Geoguide 2 : Guide to Site

Investigation,' Hong Kong Government 1987.
(4)
That the test was carried out in accordance with this General Materials and

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APPENDIX A8.2
DETERMINATION OF THE FLOW OF GROUT
A8.2.1 Scope
This method covers the determination of the flow of grout by measuring the time of
efflux of a specified volume of grout from a standard flow cone.
A8.2.2 Apparatus
The following apparatus is required :(1)
A flow cone reviewed without objection by the Project Manager
(2)
A stop watch with a least reading of not more than 0.2s.
(3)
A thermometer.
A8.2.3 Procedure : Calibration

The procedure for calibrating the flow cone shall be as follows :(1)
The flow cone shall be firmly mounted in such a manner that the top will be
level and the cone will be free from vibration.
(2)
The discharge tube shall be closed by placing the finger over the lower end.
A quantity of 1725 mL 1 mL of water shall be introduced to the cone.
(3)
The point gauge shall be adjusted to show the level of the water surface.
A8.2.4 Procedure : Flow Test

The procedure for determination of the flow of the grout shall be as follows :
(1)
Two specimens of grout shall be taken from the sample of grout. The size of
each specimen shall be 1725 mL 1 mL.
(2)
The inside surface of the flow cone shall be wetted by filling the cone with
water and allowing the water to drain from the cone 1 minute before the
specimen of grout is introduced to the cone.
(3)
The temperature of the grout shall be recorded.
(4)
The discharge tube shall be closed by placing the finger over the lower end.
The specimen shall be introduced to the cone until the surface of the grout is
in contact with the point gauge.
(5)
The stop watch shall be started and the finger removed from the discharge
tube simultaneously.

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January 2011
(6)
The stop watch shall be stopped at the first break in the continuous flow of
grout from the discharge tube. The time shall be recorded to the nearest 0.2s
as the time of efflux.
(7)
The cone shall be thoroughly cleaned and the procedure stated in Clauses
A8.2.3 and A8.2.4 (1) to (6) shall be repeated for the second specimen.
A8.2.5 Calculation
The average time of efflux of the 2 specimens shall be calculated.
The following shall be reported :
(1)
The times of efflux of each specimen to the nearest 0.2s.
(2)
The average time of efflux to the nearest 0.2s.
(3)
The temperature of the specimens.
(4)
The ambient temperature.
(5)
Composition of the sample.
(6)
Description of physical characteristics of the sample.
(7)
That the test was carried out in accordance with this General Materials and

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SECTION 9
CARRIAGEWAYS: SUB-BASE MATERIAL AND BITUMINOUS MATERIALS
9.1
9.1.1
Nominal maximum aggregate size

Nominal maximum aggregate size is the smallest BS sieve size for which the upper
limit of the percentage of the aggregate by mass passing is 100%.
9.2
9.2.1
Design procedure for sub-base material and bituminous materials
9.2.2
(a)
Sub-base material and bituminous roadbase materials shall be recipe mixes.

Laboratory design mixes other than those for sub-base material and
bituminous roadbase materials shall be made and tested as part of the design
procedure at a laboratory reviewed without objection by the Project Manager.
(b)
Mix designs and associated tests shall be carried out by the Contractor in the
presence of the Project Manager. The Contractor shall notify the Project
Manager at least 7 days before carrying out the mix designs.
Design of bituminous materials

(a)
Bituminous materials shall consist of coarse and fine aggregates complying

with Clause 9.3.2, filler complying with Clause 9.3.3 and bitumen complying
with Clause 9.3.4. The different types of bituminous materials shall have
particle size distribution and bitumen content within the limits stated in Table
9.4.
(b)
The properties of the different types of bituminous materials shall be as stated

in Table 9.1.
(c)
Bituminous materials of all aggregate sizes, other than bituminous roadbase

material, shall be designed in accordance with the Marshall Method of Mix
Design stated in The Asphalt Institute Handbook 'MS-2 Mix Design Methods
for Asphalt Concrete and other Hot-mix Types,' 1984. The compaction
standard shall be 75 blows per side.
(d)
Design procedures for bituminous friction course material shall be as stated in

Clause 9.2.2(c) except that the mixing and compaction temperatures shall be
consistent with bitumen viscosities of 900 100 centistokes and 2000 200
centistokes respectively.

Section 9 Carriageways: Sub-base Material &
Bituminous Materials
1/25
January 2011
Table 9.1: Properties of Designed Bituminous Materials
Properties
Minimum Marshall
Stability (kN)
Maximum flow value
(mm)
Minimum voids in
mineral aggregate as
a percentage of total
bulk volume
Air voids in mix as
a percentage of total
bulk volume
9.3
MATERIALS
9.3.1
Sub-base material
Type of bituminous material

Base course
Wearing course
Friction course
Nominal maximum aggregate size (mm)
37.5
28
20
10
10
10.0
10.0
4.0
12.5
3.0
4.0
13.0
14.0
5.0
3.0
16.0
5.0
25.0
18.0 - 25.0
Sub-base material shall be crushed rock and shall have the properties stated in
Table 9.2. Sub-base material passing the 425 m BS test sieve, when tested in
accordance with Clause 9.6.10(c) shall be non-plastic.
Table 9.2: Properties of Sub-base Material
Properties
BS test sieve
75
37.5
20
10
5
600
75
Ten percent fines value
9.3.2
mm
mm
mm
mm
mm
m
m
Percentage by
mass passing
100
85 - 100
60 - 85
40 - 70
25 - 45
8 - 22
0 - 10
> 50 kN
Aggregates for bituminous materials

(a)
Coarse aggregate for bituminous materials shall be crushed rock all retained
on a 5 mm BS test sieve and shall have the properties stated in Table 9.3.
(b)
Fine aggregate for bituminous materials shall be crushed rock, river sand or a
mixture of crushed rock and river sand all passing 5 mm BS test sieve. The
water absorption of fine aggregate shall not exceed 2.0%.

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January 2011
(c)
For the purpose of mix design, the combined grading of aggregates for
bituminous materials shall be such that the particle size distribution lies within
the limits stated in Table 9.4 for the relevant bituminous material.
Table 9.3: Properties of Coarse Aggregate for Bituminous Materials

Properties
Flakiness index
37.5
28
20
10
25.0%
26.0%
27.0%
30.0%

Water absorption
> 100 kN
2.0%
Table 9.4: Design Limits for Particle Size Distribution and Bitumen Content
for Bituminous Materials
Properties
Nominal maximum
aggregate
size (mm)
BS test
sieve
50mm
37.5mm
28mm
20mm
14mm
Particle size 10mm
distribution
5mm
2.36mm
1.18mm
600m
300m
150m
75m
Bitumen
min.
content
max.
as
percentage
of total
mass
including
binder

Roadbase
(recipe
mix)
37.5
Base course
37.5
28
Wearing
course
20
Friction
course
10
10
100
87-100
62 - 80
42 - 58
34 - 48
24 - 38
16 - 28
8 - 18
4 - 8
6.0
7.0
100
85-100
20 - 40
5 - 15
2 - 6
4.5
5.5

100
90-100
70 - 94
62 - 84
49 - 67
37 - 55
27 - 43
13 - 28
7 - 21
2 - 8
3.0
4.0
3/25
100
91-100
70 - 94
62 - 84
55 - 76
49 - 67
37 - 55
27 - 43
20 - 35
13 - 28
7 - 21
4 - 14
2 - 8
4.0
4.5
100
91-100
85 - 95
72 - 87
55 - 75
35 - 53
25 - 40
15 - 30
12 - 24
8 - 18
5 - 12
3 - 6
4.5
5.0
100
91-100
78 - 90
68 - 84
54 - 72
42 - 58
34 - 48
24 - 38
16 - 28
8 - 18
4 - 8
5.0
5.5
January 2011
9.3.3
9.3.4
Filler for bituminous materials

(a)
Filler for bituminous materials shall be crushed rock filler, OPC, PPFAC, PFA
or hydrated lime. Filler shall be free-flowing and dry before addition to the
bituminous mixture.
(b)
Filler for bituminous friction course material shall contain hydrated lime; the
amount of hydrated lime, expressed as a percentage by mass of the total
aggregates, shall be at least 1.5%.
(c)
OPC shall comply with BS 12. PPFAC shall comply with BS 6588.
(d)
PFA shall comply with BS 3892 : Part 1 except that the criterion for maximum
water requirement shall not apply.
(e)
Crushed rock filler and hydrated lime shall comply with ASTM D 242.
Bitumen
Bitumen for bituminous materials shall comply with ASTM D 946, Grade 60-70 and
shall have a softening point exceeding 44C and less than 55C. Blending or mixing
of bitumen shall be carried out at a refinery reviewed without objection by the Project
Manager.
9.3.5
Bituminous emulsion
Bituminous emulsion shall be anionic bituminous emulsion complying with BS 434 :
Part 1, Table 1, Class A1-40 or cationic bituminous emulsion complying with BS 434
: Part 1, Table 2, Class K1-40.
9.3.6
Bituminous priming material

Bituminous priming material shall be medium curing-grade cutback bitumen
complying with ASTM D 2027, Table 1, Class MC-30.
9.3.7
Handling and storage of sub-base material and bituminous materials

(a)
Cement and PFA shall be stored as stated in Clause 20.33.
(b)
Sub-base material and bituminous materials shall not be handled or stored in a

manner which will result in mixing of the different types and sizes or in
segregation or contamination of the materials.
(c)
Bituminous materials shall not be stored in heated surge bins for more than 12
hours or in transport vehicles for more than 3 hours.
(d)
Bituminous friction course material shall not be stored in surge bins for more
than 30 minutes.

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January 2011
9.3.8
Transport of sub-base material and bituminous materials

(a)
Sub-base material and bituminous materials shall be protected by covers while

being transported and before laying. Covers for bituminous materials shall be
heavy canvas or a similar insulating material; the covers shall completely
cover the material and shall be securely fixed to minimise loss of heat and to
protect the materials from contamination by dust or other deleterious material.
(b)
Sub-base material and bituminous materials shall be transported in clean

vehicles with smooth trays and sides.
(c)
The trays of vehicles transporting bituminous materials may be lubricated with

soap solution or light oil sprayed on the trays. Vehicles transporting
bituminous friction course material shall not be lubricated with light oil.
9.4
SUBMISSIONS
9.4.1
Particulars of filler and bitumen for bituminous materials

(a)
(b)
The following particulars of the proposed filler and bitumen for bituminous
materials shall be submitted to the Project Manager for review:
(i)
a certificate from the manufacturer for each type of filler showing the
manufacturer's name, the date and place of manufacture and showing
that the filler complies with the Specification and including results of tests
for particle size distribution; and
(ii)
a certificate from the manufacturer for bitumen showing the

that the bitumen complies with the Specification, including a
temperature-viscosity relationship for the bitumen, and including results
of tests for:
relative density;
softening point;
penetration;
ductility;
retained penetration after thin film oven test;
solubility;
viscosity; and
loss on heating.
Further certificates showing that the materials comply with the Specification
shall be submitted at intervals reviewed without objection by the Project
Manager.

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January 2011
9.4.2
Particulars of mixes for sub-base material and bituminous materials

(a)
(b)
9.4.3
The following particulars of sub-base material and bituminous roadbase

materials shall be submitted to the Project Manager for review:
(i)
source and type of aggregates;
(ii)
grading details in tabular and graphical form; and
(iii)
details of each mixing plant proposed.
The following particulars of bituminous materials shall be submitted to the

(i)
certified copies of work sheets for mix designs, which shall include the
relative density of the mixed aggregates;
(ii)
source of bitumen; and
(iii)
past test records of the same mix produced in the same plant.
Particulars of supplier of sub-base material and bituminous materials

The name of the supplier and the location of each plant from which the Contractor
proposes to obtain sub-base material and bituminous materials shall be submitted to
the Project Manager for review, together with a certificate of origin and certificate of
quality.
9.4.4
Particulars of methods of laying and compacting sub-bases and bituminous

materials
(a)
9.4.5
The following particulars of the proposed methods of laying and compacting

sub-bases and bituminous materials shall be submitted to the Project Manager
for review:
(i)
details of Contractor's Equipment; and
(ii)
programme and rate of working.
Representative samples of sub-base material, aggregate, filler and bitumen

One representative sample of each type of sub-base material, and one
representative sample of each type of aggregate, filler and bitumen for bituminous
material of each proposed suppliers shall be submitted to the Project Manager at the
same time as particulars are submitted.
9.5
WORKMANSHIP
9.5.1
Mixing of sub-base material and bituminous materials

Mixing of sub-base material and mixing of bituminous materials shall be carried out
before delivery to Site at mixing plants reviewed without objection by the Project
Manager. The plants shall be designed and operated to produce uniform mixes
which comply with the specified requirements.

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January 2011
9.5.2
9.5.3
Mixing plant for bituminous materials

(a)
The mixing plant for bituminous materials shall have at least four separate cold
feed bins for preliminary cold batching of the coarse and fine aggregates, and
a rotary drum dryer which will continuously agitate the aggregates during the
heating and drying processes. After passing through the dryer, the aggregates
shall be screened into at least four hot storage bins before mixing.
(b)
Bitumen heating and storage tanks shall be fitted with circulating pumps to
ensure an even temperature throughout the tanks.
(c)
The mixing plant shall be provided with sampling devices to enable samples of
hot aggregates, filler and bitumen to be taken before mixing.
(d)
Insulated surge bins, if fitted to the mixing plant, shall be designed and
operated to prevent segregation occurring in the mix. Heating devices fitted to
surge bins shall be capable of maintaining the temperature of the mix to within
the specified limits.
(e)
Measuring and weighing equipment shall be maintained in a clean, serviceable

condition. The equipment shall be set to zero daily and calibrated before
mixes for the Permanent Works are produced, and at regular intervals not
exceeding 6 months.
Mixing bituminous materials

(a)
Aggregates and filler for bituminous materials shall be measured to an

accuracy of 3.0% by mass. The aggregate moisture content after drying shall
not exceed 0.4% by mass.
(b)
Mixing of bituminous materials shall continue after the addition of all

constituents for such period as is necessary to ensure that the aggregates and
filler are uniformly coated with bitumen.
(c)
Bituminous materials shall comply with the temperature requirements as

stated in Table 9.5 during and after mixing.
Table 9.5: Temperature Requirements for Bituminous Materials

Aggregate temperature at mixing ( C)
Binder temperature at mixing ( C)
Bituminous mixture temperature
after mixing ( C)
at laying ( C)
at start of compaction ( C)

7/25
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Roadbase,
base course
and wearing
course
Friction
course
130
175
135
165
130
165
-
115
135
115
165
115
135
110
135
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January 2011
9.5.4
9.5.5
Installation of utilities
(a)
Pipes, cables, manholes, chambers, gullies and other utilities below

carriageways shall be completed and fill material shall be deposited and
compacted in trenches before the carriageway is constructed. Openings to
manholes, chambers and gullies shall be protected by temporary covers.
(b)
Covers, frames and other hardware which will prevent continuous laying of
bituminous materials for roadbase and base course shall not be fixed in
position until such work is complete.
(c)
After the penultimate layer of bituminous material has been laid and
compacted, the layers of asphalt shall be cut out, temporary covers shall be
removed and the permanent covers, frames and other hardware shall be
installed.
(d)
Finishing around covers, frames and other hardware shall be carried out using
bituminous material of the same type as that in the adjacent surface. The
material shall be compacted in layers not exceeding 50 mm thick using
handrammers or mechanical equipment up to the underside of the wearing
course or friction course.
Laying and compaction of sub-base material

(a)
Sub-base material shall be laid and compacted in a manner which will not
result in segregation of the material and at a moisture content which allows the
compaction stated in Clause 9.5.5(f) to be achieved. The moisture content
shall not be less than 2%.
(b)
Sub-base material shall be laid in layers and compacted. The thickness of

each compacted layer shall not exceed 225mm. The minimum thickness of
each layer shall be 100mm and, if the layers are of unequal thickness, the
lowest layer shall be the thickest.
(c)
Each layer of sub-base material shall be evenly spread immediately after

placing in position and shall be compacted immediately after spreading.
(d)
The minimum compaction plant to be used for compaction of sub-base

material shall be of the type as stated in Clause 9.5.9(a).
(e)
The Project Manager shall be notified before the next layer is placed on each
layer of compacted sub-base material.
(f)
Sub-base material shall be compacted to obtain a relative compaction of at

least 95% maximum dry density throughout.
(g)
The surface of each layer of sub-base shall be maintained in a compacted

condition until the next layer of sub-base material or roadbase material is laid;
the surface shall not be disturbed by Contractor's Equipment or other vehicles,
and shall be free from ridges, cracks, loose material, pot-holes, ruts or other
defects.

8/25
January 2011
9.5.6
9.5.7
Laying and compaction of bituminous materials

(a)
Bituminous materials shall not be laid during periods of wet weather or when
ponded water is present on the underlying surface.
(b)
Bituminous wearing course material shall not be laid when the ambient air
temperature is below 8C and bituminous friction course material shall not be
laid when the ambient air temperature is below 10C. Temperatures shall be
measured in the shade near to the surface on which laying is to be carried out.
(c)
Surfaces on which bituminous materials are laid shall be clean and free from
mud, grit and other deleterious material.
(d)
A tack coat of bituminous emulsion shall be applied to surfaces on or against

which bituminous materials will be laid. The tack coat shall be evenly applied
at a rate of between 0.4 L/m and 0.6 L/m using a spray machine complying
with BS 434 : Part 2. Bituminous materials shall not be laid until the tack coat
has cured. Contractor's Equipment and other vehicles shall only run on the
tack coat as necessary to lay the bituminous materials.
(e)
If permitted by the Project Manager, surfaces of existing carriageways may be

regulated before the overlying bituminous material is laid; bituminous
regulating course material shall be a material reviewed without objection by
the Project Manager complying with the requirements for the 10 mm nominal
maximum aggregate size wearing course material as specified in Table 9.3.
Regulating course material shall be laid by paving machines.
(f)
Bituminous materials shall comply with the temperature requirements as

stated in Table 9.5 during laying and compaction.
(g)
Where paved hard shoulders are provided, friction course shall be left proud of
the immediate underlying layer and in line with the front edge of the gully
gratings or drainage channel, provided the friction course extends more than
0.5 m beyond the lane edge.
Laying bituminous materials by paving machine

(a)
Bituminous materials shall be placed and spread using a self-propelled paving

machine with a screw auger and attached screed capable of spreading and
laying the material to the full width required. The paving machine shall be
capable of giving initial compaction to the material and finishing it to a level
suitable for subsequent compaction.
(b)
Paving machines may be fitted with cut-off shoes or extensions to limit or

extend the width of the screed; screed extensions shall not be used unless the
screw auger is extended in accordance with the manufacturer's
recommendations. The surface texture produced by paving machines shall be
free from segregation and from pushing or dragging marks.
(c)
Bituminous materials laid by paving machines shall be placed directly from the
vehicles transporting the material into the hopper of the paving machine.
Delivery of materials to the paving machine and laying of the materials shall be
at a uniform rate appropriate to the capacity of the paving machine and
compaction plant.

9/25
January 2011
9.5.8
(d)
If any delay in laying operations occurs, the paving machine shall be removed,
the uncompacted cold material shall be removed and a transverse joint shall
be formed as stated in Clause 9.5.10.
(e)
Paving machines working in echelon shall be as close as practicable; the

machines shall be not more than 30 m apart unless a longitudinal joint is
formed as stated in Clause 9.5.10.
(f)
Manual placing of materials on freshly laid surfaces shall only be used for the
purpose of locally correcting levels as paving operations proceed, before
compaction by rolling is commenced.
Laying bituminous materials by manual methods

Bituminous materials shall be laid by manual methods only if in the opinion of the
Project Manager the use of a paving machine is impracticable. If permitted by the
Project Manager, bituminous materials may be laid by manual methods:
9.5.9
(a)
in courses of irregular shape and varying thickness;
(b)
in confined locations;
(c)
adjacent to expansion joints, covers, frames and other hardware; and
(d)
in reinstatements to trenches.
Compaction of bituminous materials and sub-base material

(a)
The minimum compaction plant to be used to compact bituminous roadbase,

base course, regulating course, wearing course and sub-base material shall
be:
(i)
a smooth three-wheeled steel-wheeled roller with a mass of between 6 t

and 12 t, or a vibratory tandem steel-wheeled roller with an effective
mass of between 6 t and 12 t, and a smooth pneumatic tyred-roller with a
mass of between 12 t and 25 t, and with not less than seven overlapping
wheels which have tyres that are capable of having pressures varying
between 300 MPa and 800 MPa, and suitable mechanical rammers and
hand-tools; or
(ii)
other types of rollers, vibrating plates and rammers reviewed without

objection by the Project Manager, or other similar plant reviewed without
objection by the Project Manager, necessary to produce the required
degree of compaction.
(b)
Bituminous roadbase, base course, regulating course and wearing course

materials shall be initially rolled using a steel-wheeled roller operated in a
longitudinal direction along the carriageway with the driving wheels nearest the
paving machine.
(c)
All roller marks shall be removed from the surface of bituminous roadbase,
base course and wearing course materials using either a smooth-wheeled
dead-weight roller or a smooth-wheeled vibratory roller in non-vibrating mode.

10/25
January 2011
9.5.10
(d)
Bituminous friction course material shall be compacted using rollers as stated

in Clause 9.5.9(a)(i) without the application of vibration; rollers shall not have
an excessive film of water over the front and rear wheels. Bituminous friction
course material shall be compacted until all roller marks are removed and the
required degree of compaction is achieved.
(e)
Rollers shall not be parked on newly laid or compacted bituminous materials.
(f)
Bituminous materials immediately adjacent to kerbs, covers, frames and other

hardware where rollers cannot operate effectively shall be compacted using
hand-operated mechanical compaction plant.
Joints in bituminous materials

(a)
The screed of the paving machine shall overlap previously laid strips of
bituminous material by at least 50 mm and shall be sufficiently high that
compaction will produce a smooth dense flush joint. Bituminous materials
overlapping the previously laid strip shall be pushed back to the edge of the
previously laid strip and the excess material shall be removed.
(b)
Longitudinal joints in friction course or wearing course shall be formed

coincident with the specified position of the lane-markings.
(c)
A prepared joint shall be formed between hot bituminous material and cold
material or existing bituminous material which is at a temperature below the
minimum specified laying temperature.
(d)
The distance between prepared longitudinal joints in different layers shall be at

least 150 mm and the distance between prepared transverse joints in different
layers shall be at least 500 mm.
(e)
Prepared joints in base course and wearing course shall be formed by cutting
back the face of the cold material or existing bituminous material for a
minimum distance of twice the depth of the layer or 100 mm, whichever is
greater; a vertical face shall be cut for the full depth of the layer. All loosened
materials shall be removed and the face shall be coated with bituminous
emulsion; the bituminous emulsion shall not be applied beyond the edges of
the joint. The hot bituminous materials shall be laid and compacted against
the coated face with a joint formed as stated in this sub-section.
Friction course joints shall not be coated with bituminous emulsion.
(f)
9.5.11
Protection of surfaces of sub-base material and bituminous materials

(a)
The surface of each layer of sub-base material and bituminous materials shall
be kept clean and free from deleterious material. Bituminous priming coat
shall be applied to the final surface of the sub-base layer at a rate of between
0.9 L/m and 1.1 L/m.
(b)
Layers of carriageways under construction shall not be used by Contractor's

Equipment or vehicles other than those which are essential to construct the
work.
(c)
Bituminous courses shall not be used by Contractor's Equipment or other

vehicles until 6 hours after the material has been laid and compacted.

11/25
January 2011
9.5.12
Tolerances: alignment of carriageway

The line of the edges of carriageways shall be within 25 mm of the specified line,
except at the edges of structures where it shall be within 6 mm.
9.5.13
Tolerances: level of carriageway

(a)
The levels of the surface of each layer of sub-base, roadbase, base course,
wearing course and friction course shall be determined on a grid at 10 m
centres in the longitudinal direction and at 2 m centres in the transverse
direction.
(b)
The level of the surface of each layer of sub-base, roadbase, base course,
wearing course and friction course shall be within the tolerances stated in
Table 9.6.
(c)
The difference in level of the surface of wearing course and friction course
across joints shall not exceed 3 mm.
(d)
The combination of permitted tolerances in levels shall not result in a reduction

in the thickness of the pavement, excluding the sub-base, of more than 15 mm
from the specified thickness nor a reduction in the thickness of the bituminous
wearing course or friction course of more than 5 mm from the specified
thickness.
Table 9.6: Tolerances in Level

Type of surface
Permitted tolerance in level (mm)
Sub-base
+ 10
- 20
Roadbase course
+8
- 15
Base course
Wearing course
Friction course
9.5.14
Tolerances: covers, frames and other hardware

The level of covers, frames and other hardware shall be not lower than, and shall
not be more than 5 mm higher than the surface of the carriageway. The level of
gully gratings shall not be higher than, and shall not be more than 5 mm lower than,
the surface of the carriageway.

12/25
January 2011
9.6
9.6.1
Trial areas
(a)
The Contractor shall produce trial areas of each type and layer of bituminous
materials to demonstrate that the proposed materials, mixes, methods of
production and methods of construction are capable of producing a
carriageway which complies with the specified requirements.
Unless
otherwise stated in the Contract, the trial areas shall be constructed as part of
the Permanent Works at locations reviewed without objection by the Project
Manager. The width of each trial area shall be at least one lane of
carriageway, and the length shall be at least 60 m.
(b)
Trial areas shall be constructed using the materials, mixes, methods of

production and methods of construction submitted to and reviewed without
objection by the Project Manager. Materials shall be delivered in not less than
two loads.
(c)
The Contractor shall notify the Project Manager 48 hours before constructing
trial areas.
(d)
The Contractor shall notify the Project Manager before each layer of material
is placed in the trial area.
(e)
The Contractor shall not proceed placing materials of the same type in the
permanent carriageway until he obtains a notice of no objection from the
Project Manager.
Table 9.7: Sampling and Testing Bituminous Materials

Type of material
Properties
Bituminous base
course and wearing
course material
Particle size
distribution
Bitumen content
Rice's specific gravity
Void content
Particle size
distribution
Bitumen content
Texture depth and
permeability
Bituminous friction
course material
9.6.2
Methods of
sampling
Clause 9.6.13(b)
Clause 9.6.13(b)
Clause 9.6.13(b)
Clause 9.6.15(a)
Methods of
testing
Clause 9.6.13(c)
Clause 9.6.13(c)
Clause 9.6.13(c)
Clause 9.6.15(b)
Clause 9.6.14(b)
Clause 9.6.14(a)
Clause 9.6.14(b)
-
Clause 9.6.14(a)
Clause 9.6.16(a)
Samples: trial areas

(a)
One sample of bituminous materials, excluding bituminous roadbase

materials, shall be provided from each mix used in trial areas. The method of
sampling shall be as stated in Table 9.7
(b)
Ten cores shall be cut from each layer of base course and wearing course in
trial areas. The method of taking cores shall be as stated in Clause 9.6.15 (a).

13/25
January 2011
9.6.3
9.6.4
Testing: trial areas

(a)
Each sample of bituminous material taken as stated in Clause 9.6.2, shall be

tested to determine the properties stated in Table 9.5. The method of testing
(b)
If the layer is to form part of the Permanent Works, each layer of bituminous
material in trial areas, excluding bituminous roadbase material, shall be tested
as stated in Clause 9.5.13 to determine the level of the surface.
(c)
The layer which is to be the final layer of the carriageway in each trial area
shall be tested as stated in Clauses 9.6.9 (a) and 9.6.9 (b) to determine the
surface regularity, if the layer is to form part of the Permanent Works.
(d)
The layer of friction course in each trial area shall be tested as stated in
Clauses 9.6.16 (a) to 9.6.16 (c) to determine the texture depth and
permeability.
(e)
Cores shall be tested as stated in Clauses 9.6.15 (a) to 9.6.15 (d) to determine
the compacted layer thickness and air void content.
Compliance criteria: trial areas

The properties of the materials, the levels of the surface, compaction, surface
regularity, texture depth and permeability of bituminous materials laid in the trial
areas shall comply with the specified requirements for the permanent carriageway.
9.6.5
9.6.6
Non-compliance: trial areas

(a)
If the result of any test on trial areas does not comply with the specified
requirements for trial areas, particulars of proposed changes to the materials,
mixes, methods of production or methods of construction shall be submitted to
the Project Manager for review and further trial areas shall be constructed until
the result of every test on trial areas complies with the specified requirements
for the trial areas.
(b)
Trial areas, or parts of trial areas, which do not comply with the specified
requirements for the trial area shall be removed.
Acceptable mix for bituminous materials other than bituminous roadbase

material
(a)
A mix for bituminous materials other than bituminous roadbase material which
complies with the specified requirements for designed mixes and for trial areas
is defined as an "Acceptable Mix".
(b)
The "Acceptable Gradation Envelope" for bituminous materials other than

bituminous roadbase material is defined as the gradation envelope found by
applying the tolerances stated in Table 9.8 to the particle size distribution of
the "Acceptable Mix".
(c)
The "Acceptable Bitumen Content Range" for bituminous materials other than
bituminous roadbase material is defined as the bitumen content range formed
by applying a tolerance of 0.5% to the bitumen content of the "Acceptable
Mix".

14/25
January 2011
Table 9.8: Tolerances for Particle Size Distribution from Acceptable Mix
BS test sieve
50
37.5
28
20
14
10
5
2.36
1.18
600
300
150
75
9.6.7
mm
mm
mm
mm
mm
mm
mm
mm
mm
m
m
m
m
Tolerance of particle size distribution in percentage

By mass of total mix passing BS test sieve
37.5
28
20
10
0
4
0
7
4
0
7
7
4
7
7
7
0
7
7
7
4
7
7
7
7
7
7
7
7
7
7
7
7
5
5
5
5
5
5
5
5
3
3
3
3
2
2
2
2
Commencement of placing bituminous materials

Bituminous material shall not be placed in the Permanent Works until the mix has
been reviewed without objection by the Project Manager.
9.6.8
Changes in materials and methods of construction

The materials and methods of production used in producing the mixes and the
methods of construction used in trial areas shall not be changed after having been
9.6.9
Testing: surface regularity

(a)
Testing method
The surface regularity of the final layer of the pavement shall be determined
as stated in Clause 10.5.8(a).
(b)
Compliance criteria: surface regularity

The results of tests for surface regularity shall comply with Clause 10.5.8(b)
9.6.10
Testing : Sub-Base Material

(a)
Batch: sub-base material

A batch of sub-base material is a quantity not exceeding 250 m of sub-base
material of the same type and same mix produced at the same mixing plant,
and delivered to Site at any one time.
(b)
Samples: sub-base material

(i)
(ii)
One sample of each type of sub-base material shall be provided from

each batch of sub-base material delivered to Site.
The size of each sample shall be at least 50 kg. The method of
sampling shall be in accordance with BS 812 : Part 102.

15/25
January 2011
(c)
9.6.11
Testing: sub-base material

(i)
Each sample of sub-base material shall be tested to determine the

particle size distribution, ten percent fines value, maximum dry density,
optimum moisture content and plasticity index of the portion passing a
425m BS test sieve.
(ii)
The method of testing for particle size distribution shall be in accordance

with BS 812:Part 103.1.
(iii)
The method of testing for ten percent fines value shall be in accordance
with BS 812:Part 111, except that the sample shall be soaked in water at
room temperature for 24 hours and shall not be oven-dried before
testing.
(iv)
The method of testing for plasticity index shall be in accordance with

GEO Report No. 36, Tests 2.4.3 and 2.5.3, except that sample
preparation shall be by wet sieving the material over a 425 m BS test
sieve.
(v)
The method of testing for maximum dry density and optimum moisture
content shall be in accordance with BS 1377 : 1975, Test 13, and
Appendix 7.5 of this General Materials and Workmanship Specification.
Testing : Relative Compaction Of Sub-Base

(a)
(b)
Testing methodology
(i)
Each area of sub-base which contains sub-base material of the same

type and same mix produced at the same mixing plant and which is laid
and compacted in a single layer in one day shall be tested to determine
the relative compaction. Tests shall be carried out after the sub-base
material has been laid and compacted in the final position.
(ii)
Two tests shall be carried out on each area of 1000 m or part thereof
laid and compacted each day.
(iii)
Tests shall be carried out at positions which are representative of the

area of compacted sub-base as a whole.
(iv)
The method of testing for relative compaction shall be as stated in

Clause 7.6.17(d) Method 1 for fill material, except that the determination
of maximum dry density shall be in accordance with Clause 9.6.10(c)(v),
and the in-situ density in accordance with Clause 7.6.17(e).
Compliance criteria: relative compaction of sub-base

The results of tests for relative compaction of sub-base shall comply with the
requirements stated in Clause 9.5.5(f).
(c)
Non-compliance: relative compaction of sub-base

If the result of any test for relative compaction of sub-base does not comply
with the specified requirements for relative compaction of sub-base, the area
shall be re-compacted and two additional tests for relative compaction of
sub-base shall be carried out on the area.

16/25
January 2011
9.6.12
Testing : Aggregates, Filler And Bitumen For Bituminous Materials

(a)
Batch: aggregates, filler and bitumen for bituminous materials

A batch of aggregate, filler or bitumen for bituminous materials is any quantity
of aggregate, filler or bitumen for bituminous materials of the same type,
manufactured or produced in the same place and covered by the same
certificates delivered to Site at any one time.
(b)
Samples: aggregates, filler and bitumen for bituminous materials

(i)
One sample of each type of aggregate, filler and bitumen for bituminous
materials shall be provided from each batch.
(ii)
The size of each sample and the method of sampling shall be as stated
in Table 9.9.
Table 9.9: Size of Samples and Method of Sampling for Aggregates, Filler and
Bitumen
Minimum size
Material
of sample
Method of sampling
Aggregate, nominal maximum

aggregate size exceeding 28 mm
50 kg

aggregate size 5 mm to 28 mm
25 kg

aggregate size less than 5 mm
10 kg
Filler
5 kg
ASTM D 242
2 litres
ASTM D 140
Bitumen
(c)
BS 812:Part 102
Testing: aggregates, filler and bitumen for bituminous materials

Each sample of aggregate, filler and bitumen for bituminous materials shall be
tested to determine the properties stated in Table 9.10. The method of testing

17/25
January 2011
Table 9.10: Testing Aggregates, Filler and Bitumen for Bituminous Materials
Material
Property
Method of testing
Coarse aggregate
Relative density
BS 812 : Part 2
Water absorption
Fine aggregate
BS 812 : Part 111
BS 812 : Part 103.1
Flakiness index
BS 812 : Part 105
Relative density
BS 812 : Part 2
Water absorption
Filler
Bitumen
9.6.13
GEO Report No. 36, test 2.9.2B
Relative density
BS 4550 : Part 3
BS 812 : Part 103.1
Relative density
ASTM D 3289
Softening point
BS 2000
Penetration
ASTM D 5
Ductility
ASTM D 113
Retained penetration
after thin film oven test
ASTM D 1754
Solubility
ASTM D 2042
Viscosity
ASTM D 2171 or BS 2000
Loss on heating
BS 2000
Testing : Bituminous Materials Other Than Bituminous Friction Course

Material
(a)
Batch: bituminous materials other than bituminous friction course material

A batch of bituminous materials other than bituminous friction coarse material
is a quantity not exceeding the limits stated in Table 9.11 of bituminous
materials of the same type and same mix produced at the same mixing plant in
one day.
Table 9.11: Maximum Size of Batch for Bituminous Materials other than
Bituminous Friction Course Material
Material
Maximum batch size (t)
Wearing course
100
Base course
150
Road base
200
(b)
Samples: bituminous materials other than bituminous friction course material

(i)
One sample of bituminous material other than bituminous friction course

material shall be provided from each batch unless otherwise required by

18/25
January 2011
(ii)
The size of each sample shall be as stated in Table 9.12.
(iii)
Samples shall be taken at the mixing plant or at the location where the
bituminous material will be laid as directed by the Project Manager.
Samples taken at the mixing plant shall be taken from the delivery
vehicle immediately after loading from the plant or from the surge bin.
Samples taken at the location where the bituminous materials will be laid
shall be taken from the delivery vehicle.
(iv)
The method of sampling shall be in accordance with ASTM D 979.
Table 9.12: Size of Samples for Bituminous Materials other than Bituminous
Friction Course Material
Material
Minimum size of sample (kg)
Wearing course
10
(10mm nominal maximum aggregate size)

Wearing course
16
(20mm nominal maximum aggregate size)

Base course
24
Roadbase
24
(c)
Testing: bituminous materials other than bituminous friction course material

(i)
Each sample of bituminous materials taken as stated in Clause 9.6.13(b)

(i) shall be tested to determine the particle size distribution, bitumen
content and Rice's specific gravity.
(ii)

ASTM C 136 with modifications and

ASTM C 117, Method B
Bitumen content
ASTM D 2172, Method A
Rice's specific gravity
ASTM D
method
Bulk specific gravity
ASTM D 2726

19/25
2041,
Weighting-in-water
January 2011
(iii)
For particle size distribution tests in accordance with ASTM C 136, the
modifications are:
Sieves to BS410 instead of sieves to ASTM E11 shall be used.
shall be reduced to test specimen of suitable size as follows:
Nominal Maximum
Aggregate Size (mm)
Minimum Sample Size (kg)
37.5
28.0
20.0
10.0
(iv)
(d)
2.5
2.0
1.5
1.0
The residual pressure manometer specified in ASTM D 2041 shall be

replaced by a vacuum gauge.
Compliance criteria : bituminous materials other than bituminous friction

course material
The results of tests on bituminous materials other than bituminous friction
course material shall comply with the following requirements:
9.6.14
(i)
The particle size distribution shall be such that not more than two points
on the particle size distribution curve are outside the "Acceptable
Gradation Envelopes" determined as stated in Clause 9.6.6(b). The
percentage passing the 75 m BS test sieve shall not exceed the
acceptable design value by more than 3%.
(ii)
The bitumen content shall be within the "Acceptable Bitumen Content

Range" determined as stated in Clause 9.6.6(c).
Testing : Bituminous Friction Course Material

(a)
Batch: bituminous friction course material

A batch of bituminous friction course material is a quantity not exceeding 100 t
of bituminous friction course material of the same mix produced at the same
mixing plant in one day.
(b)
Samples: bituminous friction course material

(i)
One sample of bituminous friction course material shall be provided from

each batch of bituminous friction course material.
(ii)
The size of each sample shall be at least 15 kg.
(iii)
Samples shall be taken at the mixing plant from the delivery vehicle
immediately after loading from the plant or from the surge bin.
(iv)
The method of sampling shall be in accordance with ASTM D 979.

20/25
January 2011
(c)
Testing: bituminous friction course material

(i)
Each sample of bituminous friction course material shall be tested to

determine the particle size distribution and bitumen content.
(ii)
(iii)
ASTM C 136 with modifications and

ASTM C 117, Method B
Bitumen content
ASTM D 2172, Method A
For particle size distribution tests in accordance with ASTM C 136, the
modifications are:
Sieves to BS410 instead of sieves to ASTM E11 shall be used.
shall be reduced to test specimen of suitable size as follows:
Nominal Maximum
Aggregate Size (mm)
Minimum Sample Size (kg)
37.5
28.0
20.0
10.0
(d)
2.5
2.0
1.5
1.0
Compliance criteria: bituminous friction course material

The results of tests on bituminous friction course material shall comply with
9.6.15
(i)
The particle size distribution shall be within the "Acceptable Gradation

Envelopes" as determined in Clause 9.6.6(b).
(ii)
The bitumen content shall be within the "Acceptable Bitumen Content

Range" as determined in Clause 9.6.6(c).
Testing : Bituminous Material Cores

(a)
Samples: bituminous material cores

(i)
Each area of roadbase, base course and wearing course which contains
bituminous material of the same type and same mix produced at the
same mixing plant and which is laid and compacted in a single layer in
one day shall be tested to determine the compacted layer thickness.
(ii)
Each area of bituminous material to be tested shall be divided into

approximately equal sub-areas as stated in Table 9.13. One core shall
be taken at random from each sub-area.
(iii)
Cores shall not be taken from within 300 mm of covers, frames and other
hardware, or construction joints in the bituminous material.

21/25
January 2011
(iv)
Cores shall be taken by a mechanically operated coring machine.
(v)
Cores shall be 150 mm diameter for bituminous material with a designed

layer thickness of 40 mm or greater and shall be 100 mm diameter for
bituminous material with a designed layer thickness of less than 40 mm.
(vi)
Cores shall be taken as soon as practicable but not later than 48 hours
after completion of the paving operation.
(vii) If permitted by the Project Manager, the sampling rate for roadbase may
be applied to wearing course and base course.
(viii) Holes formed by taking cores shall be filled with compatible bituminous
material as soon as practicable after the core has been taken.
Table 9.13: Rate of Sampling for Bituminous Material Cores
No. of sub-areas/cores
Area of bituminous material
Roadbase
Wearing course
and Base course
< 5 000 m
10
5 000 - 10 000 m
10
15
> 10 000 m
20
20
laid and compacted in one day
(b)
(c)
Testing: bituminous material cores

(i)
Each bituminous material core shall be measured to determine the

compacted layer thickness of the bituminous material and tested to
determine the air void content.
(ii)
The method of testing for air void content shall be in accordance with
ASTM D 3203.
Compliance criteria: bituminous material cores

The results of tests on bituminous material cores shall comply with the
(i)
The average air void content of the cores taken from an area of
bituminous base course or wearing course material shall be not less than
3.0% and not greater than 6.0%.
(ii)
The air void content of each core taken from an area of bituminous base
course or wearing course material shall be not less than 2.5% and not
greater than 7.5%.
(iii)
The air void content of each core taken from an area of bituminous
roadbase material shall be not less than 3.0% and not greater than
9.0%.
(iv)
The compacted layer thickness as measured from each core shall

comply with the thickness requirements stated in Clause 9.5.13(d) and
shall be compatible with the level tolerances stated in Table 9.6.

22/25
January 2011
(d)
Non-compliance: bituminous material cores

(i)
9.6.16
If the result of any test for air void content of cores does not comply with
the specified requirements for air void content, the following procedure
shall apply:
Four additional cores, shall be taken from each sub-area for which
the original core did not comply with the specified requirements
for air void content. The cores shall be taken at locations evenly
spaced throughout the sub-area such that they are representative
of the sub-area as a whole.
Each additional core shall be tested to determine the air void

content and the test results of the additional cores from the same
sub-area shall be averaged.
The average air void content of the sub-area thus obtained shall
replace the original air void content of the respective sub-area.
The new average air void content of the area of bituminous
material tested shall then be calculated for compliance checking.
(ii)
If the air void content of any of the four additional cores determined as
stated in Clause 9.6.15(b)(ii) is less than 2.5% or greater than 7.5% for
bituminous base course material and bituminous wearing course
material, or less than 3.0% or greater than 9.0% for bituminous roadbase
material, the sub-area from which the cores were taken shall be
considered as not complying with the specified requirements.
(iii)
The area of bituminous material tested shall be considered as not

complying with the specified requirements for average air void content if
the average air void content of the cores taken from the area does not
comply with the specified requirements for average air void content.
(iv)
If the result of any test for compacted layer thickness of cores is not
compatible with the requirements of Table 9.6 or Clause 9.5.13(d), four
additional cores shall be taken from the same sub-area and the results
averaged to determine the average compacted layer thickness. The
cores shall be taken at locations evenly spaced throughout the sub-area
such that they are representative of the sub-area as a whole.
(v)
If the average compacted layer thickness determined as stated in Clause

9.6.15(d)(iv) is not in accordance with the permitted compacted layer
thickness stated in Clause 9.6.15(c)(iv), the sub-area from which the
cores were taken shall be considered as not complying with the specified
requirements.
Testing : Texture Depth And Permeability

(a)
Testing: texture depth and permeability

(i)
Each area of friction course to be tested shall be divided into

approximately equal sub-areas as stated in Table 9.14. Tests for texture
depth and permeability shall be carried out on each sub-area at positions
which are representative of the sub-area of friction course as a whole.
No measurement shall be taken within 300 mm of the longitudinal edge
of the carriageway.
(ii)
If permitted by the Project Manager the number of tests for texture depth
and permeability may be reduced to the minimum stated in Table 9.14.

23/25
January 2011
(b)
(iii)
Tests shall be carried out before the area of friction course is used by
Contractor's Equipment or other vehicles.
(iv)
Testing to determine the texture depth will be carried out by the

Contractor in the presence of the Project Manager. The method of
testing shall be by the sand patch test in accordance with Appendix 10.1.
(v)
Testing to determine the permeability will be carried out by the

testing shall be in accordance with Appendix A9.1.
Compliance criteria: texture depth

The results of tests for texture depth on an area of course shall comply with
(c)
(i)
the average texture depth shall not be less than 1.5 mm; and
(ii)
not more than one of the tests for texture depth shall give a result of less
than 1.2 mm.
Compliance criteria: permeability

The time for 150 mL of water to drain into the friction course in the
permeability test stated in Clause 9.6.16(a)(v) shall not exceed 30 seconds.
Table 9.14: Rate of Testing for Texture Depth and Permeability

Area of bituminous material
laid and compacted in one
day
< 5 000 m
5 000 10 000 m
> 10 000 m

No. of sub-areas/tests
Normal
10
15
20
24/25
Minimum
4
10
20
January 2011
APPENDIX A9.1
DETERMINATION OF THE PERMEABILITY OF
FRICTION COURSE MATERIAL
A9.1.1 Scope
This method covers the determination of the permeability of friction course material
by measuring the time taken for 150 mL of water to drain into the material.
A9.1.2 Apparatus
(1)
a non-porous ring with an opening of internal diameter of 150 mm 2 mm,

and a minimum height of 20 mm;
(2)
suitable sealant for sealing one end of the ring onto the friction course
surface;
(3)
a measuring cylinder for measuring 150 mL of water to an accuracy of 1 mL;
(4)
two containers, each suitable for containing and pouring 150 mL of water; and
(5)
a stop watch.
A9.1.3 Procedure
(1)
carefully inspect the specified test location and record any unusual features;
(2)
place one end of the ring on the friction course at the location to be tested,
and seal the interface with sealant to prevent any leakage of water;
(3)
prepare two volumes of water of 150 mL each using the measuring cylinder
and the two containers;
(4)
pour one 150 mL measure of water into the ring quickly and steadily without
spillage;
(5)
as soon as all of the water has drained into the friction course, pour the
second 150 mL of water into the ring quickly and steadily without spillage, and
at the same time start the stop watch;
(6)
record the time taken for the second 150 mL of water to drain into the friction
course surface.

(1)
the test location; and
(2)
the time taken for the second 150 mL of water to drain into the friction course
surface, to the nearest one second.

25/25
January 2011
SECTION 10 CONCRETE CARRIAGEWAYS
10.1
GENERAL
10.1.1
General requirements
The Permanent Works and materials specified shall comply with the Sections
(a)
Formwork and finishes to concrete for concrete carriageways shall comply

with Section 18.
(b)
Steel reinforcement for concrete carriageways shall comply with Section 19.
(c)
Concrete for concrete carriageways shall comply with Section 20.
(d)
Curing compound for concrete carriageways shall comply with Section 20.
(e)
Earthworks for concrete carriageways shall comply with Section 7.
10.2
MATERIALS
10.2.1
Reinforcement
10.2.2
(a)
Fabric reinforcement shall be steel fabric complying with BS 4483; the fabric
shall be manufactured from steel wire which complies with BS 4482 and which
has a type 2 bond classification.
(b)
Dowel bars, tie bars, cradles and tie bars for cradles shall be Grade 250 plain
round steel bars complying with CS2. Dowel bars and tie bars shall be
straight; both ends of dowel bars and one end of tie bars shall be sawn square
with all burrs removed.
Cement mortar for cradles

Cement mortar for supporting cradles shall consist of 1 part of cement to 3 parts of
fine aggregate together with the minimum amount of water necessary to achieve a
consistency suitable for the required work. Fine aggregates shall be sand or
crushed rock to BS 1200 and shall pass a 5 mm BS test sieve.
10.2.3
Fine aggregate
Fine aggregate for concrete shall be natural river-deposited sand consisting of at
least 95% by mass of quartz grains.
10.2.4
Polyethylene sheeting
0.125 mm.

Section 10 Concrete Carriageways
1/20
January 2011
10.2.5
Joint filler
Joint filler shall be a proprietary type reviewed without objection by the Project
Manager and shall be a firm, compressible, single thickness, non-rotting filler.
10.2.6
10.2.7
Joint sealant
(a)
Joint sealant shall be of a grade suited to the climatic conditions of Hong Kong
and shall perform effectively over a temperature range of 0C to 60C.
(b)
Joint sealant shall be a cold poured two-part polymer-based sealant complying

with BS 5212, Type N.
(c)
Primers and caulking material for use with joint sealant shall be proprietary
types recommended by the joint sealant manufacturer and reviewed without
Bond breaker tape

Bond breaker tape shall be a proprietary type recommended by the joint sealant
manufacturer and reviewed without objection by the Project Manager. The tape
shall be a polyethylene film with adhesive applied on one side and shall be the full
width of the groove.
10.2.8
10.2.9
Groove forming strip

(a)
Groove forming strip shall be a proprietary type reviewed without objection by

the Project Manager. The strip shall be a firm compressible strip of either
ethylene vinyl acetate foam with a density of at least 90 kg/m or synthetic
rubber. The strip shall be 25 mm deep and 5 mm thick and shall be
sufficiently rigid to remain in position during concreting without deforming or
stretching.
(b)
Adhesive for groove forming strip shall be a proprietary type recommended by

the groove forming strip manufacturer and reviewed without objection by the
Project Manager.
Sleeves for dowel bars and tie bars

Sleeves for dowel bars and tie bars shall be PVC and shall have a nominal wall
thickness not exceeding 1.5 mm; the sleeves shall fit tightly to the bars.
10.2.10 Epoxy resin grout

Epoxy resin grout shall be a proprietary type reviewed without objection by the
Project Manager.

2/20
January 2011
10.2.11 Concrete mix

Concrete for concrete carriageways shall comply with the following requirements:
(a)
concrete shall be Grade 40/20 and shall be a designed mix;
(b)
the concrete mix shall contain either PPFAC or a minimum of 265 kg of OPC
plus a minimum of 85 kg of PFA per m of compacted concrete;
(c)
the percentage by mass of fine aggregate to total aggregate shall be at least

30%; and
(d)
the workability in terms of designed slump value shall not exceed 25 mm.
10.2.12 Cementitious content of concrete

The minimum cementitious content of concrete for concrete carriageways shall be
350 kg/m.
10.3
SUBMISSIONS
10.3.1
Particulars of materials for joints

(a)
The following particulars of the proposed materials for joints in concrete

carriageways shall be submitted to the Project Manager:
(i)
manufacturer's literature and a certificate for joint filler showing the

manufacturer's name, the date and place of manufacture and stating
that the joint filler complies with the Specification, including results of
tests for:
disintegration and shrinkage;
recovery value and reduction in mass; and
extrusion;
(ii)
manufacturer's literature for joint sealant, including details of the method

and time required for mixing the different components, and a certificate
showing the manufacturer's name, the date and place of manufacture
and stating that the sealant complies with the Specification, including
results of tests for:
application life;
tack-free time;
resistance to flow;
recovery;
adhesion and cohesion in tension and compression; and
resistance to heat ageing;
(iii)
manufacturer's literature and a certificate for groove forming strip

and stating that the groove forming strip complies with the Specification,
including results of tests for density; and

3/20
January 2011
(iv)
(b)
10.3.2
particulars of primers and caulking material for joint sealant, adhesive for
groove forming strip, bond breaker tape and sleeves for dowel bars and
tie bars.
The particulars, including certificates, shall be submitted to the Project

Manager at least 14 days before the first delivery of the material to Site.
Certificates shall be submitted for each batch of the material delivered to Site.
Particulars of methods of construction

Particulars of proposed methods of construction for concrete carriageways shall be
submitted to the Project Manager at least 21 days for review before the trial length is
constructed.
10.3.3

the Project Manager at the same time as particulars of the material are submitted:
(a)
polyethylene sheeting;
(b)
joint filler;
(c)
bond breaker tape;
(d)
groove forming strip; and
(e)
sleeves for dowel bars, including compressible filler, and for tie bars.
10.4
WORKMANSHIP
10.4.1
Installation of utilities
10.4.2
(a)
Pipes, cables, manholes, chambers, gullies and other utilities below concrete
carriageways shall be completed and fill material shall be deposited and
compacted in trenches before the carriageway is constructed. Openings to
manholes, chambers and gullies shall be protected by temporary covers.
(b)
Box-outs shall be formed in concrete carriageways for covers, frames and

other hardware; the covers, frames and other hardware shall be fixed in
position after the main slab has been concreted and before the infill slab is
concreted.
Preparation of formation and sub-base

Construction of concrete carriageways shall start as soon as practicable after the
formation or sub-base has been completed. The formation shall be protected as
stated in Clause 7.4.33 and the sub-base shall be protected as stated in Clause
9.5.11 until construction of the carriageway starts.

4/20
January 2011
10.4.3
Laying polyethylene sheeting

Polyethylene sheeting below concrete carriageways shall be laid flat without
creases. Laps shall be at least 300 mm and there shall be no gaps at the edges of
bays.
10.4.4
10.4.5
10.4.6
Formwork
(a)
Formwork for concrete carriageways shall be steel. The finish to concrete

surfaces for transverse and longitudinal joints shall be Class F3; the finish to
concrete surfaces for other edges of the carriageway shall be Class F2.
(b)
Concrete shall not be placed against excavated surfaces or against kerbs.
(c)
Formwork shall not be loosened or removed until at least 7 hours after

concreting has been completed.
Forming joints
(a)
Materials for joints in concrete carriageways shall be used in accordance with

the manufacturers' recommendations or as otherwise specified in the
Specification.
(b)
Dowel bars, tie bars and their sleeves shall be securely fixed in position
through holes in the formwork before concreting. The bars shall be parallel to
the top surface of the slab and to each other. Bars at transverse joints shall
be parallel to the adjacent longitudinal joint or to the longitudinal axis of the
carriageway if there is no longitudinal joint or to other lines directed by the
Project Manager.
(c)
Joint filler shall be cut to size before fixing and shall be securely fixed in
position to the existing concrete surface before concreting. There shall be no
gaps between the joint filler and the formation. Holes in joint filler for dowel
bars shall be cut to form a sliding fit to the sleeved bar.
(d)
Joints shall be formed perpendicular to the top surface of the slab.
Transverse joints
(a)
Transverse joints in concrete carriageways shall be straight and perpendicular

to the longitudinal axis of the carriageway.
(b)
Transverse expansion joints and transverse contraction joints shall be formed

only at the specified positions. The joints shall be continued across
longitudinal joints and shall be in line and of the same type on both sides of
the longitudinal joint. The joints shall be continued through kerbs, edgings and
quadrants and their foundation and backing; the joint dimensions and
materials shall be the same as the transverse joints with the omission of dowel
bars. The location of additional contraction joints in accordance with Clause
11.5.15(c) shall be as directed by the Project Manager.
(c)
The joint filler and groove for joint sealant at transverse expansion joints shall
provide complete separation of adjacent slabs.

5/20
January 2011
10.4.7
Longitudinal joints
Longitudinal joints in concrete carriageways shall be formed only at the specified
positions.
10.4.8
Isolation joints
Isolation joints shall be formed in concrete carriageways at manholes and
chambers.
10.4.9
Forming grooves
(a)
Grooves in concrete carriageways for joint sealant shall be straight, shall have
parallel sides and shall be perpendicular to the top surface of the slab. The
bottom of the groove shall be flat and shall be parallel to the top surface of the
slab.
(b)
Grooves at transverse expansion joints and at isolation joints at manholes and

chambers shall be formed by sawing the groove to the specified width and
depth not less than 7 days after concreting. The grooves shall be located
over the joint filler such that the upper surface of the joint filler is entirely
contained in the groove.
(c)
Grooves at transverse contraction joints shall be formed using one of the

following methods:
(i)
Method 1 :
An initial groove shall be sawn as soon as practicable after concreting
without causing spalling of the edges. The width of the initial groove
shall be less than the specified width of the final groove and the depth of
the initial groove shall be between 1/4 and 1/3 of the thickness of the
slab. The final groove shall be sawn to the specified width and depth not
less than 7 days after concreting; or
(ii)
(d)
Method 2 :
The final groove shall be sawn to the specified width and depth as soon
as practicable after concreting without causing spalling of the edges.
The centre lines of the initial and final grooves shall coincide.
Grooves at transverse construction joints shall be formed by fixing groove

forming strip with adhesive to the concrete already placed before concreting
the adjacent slab.
10.4.10 Protection of grooves

Before permanent sealing, grooves in concrete carriageways for joint sealant shall
be protected from contamination by a temporary sealing strip.

6/20
January 2011
10.4.11 Sealing joints

(a)
The permanent sealing of joints in concrete carriageways shall be carried out

at least 7 days after concreting.
(b)
Immediately before permanent sealing, groove forming strips, temporary

seals, dirt and loose material shall be removed from the groove and the sides
of the groove shall be cleaned and roughened by water jetting or sand
blasting.
(c)
Caulking material shall be firmly packed in the bottom of the groove if the joint
sealant is not required to extend to the bottom of the groove.
(d)
Bond breaker tape shall be fixed continuously and evenly along the bottom of
the groove for the full width and length of the groove.
(e)
Primer for the joint sealant shall be applied to the sides of the groove in
accordance with the manufacturer's recommendations.
Joint sealant shall be applied between the minimum and maximum drying
times of the primer recommended by the manufacturer. The components of
the sealant shall be thoroughly mixed in accordance with the manufacturer's
recommendations using a power operated paddle mixer for sufficient time to
produce a homogeneous mass without entrapped air. The sealant shall be
dispensed into the groove as soon as practicable after mixing and within the
time recommended by the manufacturer.
(f)
(g)
The groove shall be clean and dry at the time of applying the primer and joint
sealant.
(h)
Excess joint sealant shall be removed by using a purpose made finishing tool
such that the finished surface of the sealant is between 4 mm and 6 mm below
the surface of the slab.
10.4.12 Placing and compacting concrete

(a)
Concrete shall be placed continuously between the joints in concrete

carriageways.
(b)
Concrete shall be compacted by internal vibrators to produce a dense

homogenous mass. The number and types of vibrators shall be sufficient to
ensure full compaction of the concrete at the rate at which it is placed.
Sufficient vibrators in serviceable condition shall be kept on Site so that spare
equipment is always available in the event of breakdowns.
(c)
Concrete in unreinforced slabs shall be placed and compacted to the full

thickness of the slab in one operation.

7/20
January 2011
(d)
Unless otherwise permitted by the Project Manager, concrete in reinforced

slabs shall be placed and compacted to the specified level of the fabric
reinforcement; the fabric reinforcement shall be placed in position and
concrete shall be placed and compacted to the remaining thickness of the
slab. The time between compaction of the first layer and placing of the
remaining layer shall not exceed 30 minutes unless in the opinion of the
Project Manager the concrete already placed is sufficiently workable and the
permission of the Project Manager has been obtained. Otherwise a
construction joint shall be formed as stated in Clause 20.7.14; concrete shall
not be placed against the concrete already placed for at least 24 hours.
(e)
Concrete in infill slabs at covers, frames and other hardware shall be placed
and compacted after the covers, frames and hardware have been fixed in
position and shall not be placed at the same time as the concrete in the main
slab.
10.4.13 Construction joints

(a)
Construction joints shall be formed in concrete carriageways only where

permitted by the Project Manager or in cases of emergency if concreting is
interrupted by adverse weather, plant breakdown or similar circumstances.
Construction joints shall not be formed within 2.5 m of an existing or planned
expansion or contraction joint.
(b)
Transverse construction joints shall be formed by either:

(i)
using formwork and cast-in tie bars; or
(ii)
breaking back from an unformed edge and fixing the tie bars and
sleeves with epoxy resin grout in drilled holes.
10.4.14 Surface regulation

(a)
Unless combined double beam compactor-levellers are used, after

compaction the concrete in concrete carriageways shall be struck off to slightly
above the levels of the formwork and the surface shall be regulated by a
regulating machine or a vibrating beam.
(b)
Regulating machines shall be purpose made and shall span the full width of
the slab either transversely or obliquely. The machine shall be equipped with
at least two oscillating-type transverse screeds and shall be supported on a
carriage.
(c)
Vibrating beams shall have a steel or aluminium surface and shall be mounted
on a separate carriage. The beam shall be driven by a motor to provide a
vibration frequency of at least 3500 cycles per minute.
(d)
After regulation by the regulating machine or vibrating beam, the surface of

the carriageway shall be regulated by at least two passes of a scraping
straight-edge with a blade length of at least 1.8 m. Scraping straight-edges
which operate in conjunction with regulating machines shall pass across the
surface at right angles to the longitudinal axis of the carriageway. If the
surface is torn by the straight-edge, the surface shall be regulated again by
the regulating machine or vibrating beam and by the scraping straight-edge.

8/20
January 2011
(e)
Wooden floats shall not be used to tamp and regulate small areas of the
carriageway unless permitted by the Project Manager; steel floats or trowels
shall not be used.
10.4.15 Surface texturing

(a)
After the surface of the concrete carriageway has been regulated and before
the curing compound is applied, the surface, other than the surface of
channels and edges of slabs which do not require to be textured, shall be
textured by brushing with a wire broom.
(b)
The wire broom shall be at least 450 mm wide and shall have two rows of
tufts. The rows shall be 20 mm apart and the tufts in each row shall be at 10
mm centres and in line with the centre of the gaps between the tufts in the
other row. The tufts shall contain an average of 14 wires, each of 32 gauge
and initially 100 mm long. The broom shall be replaced if any tuft wears down
to a length of 90 mm.
(c)
The surface texture shall be produced by brushing evenly across the slab in
one direction at right angles to the longitudinal axis of the carriageway.
Brushing shall be carried out after the moisture film has disappeared from the
concrete surface and before the initial set is complete.
10.4.16 Curing concrete

The surface and edges of concrete carriageways shall be protected by one of the
methods stated in Clause 20.7.15 except that covering with hessian, sacking,
canvas or other absorbent material as stated in Method 2 shall not be used. If
Method 1 is used, the curing compound shall be applied to the surface immediately
after the surface has been textured and shall be applied to the edges immediately
after the formwork has been removed.
10.4.17 Protection of concrete carriageway
(a)
Immediately after the curing system has been applied, the concrete
carriageway shall be fenced off from pedestrian traffic and covered with
protective sheeting for at least 24 hours. The sheeting shall be lapped and
securely held in position in such a manner that the surface of the carriageway
will not be damaged.
(b)
Loads from materials not forming part of the Permanent Works or from
Contractor's Equipment or other vehicles shall not be applied to the concrete
carriageway until at least 7 days after concreting has been completed and until
all grooves at joints have been temporarily or permanently sealed or
protected.
(c)
When Contractor's Equipment or other vehicles will turn on the concrete

carriageway the Contractor shall lay a 100 mm thick protection layer of mesh
reinforced 30/20 concrete over the turning area. The protection concrete shall
be separated from the concrete carriageway by two layers of polythene and it
shall be removed by the Contractor without damage to the concrete
carriageway when construction traffic ceases.

9/20
January 2011
10.4.18 Tolerances: sub-base

(a)
The level of the formation below concrete carriageways shall not be more than
10 mm higher, and shall not be more than 40 mm lower, than the specified
level.
(b)
The level of the sub-base below concrete carriageways shall not be more than
10 mm higher, and shall not be more than 20 mm lower, than the specified
level.
10.4.19 Tolerances: formwork

(a)
The line of formwork for concrete carriageways shall be within 10 mm of the

specified line of the concrete carriageway.
(b)
The level of the top of the formwork shall be within 3 mm of the specified level
of the concrete carriageway.
(c)
Abrupt irregularities in the line of the formwork and in the level of the top of
formwork shall not exceed 3 mm.
10.4.20 Tolerances: reinforcement

The cover to fabric reinforcement in concrete carriageways shall be within 10 mm of
the specified cover.
10.4.21 Tolerances: dowel bars and tie bars
(a)
Dowel bars at joints in concrete carriageways shall be within 20 mm of the

mid-depth of the slab.
(b)
Dowel bars shall be parallel to within 3 mm in half the length of the bar to:
(i)
the longitudinal joint, or the longitudinal axis of the concrete carriageway

if there is no longitudinal joint;
(ii)
the top surface of the slab; and
(iii)
adjacent dowel bars.
10.4.22 Tolerances: grooves

The depth of grooves for joint sealant in concrete carriageways shall be within 3 mm
of the specified depth.
10.4.23 Tolerances: covers, frames and other hardware
The level of covers, frames and other hardware shall not be higher than, and shall
not be more than 3 mm lower than, the surface of the adjacent carriageway.

10/20
January 2011
10.4.24 Tolerances: alignment of concrete carriageway

(a)
The best fit straight line of straight joints and of straight edges of concrete
carriageways shall be within 25 mm of the specified line. The line of straight
joints and of straight edges of concrete carriageways shall be within 10 mm of
the best fit straight line.
(b)
The best fit curved line of curved joints and of curved edges of concrete
carriageways shall be within 25 mm of the specified line. The line of curved
joints and of curved edges of concrete carriageways shall be within 10 mm of
the best fit curved line.
(c)
Joints in concrete carriageways shall be continuous across intersections of

joints to within 5 mm of the best fit straight lines or best fit curved lines of each
joint.
10.4.25 Tolerances: level of concrete carriageway

(a)
The levels of the surface of concrete carriageways shall be determined 200

mm from the edges of each bay at 10 m centres in the longitudinal direction
and at 2 m centres in the transverse direction.
(b)
The level of the surface of concrete carriageways shall be within 6 mm of the

specified level. In low lying and flat areas the Contractor shall pay special
attention to level control to ensure that falls on the surface of the carriageway
are in the specified direction.
(c)
The difference in level of the surface of concrete carriageways across joints

shall not exceed 3 mm.
(d)
The thickness of concrete carriageway slabs shall not be less than the
specified thickness minus 10 mm.
10.4.26 Rectification
(a)
Where any tolerance is exceeded, the Project Manager will determine the full
extent of the area which is out of tolerance and the Contractor shall make
good the surface of the concrete carriageway as detailed in Clause 10.4.26(c).
(b)
Where any joint tolerance is exceeded or joint construction does not meet
requirements stipulated elsewhere, the Project Manager will determine the full
extent of the area to be made good and rectification shall comprise a minimum
depth of 50 mm from the carriageway surface and a minimum distance of 50
mm from the area determined as requiring repair. Cut lines shall either be
parallel to transverse joints or parallel to longitudinal joints and shall be sawn
the full depth of the 50 mm. The remaining area shall be broken out by a
method, reviewed without objection by the Project Manager and the repair
shall be undertaken using thin bonded concrete.
(c)
High areas shall be ground or milled down to within tolerance or regularity and
the surface texture to comply with Section 11. Low areas shall be rectified by
cutting out the surface to a depth not less than 25 mm and replacing it with
concrete of a mix and method of placement reviewed without objection by the
Project Manager. Surface texture shall be restored to comply with Section 11.

11/20
January 2011
10.5
10.5.1
Compliance criteria: trial mix concrete

The results of the tests on trial mix concrete for concrete carriageways shall comply
with the following requirements: none of the six slump values shall not exceed 35
mm, and the average of the six slump values shall not exceed 30 mm.
10.5.2
10.5.3
10.5.4
Trial length
(a)
A trial length of concrete carriageway shall be constructed to demonstrate that

the proposed materials, mix design, methods of production and methods of
construction will produce a concrete carriageway which complies with the
Specification.
(b)
The trial length shall be constructed using the materials, mix design, methods
of production and methods of construction submitted to and reviewed without
(c)
Unless otherwise stated that the trial length shall be constructed in a location
separate from the permanent carriageway, the trial length shall comprise the
first 30 m of the permanent carriageway. The trial length shall be constructed
over a width of two bays and shall include at least one expansion joint, one
contraction joint and the longitudinal joint between the bays.
(d)
The Contractor shall notify the Project Manager at least 48 hours before
constructing the trial length.
(e)
The trial length shall be completed in sufficient time before the permanent
carriageway is constructed to allow the Project Manager a period of at least 7
days to determine if the specified requirements have been complied with in the
trial length.
Testing: trial length

(a)
The trial length shall be tested to determine the accuracy of the alignment and
level, the surface regularity and the texture depth. The method of testing the
surface regularity shall be as stated in Clause 10.5.8. The method of testing
the texture depth shall be as stated in Clause 10.5.9.
(b)
Concrete cores shall be cut from the trial length to determine the thickness of
the slab, the position of the reinforcement and joint components, the amount
of segregation of the constituents and the presence of voids. The method of
taking, preparing, inspecting and testing concrete cores shall be as stated in
Clauses 10.5.11.
Compliance criteria: trial length

The results of tests on trial lengths shall comply with the following requirements:
(a)
The alignment, levels and thickness of the carriageway shall comply with
Clauses 10.4.24 and 10.4.25.
(b)
The surface regularity shall comply with Clause 10.5.8(b).

12/20
January 2011
10.5.5
10.5.6
10.5.7
(c)
The texture depth shall comply with Clause 10.5.9(b).
(d)
The positions of the reinforcement and joint components shall comply with
Clauses 10.4.20, 10.4.21, 10.4.22 and 10.4.24.
(e)
The amount of segregation of the constituents and the presence of voids shall
comply with Clause 10.5.11(c).
Non-compliance: trial length

(a)
If the result of any test on the trial length does not comply with the specified
requirements for the trial length, particulars of proposed changes to the
materials, mix design, methods of production or methods of construction shall
be submitted to the Project Manager for review; further trial lengths shall be
constructed until the result of every test on the trial length complies with the
specified requirements for the trial length.
(b)
Trial lengths, or parts of trial lengths, which do not comply with the specified
requirements for the trial length shall be removed.
Commencement of concreting
(a)
Concrete shall not be placed in the permanent carriageway other than in a trial
length until the result of every test on the trial length complies with the
specified requirements for the trial length.
(b)
Concrete shall not be placed in the permanent carriageway before the results
of tests for compressive strength of the trial mix are available unless the result
of every other test on the trial mix and trial length complies with the specified
requirements for trial mix concrete and for the trial length.

Unless permitted by the Project Manager, the materials, mix design, methods of
production and methods of construction used to produce a trial length which
complies with the specified requirements shall not be changed.
10.5.8
Testing: surface regularity

(a)
Testing methodology: surface regularity

(i)
Surface regularity of concrete carriageways shall be determined by

measuring the number of irregularities in the surface. An irregularity
means that the gap between the surface of the carriageway, and a 3 m
straight-edge placed on the surface of the carriageway, exceeds the
specified amount. Irregularities shall be measured in millimetres
perpendicular to the straight-edge.
(ii)
The longitudinal surface regularity of carriageways with a total length of

75 m or more shall be measured using a rolling straight-edge of the type
designed by the UK Transport and Road Research Laboratory. The
longitudinal surface regularity of carriageways with a total length of less
than 75 m and the transverse surface regularity of carriageways shall be
measured using a 3 m straight-edge.

13/20
January 2011
(b)
(iii)
The longitudinal surface regularity shall be measured along lines parallel

to the longitudinal axis of the carriageway at approximately 0.75 m and
2.25 m from the nearside edge of each carriageway lane. The
transverse surface regularity shall be measured along lines at right
angles to the longitudinal axis of the carriageway at 10 m intervals along
the length of the carriageway.
(iv)
Testing to determine the surface regularity shall be carried out by the

Contractor in the presence of the Project Manager.
Compliance criteria: surface regularity

The results of tests for surface regularity of carriageways shall comply with the
(i)
the size and number of irregularities in the longitudinal direction shall not
exceed the size and permitted number of irregularities stated in Table
10.1; and
(ii)
there shall be no irregularity exceeding 4 mm in a 3 m length in the

transverse direction for Category A roads and there shall be no
irregularity exceeding 7 mm in a 3 m length in the transverse direction
for Category B roads.
Table 10.1: Permitted Irregularities in the Longitudinal Direction

Total length
of
carriageway
< 75 m
75 m - 300 m
Permitted number of
irregularities
Permitted number of
irregularities
(Category A road)
(Category B road)
> 4 mm
(9 x total length)/75
(18 x total length)/75
> 7 mm
> 4 mm
9 in any 75 m length
> 7 mm
Size of
irregularity
> 4 mm
> 300 m
> 7 mm
Category A roads are roads with a legal speed limit greater than 70 km/hour; all
other roads are Category B roads.
Irregularities greater than 7 mm shall also be counted as greater than 4 mm.
No irregularity greater than 10 mm shall be permitted.

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January 2011
10.5.9
Testing : Texture Depth

(a)
(b)
Testing: texture depth

(i)
The texture depth of concrete carriageways shall be determined by the

sand patch test. Tests shall be carried out at least 2 days after the
surface texturing has been carried out and before the area is used by
Contractor's Equipment or other vehicles.
(ii)
Each carriageway lane shall be divided into sections of equal length not
exceeding 150 m. Tests shall be carried out at ten locations on each
section at approximately equal spacings as directed by the Project
Manager. No measurement shall be taken within 300 mm of the
longitudinal edges of the sections.
(iii)
Testing to determine the texture depth shall be carried out by the

testing shall be in accordance with Appendix A10.1.
Compliance criteria: texture depth

The results of tests for texture depth for each section of concrete carriageway
lane shall comply with the following requirements:
(i)
the average texture depth shall not be less than 0.7mm; and
(ii)
not more than one out of the ten measured texture depths shall be less
than 0.6 mm.
10.5.10 Testing : Concrete

(a)
Testing: workability and compressive strength of concrete

Testing to determine the workability and compressive strength of concrete in
concrete carriageways shall be as stated in Clauses 20.8.5 to 20.8.15 except
as stated in Clauses 10.5.10 (b) and (c).
(b)
Compliance criteria: workability of concrete

The average slump value of the two specimens taken from one sample of
concrete shall not exceed the specified slump value by more than 10 mm.
(c)
Samples: compressive strength of concrete

One sample of concrete shall be provided from each 25 m or 25 batches of
concrete or from the amount of concrete produced each day, whichever is
less.

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January 2011
10.5.11 Testing : Concrete Cores From Trial Lengths

(a)
(b)
(c)
Samples: concrete cores from trial lengths

(i)
Two concrete cores shall be provided from each bay, and one core shall
be provided from each joint, of concrete carriageway in the trial length.
The positions from which the cores are taken shall be as directed by the
Project Manager.
(ii)
Concrete cores shall be 150 mm diameter and shall be the full depth of
the slab. Cores shall be taken as soon as the concrete has hardened
sufficiently for the core to be taken.
(iii)
The method of taking concrete cores shall be in accordance with CS 1.
(iv)
Holes formed by taking concrete cores from trial lengths which form part
of the permanent carriageway shall be reinstated using the concrete mix
previously reviewed without objection by the Project Manager; joints
shall be repaired in accordance with the method submitted to and
Testing: concrete cores from trial lengths

(i)
Each concrete core from trial lengths in concrete carriageways shall be

inspected to determine the thickness of the slab and the positions of the
reinforcement and joint components. Each core shall be inspected for
evidence of segregation of the constituents and for the presence of
voids.
(ii)
The method of preparing and inspecting concrete cores shall be in

accordance with CS 1.
Compliance criteria: concrete cores from trial lengths

Concrete cores from trial lengths in concrete carriageways shall not show
evidence of segregation. The extent of voids in the core shall be "few" in
accordance with Table 4 of CS 1 and there shall be no honeycombing.
10.5.12 Testing : Materials For Joints

(a)
Batch: joint filler, joint sealant

A batch of joint filler or joint sealant shall comply with Clause 20.8.24.
(b)
Samples: joint filler, joint sealant

Samples of joint filler or joint sealant shall comply with Clause 20.8.25.
(c)
Testing: joint filler, joint sealant

Testing of joint filler and joint sealant for joints in concrete carriageways shall
be as stated in Clauses 20.8.26 and 20.8.27 except as stated in Clause
10.5.12 (d).

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January 2011
(d)
Testing: joint sealant

Each sample of joint sealant shall be tested to determine the application life,
tack-free time, resistance to flow, recovery, adhesion and cohesion in tension
and compression and resistance to heat ageing. The method of testing shall
be in accordance with BS 5212.

17/20
January 2011
APPENDIX A10.1
DETERMINATION OF THE TEXTURE DEPTH OF CARRIAGEWAYS
A10.1.1 Scope
This method covers the determination of the texture depth of carriageways by the
sand patch test.
A10.1.2 Materials
The following material is required:
dry natural sand, with a rounded particle shape, which has been washed and then
screened such that it meets the grading stated in table 10.1.1.
Table 10A.1.1 : Grading of Sand
BS test
Percentage by
Sieve
mass passing
600 m
100
300 m
95 - 100
150 m
0-6
A10.1.3 Apparatus
(1)
a soft brush;
(2)
a robust measuring cylinder having an internal diameter of 20 mm 2 mm and

a flat top surface such that its internal volume is 25 mL 0.1 mL;
(3)
a flat wooden disc of 65 mm diameter with a 1.5 mm thick hard rubber disc
attached to one face and a handle fixed to the other face;
(4)
a steel rule calibrated to 1 mm;
(5)
a suitable wind shield;
(6)
a funnel with an outlet tube at least 100 mm long with a bore of between 4 mm
and 6 mm, and capable of accepting a volume of at least 200 mL;
(7)
a steel straight edge for screeding off the measuring cylinder; and
(8)
a steel-wire brush.

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January 2011
A10.1.4 Procedure
(1)
the test location shall be at least 300 mm square. It shall be vigorously

brushed ten times in two directions at right angles using the steel wire brush,
and then dried and swept clean with the soft brush;
(2)
sand shall be poured into the measuring cylinder to fill it to overflowing, and
any excess sand shall be screeded off using the straight edge. All sand on
the outside of the cylinder shall be removed, taking care not to drop any sand
onto the test location. Alternatively, this step in the procedure shall be carried
out in a laboratory, and the sand transferred to a suitable container ready for
pouring;
(3)
the measured volume of sand shall be poured onto the centre of the test
location through the funnel to form a heap. The wind shield shall be used to
protect the test location if required;
(4)
the sand shall be spread outwards with a circular motion over the test location,
using the rubber-faced disc with its face parallel to the surface of the
carriageway. This shall be continued until the patch of sand is approximately
circular and will spread outwards no more;
(5)
the size of the circular patch of sand shall be measured to the nearest 1 mm
along three diameters which are aligned at approximately 120 degrees to each
other;
(6)
if the difference between the maximum and minimum of the three

measurements exceeds 20% of the average of the three measurements, then
all the measurements shall be discarded and the test repeated at an adjacent
location; and
(7)
the test shall be repeated for all the ten test locations for each section of
carriageway lane.
A10.1.5 Calculation
(1)
The texture depth (T) for each test shall be calculated from the equation:
T = 31000 / D2 mm
where:
D is the average of the three diameter measurements of the sand patch
calculated to the nearest 1 mm.
(2)
The average texture depth for the ten tests shall be calculated.

19/20
January 2011

(1)
test location;
(2)
average diameter of the sand patch for each test to the nearest 1 mm;
(3)
texture depth for each test to the nearest 0.1 mm; and
(4)
average texture depth to the nearest 0.1 mm.

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January 2011
SECTION 11 MISCELLANEOUS ROADWORKS
11.1
GENERAL
11.1.1
11.1.2
(a)
(b)
Sub-base material and bituminous materials shall comply with Section 9.
(c)
Joints in concrete shall comply with Section 10.
(d)
(e)
(f)
(g)
Steelwork shall comply with Section 22.
Unit
Unit is a term used to describe a precast concrete paving slab or an interlocking
block.
11.2
11.2.1
Design of pedestrian guard-railing

Pedestrian guard-railing which is proposed by the Contractor as an alternative to
that stated in the Contract or which is erected as Temporary Works shall be
designed in accordance with BS 3049, Table 1, Class C.
11.3
MATERIALS
11.3.1
Cement mortar
Cement mortar shall consist of one part of cement to three parts of fine aggregate
by volume together with the minimum amount of water necessary to achieve a
consistency suitable for the required work. Fine aggregates shall be sand or
crushed rock to BS 1200 and shall pass a 5 mm BS test sieve.
11.3.2
Polyethylene sheeting
0.125 mm.

Section 11 Miscellaneous Roadworks
1/24
January 2011
11.3.3
Concrete mix : profile barriers

Concrete for concrete profile barriers shall be Grade 30/20.
11.3.4
Steel: pedestrian guard-railing

Steel for pedestrian guard-railing shall comply with the following:
11.3.5
Hot finished seamless tubes
: BS 6323:Part 3
Steel tubes and tubulars suitable

for screwing to BS 21 pipe threads
: BS 1387
Hot rolled sections
: BS 4:Part 1
Hot rolled structural steel sections - equal and unequal angles
: BS 4848:Part 4
Weldable structural steels
: BS 4360.
Stainless steel: pedestrian guard-railing

Stainless steel for pedestrian guard-railing shall be Grade 316 S 31 and shall
General inspection and testing procedures and specific
requirements for carbon, carbon manganese and stainless steels : BS 970:Part 1
Stainless steel tubes suitable for threading in accordance
with BS 21
11.3.6
: BS 6362.
Aluminium: pedestrian guard-railing

(a)
Aluminium for pedestrian guard-railing shall be H 30 TF and shall comply with

the following:
Wrought aluminium and aluminium alloys for general engineering purposes
(b)
(i) plate, sheet and strip
: BS 1470
(ii) drawn tube
: BS 1471
(iii) bars, extruded round tubes and sections
: BS 1474.
Aluminium shall be anodised to Grade AA 25 in accordance with BS 1615.

2/24
January 2011
11.3.7
Bolts, nuts, screws, washers and rivets

(a)
11.3.8
Bolts, nuts, screws, washers and rivets for pedestrian guard-railing shall
: BS 4190
ISO metric black cup and countersunk head

bolts and screws with hexagon nuts
: BS 4933
Metal washers for general engineering purposes
: BS 4320
Rivets for general engineering purposes
: BS 4620
Wrought aluminium and aluminium alloys for general

engineering purposes - rivet, bolt and screw stock
: BS 1473.
(b)
projects through the nut by at least one thread and by not more than
four threads.
(c)
Rag and indented bolts shall comply with BS1494 : Part 2. Expansion bolts
and resin bonded bolts shall be proprietary types reviewed without objection
by the Project Manager and shall be capable of withstanding the design
loading.
(d)
Galvanized bolts, nuts, screws, washers and rivets shall be used with
galvanized pedestrian guard-railing unless shown otherwise in the Contract.
Non-ferrous or stainless steel components shall be insulated from ferrous
materials by a non-conductive insulator of a type reviewed without objection
Mesh infill
Mesh infill for pedestrian guard-railing shall comply with BS 4483. The mesh infill
shall be free from surface defects, surface irregularities and mesh misalignment.
11.3.9
Storage of pedestrian guard-railing

Pedestrian guard-railing shall be stored off the ground on level supports and in a
manner which will not result in damage or deformation to the guard-railing or in
contamination of the guard-railing. Pedestrian guard-railing shall be protected from
damage and damaged guard-railing shall not be used in the Permanent Works.
11.3.10 Beams for untensioned beam barriers

(a)
Beams for untensioned beam barriers shall be formed from steel plates
complying with BS 1449 : Part 1, type BHR, grade 43/25.
(b)
The beams shall be capable of withstanding a tensile force of at least 300 kN

and shall not deflect by more than 40 mm when loaded centrally with a point
load of 1 tonne over a simply supported span of 3 m.

3/24
January 2011
(c)
Beams shall comply with the following requirements:

(i)
the base metal thickness shall be within 0.2 mm of the specified

thickness;
(ii)
the strip width shall be within + 2.5 mm and - 0 mm of the specified

width;
(iii)
the camber of the strip length shall be within 8 mm of the specified

camber;
(iv)
the beam shall be straight to within 1.5 mm in a 1.5 m length; and
(v)
angles at bends shall be within 2 of the specified angle.
(d)
Bolt slots in beams for connection to posts shall be prepared in the workshop
by cold saw-cutting. The spacing of the slots shall be such that posts will be
spaced at either 4 m or 2 m.
(e)
Beams shall be hot-dip galvanized in accordance with BS 729 to a coating

thickness of at least 460 g/m.
(f)
Welds for end beam sections shall be full-penetration butt welds.
(g)
Beams shall be shaped so as to present no sharp edges to traffic and except

where shown on the Employers Drawings shall be straight and of uniform
cross-section within manufacturing tolerances.
(h)
The beams shall be separated from the posts by blocking-out pieces which
are fabricated from materials of the same quality as the posts.
(i)
Posts and blocking-out pieces shall be drilled to take the specified post bolts
for affixing the beams.
11.3.11 Posts for untensioned beam barriers

(a)
Posts for untensioned beam barriers shall be formed from Grade 43A steel
(b)
Posts and blocking-out pieces shall be hot-dip galvanized in accordance with

BS 729 to a coating thickness of at least 610 g/m.
(c)
Posts fabricated from hollow sections shall be sealed by welding mild steel
sealing plates over the open ends; the plates shall be at least 3 mm thick.
(d)
Posts shall be within the tolerances stated in BS 4.
11.3.12 Anchorages for untensioned beam barriers

(a)
End beam sections shall be cut and welded with full-strength butt welds.
(b)
Anchor blocks shall be constructed of concrete which shall be cast directly

against the sides of the excavation.

4/24
January 2011
11.3.13 Cleats and struts for untensioned beam barriers

(a)
Cleats and struts for untensioned beam barriers shall be fabricated from angle
sections complying with BS 4 and shall be weldable structural steel complying
with BS 4360, Grade 43A.
(b)
Cleats and struts shall be hot-dip galvanized in accordance with BS 729 to a

coating thickness of at least 610 g/m.
(c)
The dimensional tolerances of steel angles for cleats and struts shall comply
with BS 4.
11.3.14 Bolts and nuts for untensioned beam barriers

(a)
Bolts for untensioned beam barriers shall be M 16 size and strength grade 4.6
complying with BS 4190. Bolts for beam splicing, bolts for connecting beams
to posts and bolts for connecting beams to cleats shall be round or
button-headed with oval shoulders; other bolts shall be ISO metric black
hexagon type.
(b)
Nuts for untensioned beam barriers shall be of strength grade 4 or 5

(c)
Bolts and nuts shall be hot-dip galvanized in accordance with BS 729 to a

(d)
Nuts shall be tapped 0.4 mm oversize to accommodate the galvanized

coating.
(e)
projects through the nut by at least one thread and by not more than
four threads.
(f)
Rag and indented bolts shall comply with BS1494 : Part 2. Expansion bolts
and resin bonded bolts shall be proprietary types reviewed without objection
loading.
11.3.15 Washers
(a)
Washers for untensioned beam barriers shall be black mild steel and shall
comply with BS 4320, Form E, F or G; washers shall be manufactured from
steel complying with BS 1449 : Part 1, grade 250.
(b)
Plain washers shall be 2 mm thick and shall be of dimensions suitable for use
with M 16 bolts and nuts.
(c)
Plain washers shall be hot-dip galvanized in accordance with BS 729 to a

(d)
Shaped washers shall have a thickness of at least 5 mm and shall be cast

iron complying with BS 3468; the washers shall be shaped to fit the curvature
of circular hollow sections used as posts.

5/24
January 2011
11.3.16 Storage of beams and posts

Beams and posts for untensioned beam barriers shall be stored off the ground on
level supports and in a manner which will not result in damage or deformation to the
beams and posts or in contamination of the beams and posts. Beams and posts
shall be protected from damage and damaged beams and posts shall not be used
in the Permanent Works.
11.3.17 Concrete kerbs, edgings and quadrants
(a)
Concrete for kerbs, edgings and quadrants shall be Grade 30/20. Concrete
for foundations and backings to kerbs, edgings and quadrants shall be
Grade 20/20.
(b)
Precast concrete kerbs, edgings and quadrants shall comply with BS 7263 :
Part 1 except that the requirement for testing of water absorption shall not be
applied. The nominal length of kerbs shall be 1 m and the nominal length of
edgings shall be 750 mm.
11.3.18 Supply of precast concrete kerbs type K1 and K2

(a)
The Contractor shall, within 6 weeks from the date for commencement of
Works, submit a programme prepared to such detail as the Project Manager
may require showing a month by month batch forecast of the total kerb
requirements. The Project Manager will forward this programme to the
Superintendent of the Tai Lam Correctional Institute who will advise whether he
will be able to fulfil the order to the programme required.
(b)
The Contractor shall update this programme from time to time and shall
provide the Project Manager with 3 months notice of his requirements for any
particular batch. The Project Manager will forward a copy of this notice to the
Superintendent who will confirm within 1 month of the date of the notice
whether or not he will be able to supply the particular batch.
(c)
Having regard to the progress of the Works and upon receipt of confirmation
from the Correctional Services Department that a particular batch or part
thereof can be supplied the Project Manager will issue a copy of the
Requisition Order to the Contractor who shall thereafter be responsible for
agreeing with the Superintendent of Tai Lam Correctional Institute a suitable
date and time for collection of the kerbs.
(d)
If the Superintendent is unable to confirm within 1 month, as stated in

paragraph (c), that he will be able to supply any batch or part thereof or if the
Project Manager so instructs the Contractor shall provide kerbs from his own
source. Appropriate items are included in the Bill of Quantities for this
eventuality.
11.3.19 Granite kerbs, edgings and quadrants

(a)
Granite kerbs, edgings and quadrants shall be worked straight or circular.

Corners shall be square and the top front and back edges shall be parallel.
The length of granite kerbs and edgings shall be at least 600 mm.

6/24
January 2011
(b)
The ends of the kerbs, edgings and quadrants shall be chisel-dressed square
to form a close butt-joint with adjacent kerbs. Kerbs shall be chisel-dressed to
a depth of at least 140 mm on the front face, at least 75 mm on the back face
and for the full width of the top face.
11.3.20 Concrete for footways, cycletracks and paved areas

Concrete for footways, cycletracks and paved areas shall be Grade 30/20.
11.3.21 Cobble stone paving
Cobble-stone paving shall consist of stones placed in a 100 mm thick grade 30/20
concrete bed. The stones shall be roughly elliptical and have a maximum dimension
not exceeding 150mm and a minimum dimension not less than 100mm.
11.3.22 Rubble stone facing and paving
Rubble stone facing and paving shall consist of random stone whose maximum
dimension on the exposed face shall not be less than 300 mm, whose minimum
dimension on the exposed face shall not be less than 200 mm and whose thickness
shall not be less than 200 mm.
11.3.23 Paving slabs and interlocking blocks
(a)
Concrete for precast concrete paving slabs shall be Grade 30.
(b)
Concrete for precast concrete interlocking blocks in footways and cycletracks

shall be Grade 30; concrete for precast concrete interlocking blocks in
carriageways or areas to which vehicles will have access shall be Grade 45.
(c)
The nominal maximum aggregate size of aggregate for concrete in precast

units shall be 10 mm.
The dimensions of the precast units shall be within 3 mm of the specified
dimensions; chamfers shall not exceed 8 mm.
(d)
(e)
Paving slabs shall be square or rectangular and interlocking blocks shall be

rectangular unless otherwise selected in the Contract.
(f)
The colour of precast units shall be consistent over the area to be paved.
11.3.24 Sand for precast paving and blocking

(a)
Sand for bedding precast units shall have the particle size distribution stated
in Table 11.1. The sand shall have a moisture content exceeding 4% and not
exceeding 8% at the time of laying.
(b)
Sand for filling joints between precast units shall have the particle size
distribution stated in Table 11.2. The sand shall have a moisture content of
less than 0.5% at the time of filling joints.

7/24
January 2011
Table 11.1: Particle Size Distribution of Sand for Bedding Precast Units
BS test sieve size
10 mm
100
5 mm
85 - 100
2.36 mm
65 - 100
1.18 mm
40 - 98
600 m
25 - 72
300 m
10 - 35
150 m
0 - 15
75 m
0 - 10
Table 11.2 : Particle Size Distribution of Sand for Filling Joint between
Precast Units
BS test sieve size
2.36 mm
100
1.18 mm
90 - 100
600 m
60 - 90
300 m
30 - 60
150 m
15 - 30
75 m
5 10
11.3.25 Handling and storage of units

Units shall be handled and stored on pallets to avoid damage to corners and
chamfer edges. Pallets shall be stored on a level base and in a manner which will
not result in damage to the units or in contamination of the units. The units shall be
protected from damage and damaged units shall not be used.
11.3.26 Storage of sand
Sand for filling joints between units shall be stored in waterproof bags and shall be
kept under cover until used.

8/24
January 2011
11.4
SUBMISSIONS
11.4.1
Particulars of concrete profile barriers

(a)
11.4.2
(i)
particulars of formwork as stated in Clause 18.5.1 for in-situ

construction using fixed forms;
(ii)
details of slip-form machine for in-situ construction between sliding

forms; and
(iii)
methods of manufacture, handling, transport, storage and fixing in

position of precast units.
Particulars of pedestrian guard-railing

(a)
11.4.3
The following particulars of the proposed methods of construction for concrete

profile barriers shall be submitted to the Project Manager for review without
objection:
The following particulars of the proposed pedestrian guard-railing shall be

(i)
a certificate from the manufacturer showing the manufacturer's name,

the date and place of manufacture and showing that the materials
comply with the requirements stated in the Contract; and
(ii)
details of alternative designs proposed by the Contractor, including

drawings, showing the proposals and that the pedestrian guard-railing
has been designed in accordance with Clause 11.2.1.

the Project Manager for review without objection of the source and type of each
material at the same time as particulars of the pedestrian guard-railing are
submitted:
11.4.4
(a)
each type of pedestrian guard-railing;
(b)
mesh infill; and
(c)
each type of bolt, nut, and washer.
Particulars of untensioned beam barriers

(a)

construction for untensioned beam barriers shall be submitted to the Project
Manager for review without objection:
(i)
a certificate from the manufacturer for beams in the format stated in

BS 4360 showing the manufacturer's name, the date and place of
manufacture and showing that the beams comply with the requirements
stated in the Contract and including carbon equivalent values; and
(ii)
details of installation method.

9/24
January 2011
11.4.5
Representative samples of materials for untensioned beam barriers

the Project Manager for review without objection of the source and type of each
material at the same time as particulars of the material are submitted:
11.4.6
(a)
Beams;
(b)
posts, cleats and struts; and
(c)
bolts, nuts and washers.
Particulars of units
(a)
11.4.7

construction for paving slabs and interlocking blocks shall be submitted to the
Project Manager for review without objection:
(i)
name and address of manufacturer;
(ii)
a certificate from the manufacturer showing the manufacturer's name

and the date and place of manufacture and including results of tests for:
compressive strength of concrete cubes at 28 days; and
compressive strength of interlocking blocks; and
(iii)
Contractors Drawings showing the layout of the units within the paved
area.

Representative samples of each type of unit shall be submitted to the Project
Manager for review without objection of the source and type of each unit at the
same time as particulars of the unit are submitted.
11.5
WORKMANSHIP
11.5.1
Formwork: Concrete profile barriers
11.5.2
(a)
Formwork for concrete profile barriers shall be steel. The Contractor shall
take measures, reviewed without objection by the Project Manager, to avoid
retention of air bubbles on the inside face of the formwork.
(b)
Formwork shall not be loosened or removed until at least 7 hours after

concreting has been completed.
Finishes to concrete: Concrete profile barriers

(a)
The finish to unformed concrete surfaces of concrete profile barriers shall be

Class U5.
(b)
The finish to concrete surfaces for transverse joints shall be Class F3 and the
finish to exposed concrete surfaces shall be Class F5.

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January 2011
11.5.3
11.5.4
Joints in concrete profile barriers

(a)
Joints shall be formed in concrete profile barriers at locations which coincide

with expansion or construction joints in the adjoining structure or carriageway
or at intervals not exceeding 12 m, whichever is less.
(b)
Joints in concrete profile barriers shall comply with Section 20.
Construction of concrete profile barriers

(a)
Construction by slip-form machine

Construction of concrete profile barriers by slip-form machine between sliding
forms shall be carried out in accordance with BS 5931. Slip-form machines
shall comply with BS 5931, Appendix A.
(b)
Construction using precast units

Precast concrete profile barriers shall be laid on a cement mortar regulating
layer of between 10 mm and 40 mm thick.
11.5.5
Protection of concrete profile barriers

Immediately after the formwork has been removed or the curing compound has
been applied, concrete profile barriers shall be protected by polyethylene sheeting
for at least 24 hours from exposure to conditions which may affect the concrete.
The sheeting shall be lapped and securely held in position in such a manner that
the surface of the concrete will not be damaged.
11.5.6
Tolerances: concrete profile barriers

Concrete profile barriers shall comply with the following requirements:
(a)
The horizontal dimensions of cross-sections shall be within 5 mm of the

specified dimensions.
(b)
The vertical dimensions of cross-sections shall be within 10 mm of the

specified dimensions.
(c)
The horizontal alignment along the centreline shall be within 10 mm of the

specified centreline.
(d)
The level of the formation shall be within 10 mm of the specified level.
(e)
The level of the top of the barriers shall be within 10 mm of the specified level.
(f)
The barriers shall form a smooth alignment.

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January 2011
11.5.7
Galvanizing to steel
(a)
(b)
11.5.8
11.5.9
Steel components forming pedestrian guard-railing shall be hot-dip galvanized

in accordance with BS 729 to a coating thickness of at least:
(i)
500g/m2 for railing other than on highway structures
(ii)
600 g/m2 for highway structures
Galvanizing to steel shall be applied after welding, drilling and cutting are
complete.
Welding steel
(a)
Welding for fabrication of pedestrian guard-railing shall be fillet welds.

Welded surfaces shall be full depth clean and flush before application of the
protective coating.
(b)
Steel shall not be welded after galvanizing unless permitted by the Project
Manager; if permitted, the welded areas shall be free from scale and slag and
shall be treated with a zinc-coating system reviewed without objection by the
Project Manager.
Installation of pedestrian guard-railing

(a)
Pedestrian guard-railing shall be installed to a smooth alignment to within

10 mm of the specified position and height or as directed by the Project
Manager.
(b)
Pedestrian guard-railing which is to be installed to a radius of less than 45 m

shall be curved in the workshop and shall not be made up of a series of
straight lengths.
(c)
Pedestrian guard-railing shall be fixed to concrete using rag, indented,

expansion or resin bonded bolts and shall be bolted to metalwork. Bolts for
fixing to concrete shall be fitted into pockets filled with cement mortar or resin
grout.
11.5.10 Installation of untensioned beam barriers

(a)
Untensioned beam barriers shall be ready for assembly when delivered to

Site. Beams and posts shall be free from blisters, flux, uncoated spots and
other defects.
(b)
The horizontal alignment of fences shall not depart from the road alignment by
more than (+ or -) 30mm nor deviate from the straight by more than 12mm in
any two section lengths. The horizontal centre line of the beam shall be
600mm above the edge of the adjacent carriageway or above the datum level
shown on the Employers Drawings, within a tolerance of (+ or -) 30mm. In
addition the deviation from the straight shall not exceed (+ or -) 6mm in any
two section lengths.
(c)
Beams which are to be installed to a radius of less than 45 m shall be curved

in the workshop.

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January 2011
(d)
Adjacent beams shall not connected by lap joints made in the direction of the
adjacent traffic movement to avoid vehicles striking beam ends. Bolts are to
be so located that they present no projection to traffic.
(e)
Untensioned beam barriers shall be fixed to concrete using rag, indented,

expansion or resin bonded bolts and shall be bolted to metalwork. Bolts for
fixing to concrete shall be fitted into pockets filled with cement mortar or resin
grout.
11.5.11 Compacted earth footings

(a)
Sub-base material shall be deposited and compacted in the bottom 250 mm

of pits for foundations of untensioned beam barriers with compacted earth
footings. Fine fill material shall be deposited and compacted to the remainder
of the pit. The sub-base material and fill material shall be compacted to
obtain a relative compaction of at least 95% throughout.
(b)
Posts for untensioned beam barriers shall be securely fixed in position during
deposition and compaction of fill material.
11.5.12 Concrete footings

(a)
Concrete for concrete footings shall be Grade 20/20.
(b)
The top surface of concrete footings shall be finished level with the adjoining
ground unless otherwise shown on the Employer's Drawings; the finish to the
concrete surface shall be Class U5.
(c)
Posts shall be surrounded with polyethylene sheeting before concrete is

placed and shall be securely fixed in position during concreting.
11.5.13 Anchor blocks

(a)
Concrete for anchor blocks shall be Grade 20/20.
(b)
The finish to concrete surfaces of anchor blocks shall be Class F5 for formed
finishes and Class U5 for unformed finishes.
11.5.14 Construction of precast concrete and granite kerbs, edgings and quadrants
(a)
Precast concrete and granite kerbs, edgings and quadrants shall be laid and
bedded on a regulating layer of cement mortar; the thickness of the layer shall
be at least 10 mm and shall not exceed 40 mm.
(b)
Except as stated in this Clause, joints between each kerb, edging and
quadrant shall not exceed 10 mm in width and shall be filled and flush pointed
with cement mortar. Joints in kerbs, edgings and quadrants at expansion
joints on bridge decks shall be as stated in the Contract. Transverse
expansion and contraction joints in kerbs, edgings and quadrants laid on or
adjacent to concrete carriageways shall be in accordance with
Clause 10.4.6(b).
(c)
Radius kerbs shall be used for curves less than 10 m external radius.

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January 2011
11.5.15 Construction of in-situ kerbs, edgings and quadrants

(a)
In-situ concrete kerbs, edgings and quadrants shall be constructed in

accordance with BS 5931 and shall be laid by an automatic extrusion machine
of a type reviewed without objection by the Project Manager.
(b)
In-situ concrete kerbs, quadrants and edgings shall have regular sides,
edges, arrises and chamfers; the finish to the concrete surface shall be
Class U5. Kerbs, edges and quadrants shall not be finished or dressed with
cement mortar.
Contraction joints shall be formed at intervals not greater than approximately
4 m. Transverse expansion and contraction joints in kerbs, edgings and
quadrants which are laid on or adjacent to concrete carriageways shall be in
accordance with Clause 10.4.6(b). Joints shall be flush pointed with cement
mortar.
(c)
11.5.16 Tolerances: kerbs, edgings and quadrants

(a)
The line of kerbs, edgings and quadrants shall be within 3 mm of the specified
line.
(b)
The level of the top of kerbs, edgings and quadrants shall be within 3 mm of
the specified level.
11.5.17 In-situ concrete footways, cycletracks and paved areas

(a)
In-situ concrete for footways, cycletracks and paved areas shall be laid in
areas not exceeding 20 m. The finish to the concrete surface shall be
Class U4.
(b)
Expansion joints shall be formed in concrete footways and cycle tracks at a

spacing of not more than 8 metres.
11.5.18 Flexible surfacing to footways, cycletracks and paved areas

(a)
Bituminous materials for footways, cycletracks and paved areas shall be laid
and compacted with steel-wheeled and pneumatic-tyred rollers. Compaction
shall start before the temperature of the newly laid material falls below 100C
and shall continue until all roller marks have been removed. For locations
where rollers cannot operate effectively, the bituminous material can be
compacted by hand-operated mechanical compaction plant reviewed without
(b)
Cores shall be taken in accordance with Clause 9.6.15(a) for the checking of
air void content and compacted layer thickness of the bituminous material for
works with area of not less than 200 m2. For works with area smaller than 200
m2 but greater than 50 m2, at least 2 cores shall be taken from each layer of
bituminous material laid. For works with area less than 50 m2, no coring is
required unless otherwise instructed by the Project Manager.

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January 2011
(c)
The cores taken in accordance with Clause 11.5.18(b) shall be tested to

determine the air void content. The average air void content of the cores shall
be not less than 3% nor greater than 9%. If the test result does not comply
with the specified requirement, 2 additional cores shall be taken at locations
agreed by the Project Manager and the average air void content determined
from these 2 cores shall replace the original value for compliance checking.
Notwithstanding this, no cores shall have an air void content of less than 2.5%
nor greater than 10%.
(d)
Each core taken from the final surfacing layer shall also be measured to
determine the compacted layer thickness that shall not deviate by more than 5
mm from the specified thickness. If the measured thickness does not comply
with the requirement, 2 additional cores shall be taken at locations agreed by
the Project Manager and the average thickness determined from these 2
cores shall replace the original measured value for compliance checking.
If no bulk sample is taken for determination of the Rices specific gravity, the
corresponding value obtained from the mix design shall be used in
determining the air void content of the core unless other value is suggested by
the Contractor and agreed by the Project Manager.
(e)
11.5.19 Protection of footways, cycletracks and paved areas

Footways, cycletracks and paved areas shall not be used by Contractor's
Equipment or vehicles other than those which are essential to construct the
subsequent work.
11.5.20 Cobble stone paving construction
The stones shall be placed on the concrete bed to such a depth that the nominal
line of the horizontal diameter of the stones is about 10 mm below the finished
concrete level. The clearance between each stone shall be 75 mm maximum and
40 mm minimum. Cement wash shall not coat the exposed surface of the stones.
Before the Contractor places any cobble-stone paving in the Permanent Works he
shall prepare, for review without objection by the Project Manager, a 2 m square
trial panel of finished cobble-stone paving.
11.5.21 Rubble stone facing and paving construction
Stones shall be carefully shaped to obtain as close a fit as possible at beds and
joints. When placed on the ground the stones shall be placed on material trimmed
and compacted to make a firm bed.
Rubble stone paving stones shall be bedded on 100 mm of concrete Grade 20/40
and sufficient space shall be left between stones to allow the joints to be filled
completely with concrete or mortar. The stones shall be bedded on the concrete
while it is still fresh, or alternatively the concrete shall be left with a rough finish and
the stones shall be bedded on a thin layer of mortar after the concrete has set. No
cavities shall be left under or between the stones.

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January 2011
11.5.22 Laying paving slabs and interlocking blocks

(a)
Laying units
(i)
Paving slabs and interlocking blocks shall not be laid until the layout of
the units within the paved area has been reviewed without objection by
(ii)
Kerbs and edgings shall be completed before the units are laid; the
compressive strength of the concrete used for in-situ concrete kerbs
and edgings shall be at least 20 MPa before units are laid.
(iii)
Measures shall be taken to prevent water draining across or through the

area during laying, bedding and compaction of the units.
(iv)
Laying of units shall start as soon as practicable after the formation has
been completed. The formation shall be protected as stated in
Clause 7.4.33 until laying starts.
(v)
Interlocking blocks for carriageways and paved areas to which vehicles

will have access shall be laid in a herring-bone pattern unless otherwise
(vi)
Units shall be cut to size where required using mechanical cutting

devices. The cut edge shall be similar to that of an uncut unit and shall
be true to line and free from chips and cracks.
(vii) On circular work where the radius is 12 m or less all flags shall be
radially cut on both edges to the required line.
(b)
(c)
Laying sand
(i)
A layer of sand shall be laid and shall be screeded and tamped to a

uniform depth over the complete width of the area to be paved. The
quantity of sand shall be sufficient to permit screeding to waste and to
achieve a tamped thickness which exceeds 20 mm and does not
exceed 30 mm.
(ii)
The sand layer shall not be disturbed by additional compaction, footmarks or other damage after the layer has been screeded and tamped
to the required level and before the units are laid.
(iii)
Sand shall not be screeded and tamped more than 1 m in advance of

the units which have been laid.
Bedding paving slabs

(i)
Paving slabs shall be laid on the prepared sand layer immediately after
screeding and tamping in such a manner that the sand is not disturbed.
(ii)
Paving slabs shall be adjusted to form uniform joints between 2 mm and

3 mm wide and shall be bedded into the final position using a wooden
mallet or a plate vibrator fitted with a rubber base-pad.

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January 2011
(d)
(e)
(iii)
Paving slabs shall not be bedded closer than 1 m behind the laying
edge other than on completion of the paved area against a kerb or
edging.
(iv)
Final levelling of the slabs shall be carried out as soon as practicable

after bedding and before changes in the moisture content of the
prepared sand layer occur.
(v)
Damaged paving slabs shall be immediately removed and replaced.
Bedding interlocking blocks

(i)
Interlocking blocks shall be laid on the prepared sand layer immediately

after screeding and tamping in such a manner that the sand is not
disturbed. Interlocking blocks shall be individually laid on the prepared
sand layer by manual methods or in clusters by mechanical methods.
(ii)
Interlocking blocks shall be laid in such a manner that the blocks are not
in direct contact with each other and that uniform joints of between
2 mm and 3 mm wide are formed. Interlocking blocks shall be bedded
flush by at least two passes of a heavy-duty plate compactor fitted with
a rubber base-pad.
(iii)
Interlocking blocks shall not be bedded closer than 1 m behind the

laying edge other than on completion of the paved area against a kerb
or edging.
(iv)
Final levelling of the blocks shall be carried out as soon as practicable

after bedding and before changes in the moisture content of the
prepared sand layer occur.
(v)
Damaged interlocking blocks shall be immediately removed and

replaced.
Filling joints and compaction of units

(i)
After the units have been bedded, sand for filling the joints shall be
spread over the surface of the units and brushed into the joints in such a
manner that all joints are completely filled.
(ii)
Joints shall be filled as soon as practicable after bedding and on the day
the units are laid and bedded.
(iii)
Paved areas shall be further compacted by at least two passes of a

plate compactor fitted with a rubber base-pad after filling the joints to
ensure that the joints are completely filled. Sand shall be added as
required and compacted into the joints.
(iv)
Carriageways and paved areas to which vehicles will have access shall
be compacted by at least ten evenly-spaced passes of a pneumatic
tyred roller having a gross weight of between 10 t and 12 t. Sand shall
be added as required and brushed and compacted into the joints.

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January 2011
(f)
(v)
Excess sand shall be removed after completion of compaction.
(vi)
Damaged units shall be immediately removed and replaced.
Mortar and concrete seal

Pigmented mortar or concrete shall be placed to the full depth of the unit to
form a seal between units and adjacent kerbs, edgings, quadrants, covers,
frames and other hardware. The pigment shall match the colour of the
adjacent units.
(g)
(h)
Reinstatement of units
(i)
If excavation is to be carried out in paved areas constructed using

paving slabs or interlocking blocks, the units shall be extracted by
manual methods for a distance of at least 300 mm beyond the limit of
the excavation.
(ii)
Unbroken units shall be thoroughly cleaned to remove all sand and

deleterious material. The units shall be stacked on pallets for re-use.
(iii)
Units to be re-used shall

Clauses 11.5.22(a) to 11.5.22(f).
be
re-laid
in
accordance
with
Tolerances: paving slabs and interlocking blocks

The level of paved areas constructed using paving slabs or interlocking
blocks shall be within 3 mm of the specified level. The difference in level of
adjacent slabs shall not exceed 2 mm.
11.6
11.6.1
Trials : Concrete profile barriers

(a)
Trial length concrete profile barriers

(i)
A trial length of concrete profile barrier shall be constructed to

demonstrate that the proposed materials, mix design, methods of
production and methods of construction will produce a concrete profile
barrier which complies with the specified requirements. If it is not stated
in the Contract that the trial length is to be constructed in a location
separate from the permanent concrete profile barrier, the trial length
shall be the first 25 m of the permanent barrier.
(ii)
The trial length shall be constructed in sufficient time before the

permanent barrier is constructed to allow the Project Manager a period
of at least 7 days to determine if the specified requirements have been
produced in the trial length.
(iii)
The Contractor shall notify the Project Manager at least 24 hours before
constructing the trial length.

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January 2011
(b)
(c)
(iv)
The trial length shall be constructed using the materials, mix design,
methods of production and methods of construction submitted to and
(v)
The trial length shall be used as a means of comparison against which

the Project Manager shall determine the compliance or otherwise of the
permanent concrete profile barrier. The trial length shall be protected
from damage and shall be left in position unless the Project Manager
directs its removal. A trial length which forms part of the permanent
barrier and which complies with the specified requirements shall not be
removed.
Testing: trial length

(i)
The trial length shall be tested to determine the accuracy of the

alignment and level and the finish of the concrete surface.
(ii)
Concrete cores shall be cut from the trial length to determine the
amount of segregation of the constituents and the presence of voids.
The method of taking, preparing, inspecting and testing concrete cores
shall be as stated in Clause 11.6.2.
Compliance criteria : trial length

The results of tests on trial lengths shall comply with the following
requirements:
(d)
(e)
(i)
The alignment and levels of the barrier shall comply with Clause 11.5.6.
(ii)
The finish of concrete surfaces shall comply with Clause 18.44.
(iii)
The amount of segregation of the constituents and the presence of

voids shall comply with Clause 10.5.11 for concrete carriageways.
Non-compliance: trial length

(i)
If the result of any test on the trial length does not comply with the
specified requirements for the trial length, particulars of proposed
changes to the materials, mix design, methods of production or methods
of construction shall be submitted to the Project Manager for review
without objection; further trial lengths shall be constructed until the result
of every test on the trial length complies with the specified requirements
for the trial length. Further trial mixes shall be made unless noncompliance of the trial length was not due to the concrete mix.
(ii)
Trial lengths, or parts of trial lengths, which do not comply with the
specified requirements for the trial length shall be removed.
Commencement of concreting
(i)
Except as stated in Clause 11.6.1(e)(ii) concrete shall not be placed in

the permanent barriers until the result of every test on the trial length
complies with the specified requirements for the trial length.

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January 2011
(ii)
(f)
Concrete may be placed in the permanent barriers before the results of

tests for compressive strength of the trial mix are available provided that
the result of every other test on the trial mix and trial length complies
with the specified requirements for trial mix concrete and for the trial
length.

The materials, mix design, methods of production and methods of
construction used to produce a trial length which complies with the specified
requirements shall not be changed. Further trial lengths shall be constructed
to demonstrate any proposed changes.
11.6.2
11.6.3
Testing concrete profile barriers: concrete cores from trial lengths

(a)
Two concrete cores shall be provided from each trial length of concrete profile
barriers. The positions from which the cores are taken shall be as directed by
(b)
Samples, testing and compliance criteria for concrete cores from trial lengths
shall be as stated in Clauses 10.5.11(a)(ii) to (iv), 10.5.11(b) & (c) for concrete
carriageways.
Testing : Characteristic compressive strength of interlocking blocks

(a)
Batch: interlocking blocks

A batch of interlocking blocks is any quantity of interlocking blocks of the
same type and size, of the same concrete grade, manufactured in the same
place, covered by the same certificates and delivered to the Site at any one
time.
(b)
(c)
(d)
Samples: interlocking blocks

(i)
One sample of each type of interlocking blocks shall be provided from

every 1000 interlocking blocks or part thereof.
(ii)
The number of interlocking blocks in each sample shall be five.
Testing: interlocking blocks

(i)
Each sample of interlocking blocks shall be tested to determine the

characteristic compressive strength at 28 days.
(ii)
The method of testing shall be as stated in Appendix 11.1.
Compliance criteria : interlocking blocks

The characteristic compressive strength of a sample of interlocking blocks
shall be:
(i)
30 MPa for blocks in footways and cycletracks; and
(ii)
45 MPa for blocks in carriageways and paved areas to which vehicles

will have access.

20/24
January 2011
11.6.4
Testing: Grading of bedding and filling sand

(a)
Batch: bedding sand

A batch of bedding sand is any stockpiled quantity of sand not exceeding a
maximum batch size of 25t. Each batch shall be of the same type produced at
the same time, and delivered to Site at any one time.
(b)
Batch: filling sand
(c)
A batch of filling sand is any quantity of bags of filling sand of the same
source, covered by the same certificate and delivered to Site at any one time.
Sample: bedding or filling sand
(d)
(i)
One sample of bedding or filling sand shall be provided from each

batch. The method of sampling shall comply with BS 812 Part 102.
(ii)
The size of each sample shall be 10 kg.
Testing
(i)
Each sample shall be tested to confirm compliance with the grading

requirements of Table 11.1.
(ii)
The method of testing shall be in accordance with BS 812 Part 103.

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January 2011
APPENDIX A11.1
DETERMINATION OF CHARACTERISTIC COMPRESSIVE STRENGTH
OF INTERLOCKING BLOCKS
A11.1.1 Scope
This method covers the determination of the characteristic compressive strength at
28 days of interlocking blocks by means of a load test.
A11.1.2 Apparatus
(1)
A compression test machine complying with CS 1. Bearing faces of the

platens on the test machine shall be at least as large as the interlocking
blocks and shall have a flatness tolerance of 0.05 mm.
(2)
If a test machine with platens smaller than the interlocking blocks is used,
auxiliary plates of adequate size shall be placed centrally between the platens
and the interlocking block to be tested. The flatness tolerance of the bearing
faces of the auxiliary platens measured in accordance with CS1 shall not be
more than 0.05 mm and the thickness of the plates shall be at least 25 mm.
(3)
Two pieces of packing, each with a thickness of between 5 mm and 6 mm and

dimensions exceeding the interlocking block by between 15 mm and 25 mm.
The packing shall be plywood, chipboard or medium density hardboard.
A11.1.3 Procedure
(1)
The interlocking block shall be capped on the running surface and underside
with a suitable capping material in accordance with Clause 15.5.2 of CS 1 and
immersed in water for at least 24 hours before compression.
(2)
The interlocking block shall be placed symmetrically on the lower platen of the
test machine, between the two pieces of packing with the running surface
facing upwards.
(3)
Load shall be applied without shock and shall be steadily increased at a

constant rate within a stress range of between 150 kPa/s and 700 kPa/s.
(4)
The load at which the interlocking block fractures shall be recorded as the
breaking load.
(5)
The test shall be repeated for the other four blocks.

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A11.1.4 Calculation
(1)
The compressive strength (C) of each interlocking block shall be calculated

from the equation:
C=
W
__
2.5
_______ MPa
L
1.5 +
H
where:
(2)
W is the breaking load (N)
A is the nominal gross plan area based on the manufacturing dimensions

of the interlocking blocks or the area of the tested portion if the interlocking
block size is reduced for testing (mm)
L is the lesser of the two plan dimensions (mm)
H is the thickness of the block (mm)
The unbiased standard deviation (s) shall be calculated from the following
equation:
s =
_____________
C - 5(Cm)
_______________ Mpa
4
where:
(3)
C is the sum of the compressive strengths of the five interlocking blocks

(MPa)
Cm is the average of the compressive strengths of the five interlocking
blocks
The characteristic strength (Cc) of the batch shall be calculated from the
following equation:
Cc = Cm - 1.65s
MPa
where:
Cm is the average of the compressive strengths of the five interlocking

blocks as stated in Clause A11.1.4(2)
s is the unbiased standard deviation as stated in Clause A11.1.4(2)

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January 2011

(1)
Source, name of manufacturer and type of blocks.
(2)
Identification marks of blocks.
(3)
Date of manufacture of blocks.
(4)
Nominal gross plan area of each block to the nearest 100 mm.
(5)
Nominal height of each block to the nearest mm.
(6)
Breaking load of each block to the nearest kN.
(7)
Compressive strength of each block to the nearest MPa.
(8)
Average of the five compressive strengths to the nearest MPa.
(9)
Unbiased standard deviation to the nearest MPa.
(10) Characteristic compressive strength to the nearest MPa.

(11) That the test method used was in accordance with this General Materials and

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SECTION 12 TRAFFIC SIGNS, ROAD MARKINGS AND ROAD STUDS
12.1
GENERAL
12.1.1
(a)
The works and materials specified shall comply with the Sections stated,
(i)
(b)
Traffic signs shall be externally illuminated, internally illuminated,

retroreflective, non-retroreflective or a combination of these types as stated in
the Contract.
12.2
12.2.1
Road Markings
Road markings are white or yellow continuous or intermittent lines, letters,
characters, figures, arrows or symbols marked on the carriageway to guide road
users and pedestrians.
12.3
12.3.1
Traffic signs
(a)
Traffic signs shall comply with the Road Traffic Ordinance, Cap 374 and its
subsidiary legislation. Traffic signs for road tunnels shall comply with the
Road Tunnels (Government) Ordinance, Cap 368 and its subsidiary
legislation.
(b)
The design of traffic signs, including letters, characters, numbers, symbols

and borders, shall be in accordance with conditions and restrictions imposed
by the Commissioner for Transport.
(c)
Unless otherwise stated in the Contract, traffic signs shall comply with the
following:
Internally illuminated signs and external lighting
luminaires
BS 873 : Part 5
Retroreflective and non-retroreflective signs
BS 873 : Part 6
Posts and fittings
BS 873 : Part 7
except that the requirements for marking signs shall not apply.

Section 12 Traffic Signs, Road Markings &
Road Studs
1/11
January 2011
12.4
MATERIALS
12.4.1
Steel
Steel for traffic signs shall comply with the following:
12.4.2
Hot finished seamless tubes
: BS 6323 :Part 3
Hot rolled sections
: BS 4 : Part 1
Hot rolled structural steel sections - equal and unequal

angles
: BS 4848 : Part 4
Weldable structural steels
: BS 4360
Stainless steel
Stainless steel for traffic signs shall be Grade 316 S 31 and shall comply with the
following:
12.4.3
General inspection and testing procedures and specific

requirements for carbon, carbon manganese and
stainless steels
: BS 970 : Part 1
Stainless steel tubes suitable for threading in

accordance with BS 21
: BS 6362
Aluminium
(a)
Aluminium for traffic signs shall be H 30 TF and shall comply with the
following:
:
:
:
(i)
(ii)
drawn tube
(iii)
bars, extruded round tubes and sections
BS 1470
BS 1471
BS 1474
(b)
(c)
Aluminium sheet shall be free from twisting, warping and buckling and the
surfaces shall be free from blemishes and other defects.

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12.4.4
Bolts, nuts, screws, washers and rivets

(a)
12.4.5
Bolts, nuts, screws, washers and rivets for traffic signs shall comply with the
following:
BS 4190
ISO metric black cup and countersunk head bolts and

screws with hexagon nuts
BS 4933
Metal washers for general engineering purposes
BS 4320
Rivets for general engineering purposes
BS 4620

engineering purposes - rivet, bolt and screw stock
BS 1473
General inspection and testing procedures and

specific requirements for carbon, carbon manganese
and stainless steels
BS 970 : Part 1
(b)
The length of bolts shall be such that after assembly the threaded portion of
each bolt projects through the nut by at least one thread and by not more than
four threads.
(c)
Rag and indented bolts shall comply with BS 1494 : Part 2. Expansion bolts
and resin bonded bolts shall be a proprietary type reviewed without objection
loading.
(d)
Galvanised bolts, nuts, screws, washers and rivets shall be used with traffic
signs secured to galvanised pedestrian guard-railing. Aluminium materials
shall be insulated from ferrous materials including any coated ferrous
materials by a non-conductive insulator at least 2 mm thick of a type reviewed
Materials for faces of traffic signs

(a)
Retroreflective sheeting shall be Class 1 material complying with BS 873 :

Part 6, Tables 1 and 2.
(b)
Non-retroreflective sheeting shall comply with BS 873 : Part 6.
(c)
Plastic sheeting shall be a proprietary type reviewed without objection by the

Project Manager.
(d)
All materials and finishes shall be mutually compatible.

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12.4.6
Hot applied thermoplastic material

(a)
12.4.7
12.4.8
Hot applied thermoplastic material shall comply with BS 3262 : Part 1 except
that:
(i)
the softening point measured in accordance with BS 3262 : Part 1,

Appendix E, shall not be less than 85C; and
(ii)
the flow resistance shall be such that a cone made and tested in
accordance with BS 3262 : Part 1 shall not slump by more than 25%
after 48 hours at 40C 2C.
(b)
Solid glass beads shall be included in the supplied mixture of hot applied
thermoplastic material.
(c)
Binder for thermoplastic material shall be synthetic hydrocarbon resin or

natural resin based as stated in the Contract.
Cold applied preformed material

(a)
Cold applied preformed material for road markings shall be a proprietary type
reviewed without objection by the Project Manager
(b)
Solid glass beads shall be applied to cold applied preformed material at the
place of manufacture.
Paint for road markings

Paint for road markings shall comply with BS 6044.
12.4.9
Solid glass beads

Solid glass beads shall comply with BS 6088, Class B.
12.4.10 Delivery and storage of thermoplastic material

Hot applied thermoplastic material shall be delivered and stored in accordance with
BS 3262 : Part 1, Clauses 9 and 10 and the manufacturer's recommendations.
12.4.11 Road studs
(a)
Road studs shall comply with the Road Traffic Ordinance, Cap 374 and its
subsidiary legislation.
(b)
Road studs shall be a proprietary type reviewed without objection by the

Project Manager.
(c)
Permanent reflecting road studs to be used as lane line markers on dual

carriageway trunk roads and primary distributor roads shall be a type to which
traffic cylinders of a type reviewed without objection by the Project Manager
can be attached. The method of attachment shall be such that the traffic
cylinder can be easily detached from the road stud.

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January 2011
(d)
Temporary reflecting road studs to be used as markers for temporary traffic

routes shall be yellow.
12.4.12 Bitumen grout

(a)
Bitumen grout for road studs shall consist of bitumen and filler. The bitumen
content shall be 25% to 30% of the total mass.
(b)
Bitumen shall be tropical grade filled bitumen, oxidised grade R 85/25.
(c)
Filler shall be hydrated lime; the percentage by mass of hydrated lime passing
a 75 m BS test sieve shall be at least 85%.
(d)
The properties of bitumen grout for road studs shall comply with the following
requirements:
(i)
the penetration at 25C shall be 124;
(ii)
the softening point shall be 105C 5C; and
(iii)
the specific gravity shall not exceed 1.80.
12.5
SUBMISSIONS
12.5.1
Particulars of traffic signs

(a)
12.5.2
The following particulars of the proposed traffic signs shall be submitted to the
(i)
name of manufacturer; and
(ii)
details of materials and finishes to be used in the manufacture of the

signs.
Particulars of road markings

The following particulars of the proposed materials for road markings shall be
submitted to the Project Manager for review:(a)
certificates for thermoplastic material, paint and solid glass beads showing the
manufacturer's name, the date and place of manufacture and showing that
the material complies with the requirements stated in the Contract and
including results of tests for softening point and flow resistance of
thermoplastic material.

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12.6
WORKMANSHIP
12.6.1
Posts for traffic signs
12.6.2
12.6.3
12.6.4
(a)
Posts for beacons at zebra crossings shall be painted with alternate black and
white stripes. Other posts shall be painted grey in accordance with
BS 5252F, Code 18B19 or shall be galvanized in accordance with BS 729.
(b)
Galvanised areas affected by cutting and drilling shall be treated using a

method reviewed without objection by the Project Manager.
(c)
Posts other than posts supporting an external luminaire shall not protrude
above the top of signs. The length of posts supporting external luminaries
protruding above the top of signs shall be as short as practicable.
Backing plates for traffic signs

(a)
Backing plates for traffic signs shall be fabricated from 3 mm aluminium sheet.
Backing plates for traffic signs not exceeding 1200 mm high x 2400 mm wide
shall be fabricated from a single sheet. If more than one sheet is used, the
number of sheets shall be kept to a minimum; the separate sheets shall be
rectangular and shall be approximately the same size.
(b)
Holes in backing plates shall be drilled before the plate is painted and before
retroreflective or non-retroreflective sheeting is applied.
Spill screens for traffic signs

(a)
Top and bottom light spill screens shall be fabricated from the same material
as the backing plate. The spill screens shall extend for the complete width of
the backing plate and the corners shall be cut to the same radius as the
corners of the backing plate.
(b)
Spill screens shall be considered as part of the backing plate and stiffeners
and mountings shall be designed to accommodate the combined size.
Faces for traffic signs

(a)
Faces for traffic signs shall be formed using retroreflective or nonretroreflective plastic sheeting. Unless otherwise permitted by the Project
Manager, a single piece of sheeting shall be used. If more than one sheet is
used, the number of sheets shall be kept to a minimum. Sheeting shall be
fixed in accordance with the manufacturer's recommendations.
(b)
Materials for faces of traffic signs, including the background, letters,

characters, numerals, symbols and borders, shall be matched for colour in
accordance with the sheeting manufacturer's recommendations at the time of
fabrication to provide a uniform appearance by day and by night.
(c)
Letters, characters, numerals, symbols and borders shall be clear cut and
sharp-edged and shall have no cracks.
(d)
Sheeting material, including letters, characters, numerals, symbols and

borders shall be fully fixed using adhesive; there shall be no air bubbles,
creases, cracks or other blemishes.

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January 2011
12.6.5
Lacquer coatings
Lacquer coatings to faces for traffic signs shall be uniform and continuous and shall
be applied at the time of manufacture of the face.
12.6.6
Painting to faces for traffic signs

(a)
Faces of traffic signs to which a painted or stoved finish is to be applied shall

be thoroughly cleaned and pre-treated before painting and stoving.
(b)
Pre-treatment shall be by anodising or by using an etching primer.
(c)
At least one undercoat and at least one finishing coat of paint shall be applied
and stoved to a thickness of between 0.0315 mm and 0.0375 mm of enamel
over a minimum thickness of 0.025 mm of primer. If light colours are to be
applied over dark colours, at least two coats of the light colour shall be
applied. The final surface shall have a uniform thickness and an egg-shell flat
finish and shall be smooth and free from defects.
(d)
The colours of the finished coating shall be uniform. The colours, including
white, shall comply with the chromaticity co-ordinates of BS 873 : Part 6,
Table 4 and, for comparative purposes, shall comply with the following gloss
paint colours in accordance with BS 381C:
(e)
12.6.7
(i)
red
: No. 537 - signal red;
(ii)
orange
: No. 557 - light orange;
(iii)
yellow
: No. 355 - lemon yellow;
(iv)
blue
: No. 109 - middle blue; and
(v)
green
: No. 225 - light brunswick green.
Parts of faces coloured black shall be non-retroreflective and shall have a

luminance factor not exceeding 0.05 as measured in accordance with BS 873
: Part 6.
Construction and assembly of traffic signs

(a)
Fittings for traffic signs shall be non-corrodible material reviewed without

(b)
Joints for framework and stiffeners which are not an integral part of the
backing plate shall be welded or joined using brackets, nuts, bolts and
washers.
(c)
Materials for rivets and other fixings for joining backing plates to framework
and stiffeners shall be compatible with the materials to be joined. The
spacing of rivets and other fixings shall be uniform; the spacing shall not
exceed 150 mm around the outside edge of sheets and shall not exceed
300 mm on cross braces.

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January 2011
12.6.8
(d)
An additional washer of neoprene or nylon shall be used to protect the faces

of traffic signs from metal nuts, bolts, washers and screws.
(e)
Backing plates shall be connected to posts by a method reviewed without

objection by the Project Manager. Banding systems shall be stainless steel.
Drilling of holes in ferrous components shall be completed before finishes are
applied.
(f)
A lacquer coating shall be applied to the edges of holes drilled in plates with
plastic sheeting immediately before rivets and bolts are inserted. The
surfaces of rivets and bolts on the faces of traffic signs shall be covered with a
material coloured to match the part of the face with which it is in contact.
(g)
Fixings for traffic signs erected on road lighting columns shall be compatible
with the column cross section. Columns shall not be drilled.
Covering of traffic signs

(a)
Traffic signs which are to be blanked out shall be covered by the following
methods:
(i)
Plate signs shall be covered using a 1.5 mm thick sheet which is

compatible with the material in the sign.
(ii)
Plate signs which are to be blanked out for a period not exceeding one
year shall alternatively be covered using a self-adhesive plastic film.
(iii)
Other signs shall be covered using a loose cover sheet of material

(b)
Cover sheets shall be fixed using 5 mm diameter stainless steel bolts,

washers and nuts or non-ferrous rivets at spacings not exceeding 600 mm.
Bolts shall pass through 5 mm x 12 mm diameter plastic distance pieces
between the face of the sign and the cover plate. Holes which remain on the
finished face of the sign shall be filled using blocked rivets; the face of the
rivets shall be coloured by a method reviewed without objection by the Project
Manager.
(c)
Self-adhesive plastic film shall be compatible with the material in the face of
the sign and shall be fixed and removed in accordance with the
(d)
Loose covers shall be securely fastened to the back of the sign. Tape or
other adhesive material shall not be applied to the faces of signs.
(e)
Coverings to traffic signs shall be sufficiently opaque to prevent reflection from

the covered sign and shall not be removed until the Project Manager so
directs.
(f)
The faces of traffic signs which have been erected and which do not relate
either wholly or in part to the traffic situation which applies at that time shall be
blanked out as stated in this Clause.

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January 2011
12.6.9
Preparation of surfaces for Road markings

(a)
Road markings shall not be laid over loose detritus, mud or similar extraneous
matter. Oil and grease shall be removed from the surface of carriageways on
which road markings will be laid.
(b)
Curing compound shall be removed from the surface of new concrete

carriageways on which road markings will be laid, by wire brushing or by other
(c)
Existing road markings which are to be replaced by a different type of material

shall be removed by high pressure water jetting, shot blasting or rotary
grinding; the existing markings shall not be masked using black paint or
similar methods.
(d)
Existing road markings which are to be renewed using a similar type of

material shall be roughened by a method reviewed without objection by the
Project Manager until the thickness of the existing material is reduced by
approximately 50%.
(e)
A tack coat shall be applied to the surface of concrete carriageways before

hot thermoplastic material is laid. The tack coat shall be compatible with the
road marking material and shall be applied in accordance with the
(f)
Rotary grinding machines shall not be used to remove or roughen existing

road markings within 100 mm of longitudinal or transverse joints on concrete
carriageways.
12.6.10 Laying hot applied thermoplastic material

(a)
Hot applied thermoplastic material shall be prepared and laid in accordance

with BS 3262 : Part 3, Clauses 4 and 5. The material shall not be laid when
the surface of the carriageway is wet, or the air ambient temperature in the
shade is less than 10C.
(b)
Hot applied thermoplastic material shall be laid by machine or by screeding

methods. The machine or apparatus shall be capable of producing a marking
to a uniform thickness and width; the marking shall have clean edges and
shall be free from streaks and blisters.
(c)
The thickness of road markings, not including surface applied solid glass
beads, shall comply with the following:
(i)
screed markings
: 4 mm;
(ii)
sprayed lines other than yellow edge lines
: 1.5 mm; and
(iii)
sprayed yellow edge lines
: 0.8 mm.
The thickness shall be measured in accordance with BS 3262 : Part 3,

Appendix B.
(d)
Traffic shall not be permitted to run over road markings until they are dry and
set.

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12.6.11 Laying cold applied preformed material

(a)
Cold applied preformed material shall be laid in accordance with the

manufacturer's recommendations. The material shall not be laid when the
surface of the carriageway is wet.
(b)
The thickness of road markings shall be at least 1.5 mm.
(c)
Traffic shall not be permitted to run over road markings until they are dry and
set.
12.6.12 Use of road marking paint

Road marking paint shall not be used other than for temporary road markings.
12.6.13 Reflectorisation
Solid glass beads shall be applied to the surface of hot applied thermoplastic
material and road marking paint immediately after the material or paint has been
applied, to enhance the reflectivity of the surface. The solid glass beads shall be
uniformly applied by a mechanical method at a rate of between 400 g/m and
500 g/m.
12.6.14 Temporary road markings
(a)
Temporary road markings shall be used at locations directed by the Project

Manager. Cold applied preformed material shall be used for temporary road
markings which are to be removed.
(b)
Temporary road markings shall be disposed of by the Contractor after

removal. All traces of tape shall be removed from the surface of the
carriageway and existing permanent road markings shall be made good such
that it is safe to allow traffic to use the road.
12.6.15 Skid resistance level

The skid resistance level of road markings measured in accordance with BS 3262 :
Part 1 shall be at least 45.
12.6.16 Tolerances: road markings
The lengths, thicknesses and widths of hot applied thermoplastic material road
markings shall comply with the following requirements:
(a)
The thickness of screed markings shall be within 1 mm of the specified

thickness.
(b)
The length and width of screed markings and sprayed lines shall be within
+10%, -5% of the specified dimension.

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12.6.17 Installation of road studs

(a)
Road studs shall be installed in accordance with the manufacturer's

recommendations.
(b)
Depressible road studs shall be installed using bitumen grout.
(c)
Road studs shall not be installed on concrete carriageways until the concrete
has reached the specified grade strength.
(d)
Surfaces to which bonded road studs are to be fixed shall be clean and all
dust, grease and other deleterious material shall be removed immediately
before the studs are installed.
12.7
12.7.1
Testing : traffic signs
12.7.2
(a)
The number of traffic signs to be tested shall be as stated in the Contract or

as directed by the Project Manager.
(b)
The number and type of tests to be carried out on the traffic signs shall be as
stated in the Contract or as directed by the Project Manager.
(c)
Testing shall be carried out in such a manner that the traffic sign will not be
damaged.
(d)
Testing shall be carried out by the Contractor at a laboratory reviewed without

Compliance criteria : traffic signs

The compliance criteria for testing traffic signs shall be in accordance with
BS 873:Part 1.

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SECTION 13 WORK FOR ELECTRICAL AND MECHANICAL INSTALLATIONS

13.1
GENERAL
13.1.1
(a)
(b)
The works and materials specified in the following sub-clauses shall comply
with the Sections stated, unless otherwise stated in this Section.
(i)
(ii)
Structural steelwork shall comply with Section 22.
For the purposes of this Section 13 of the General Materials and

Workmanship Specification, the term electrical and mechanical work shall
consist of all mechanical and electrical services, systems and equipment
including but not limited to the following :
(i)
heating, ventilation and air-conditioning systems;
(ii)
refrigeration systems;
(iii)
gas systems;
(iv)
electrically powered systems;
(v)
high and low voltage electrical distribution systems;
(vi)
lighting systems;
(vii) lightning protection systems;

(viii) earthing systems;
(ix)
fire services systems;
(x)
hydraulic, plumbing and drainage systems;
(xi)
video, data and voice communication systems;
(xii) control, supervisory and monitoring systems;

(xiii) baggage handling systems;
(xiv) utility services;
(xv) lifts, escalators and moving walkway systems; and
(xvi) automatic people movement systems.

Section 13 Work for E & M Installations
1/10
January 2011
13.1.2
Concealed electrical conduit system

Concealed electrical conduit system is an electrical conduit system, including all
bends, couplers, bushes, saddles, boxes, covers, plugs, draw wires and other
conduit fittings, which is cast into concrete or fixed in chases in brickwork with a
minimum cover of 20 mm or which is laid directly in the ground.
13.1.3
Requirements for electrical and mechanical installations

(a)
The principle requirements for electrical and mechanical installations will be

as shown on the Employer's Drawings. Confirmation of these provisions and
identification of any other requirements, including holes, sleeves and
recesses, shall be carried out in accordance with the requirements of the
Section 11 of the General Specification.
(b)
Where holes, sleeves and recesses are to be provided in concrete structures

they shall be formed prior to placing of concrete and shall not be cut through
hardened concrete.
(c)
Where pipework, cables, cable trunking or trays, ducts or fire dampers or

other elements of electrical and mechanical system pass through structural or
non-structural elements, the requirements of Sections 44-60 of the General
Materials and Workmanship Specification shall apply.
(d)
Holes, sleeves and recesses in internal floors, stairways and platforms shall
be protected with temporary covers until the electrical and mechanical
installation starts. Holes, sleeves and recesses in roofs, external walls and
external floors shall be sealed with watertight temporary covers reviewed
without objection by the Project Manager until the electrical and mechanical
installation starts.
13.2
MATERIALS
13.2.1
Electrical conduits and fittings

(a)
Electrical conduits and fittings shall comply with BS 4568 : Parts 1 and 2 and
shall have Class 4 heavy protection inside and outside. Conduits shall be
heavy gauge with screw-end construction in steel and shall have an external
diameter of at least 20 mm; conduits shall be longitudinally welded.
(b)
Metal boxes for enclosing electrical accessories shall comply with BS 4662
and shall have heavy protection inside and outside; the boxes shall be of
preferred sizes and shall be 35 mm or 47 mm deep as appropriate. Circular
ceiling boxes of deep pattern shall comply with BS 4568 : Part 2 and shall
have Class 4 heavy protection inside and outside; the boxes shall be at least
60 mm deep internally.
(c)
Circular boxes, dome covers and hook covers shall be cast iron. Bushes and
plugs shall be brass.

2/10
January 2011
13.2.2
13.2.3
13.2.4
Cable ducts and fittings

(a)
UPVC cable ducts for installation above ground or for casting into concrete
shall be Class 0 UPVC pipes complying with BS 3506. Cable ducts for
installation below ground shall be Class B UPVC pipes complying with
BS 3506. For road lighting systems, the colour of the underground UPVC pipe
shall be purple.
(b)
Joints and fittings for use with UPVC cable ducts shall comply with BS 4346 :
Part 1 and BS 4346 : Part 2. Solvent cement for UPVC pipes and fittings shall
comply with BS 4346 : Part 3.
(c)
Steel cable ducts shall be steel tubes complying with BS 1387, medium
series, screwed and socketed tubes and shall have screwed sockets suitable
for screwing to BS 21, Table 2 pipe threads. The tubes, sockets, clamps and
saddles for ducts shall be galvanized in accordance with BS 729.
Paint for conduit and duct systems

(a)
Bituminous paint for steel conduits and steel cable ducts shall comply with
BS 3416, type 1.
(b)
Anti-rust paint for concealed electrical conduit systems shall be a proprietary

type reviewed without objection by the Project Manager.
(c)
Zinc chromate primer for cable duct systems shall comply with BS 4652.
(d)
Galvanizing paint for cable duct systems shall be a proprietary type reviewed
Fire barriers
Internal fire barriers shall be a type offering adequate fire resistance for the
application. The material shall be reviewed without objection by the Project
Manager in compliance with Fire Services Department requirements and shall be
resistant to fire, smoke, gas and water.
13.2.5
Cement grout for electrical and mechanical installations

(a)
Materials for grout shall comply with Section 20.
(b)
The different types of cement grout for electrical and mechanical installations
shall consist of ordinary Portland cement, sand and PFA in the proportions by
mass stated in Table 13.1 together with the minimum amount of water
necessary to achieve a consistency suitable for completely filling the voids.
The mix shall contain a non-shrink admixture.

3/10
January 2011
Table 13.1: Mix Proportions of Cement Gout

Type
13.2.6
Mix proportions by mass

Cement
Sand
PFA
G1
G2
G3
10
G4
Cables
(a)
PVC insulated cables shall be single core of copper conductors, 450/750V

grade and flame retardant PVC insulation to BS 6004.
(b)
The current carrying capacity shall be in accordance with IEE Wiring

Regulations. Minimum size of cables shall be as follows unless other
specified:
Lighting
Control
(c)
(d)
(e)
2.5 sq mm
1.5 sq mm
All wiring shall be carried out on the loop-in system and the wires shall be
drawn into the conduits after the whole of this installation has been
completed. No joints or connectors will be allowed in any such cable, except
that connectors may be used in accessible positions with lighting fittings.
All PVC insulated cables shall be installed in galvanized conduit.
All PVC/SWA/PVC cables shall be installed as shown on the Employers
Drawings and terminated in brass glands fitted with amour clamps.
13.3
WORKMANSHIP
13.3.1
Construction of conduit systems

(a)
Concealed electrical conduit systems which are shown diagrammatically in

the Contract shall be constructed as stated in Clause 13.3.1(b) to (g).
(b)
Concealed electrical conduit systems shall be mechanically continuous and

where metallic conduits are used they shall also be electrically continuous and
effectively earthed.
(c)
Principal conduit runs shall be either vertical or horizontal. Tee pieces and
elbows, including those with provision for inspection, shall not be used.
(d)
Joints shall be made using coupler units into which the ends of the conduits
shall be inserted and tightened. Running couplings shall not be used unless
permitted by the Project Manager; if permitted, the couplings shall be made by
screwing each of the conduits half way into the coupler with a hexagonal lock
nut against each end of the coupler.

4/10
January 2011
(e)
13.3.2
13.3.3
Adaptable boxes shall be provided at:

(i)
every second bend;
(ii)
after a bend and a straight run of 10 m or less; and
(iii)
every 15 m in straight runs.
(f)
Adaptable boxes for conduits installed in floor screeds shall have the lids set
flush with the adjacent floor; the boxes shall be covered with the same
material as the remainder of the floor and shall remain accessible at all times.
(g)
The clearance between conduits entering adaptable boxes and between

adjacent or parallel conduits shall be at least the nominal maximum coarse
aggregate size of the concrete plus 5 mm.
Installation of conduit systems

(a)
Concealed electrical conduit systems shall be arranged and installed in

accordance with best trade practice and in such a manner that all cables can
be drawn with ease and without damage.
(b)
All conduit systems shall be installed fully in accordance with the

requirements of the current IEE Wiring Regulation.
(c)
Bends in concealed electrical conduit systems shall be formed by using

proprietary bending equipment of a type reviewed without objection by the
Project Manager; connections and other work shall be carried out using
purpose made equipment.
(d)
Conduits shall not be bent by more than 90 and the internal radius at bends
shall be at least 2.5 times the external diameter of the conduit. Conduits shall
not be flattened at bends.
(e)
Burrs and sharp edges shall be removed from the ends of conduits before
installation.
(f)
Concealed electrical conduit systems which are to be cast into concrete shall
be fastened to the reinforcement with tying wire of the same type used for the
reinforcement. The conduit systems shall not be positioned between the
reinforcement and the outside face of the concrete.
(g)
Conduit boxes shall be of a compatible size and shall have a single extension
ring of the required depth if the plaster finish exceeds 13 mm thick; multiple
extension rings shall not be used.
Terminations of conduit systems

Screw fitting couplers shall be provided at each end of conduits which terminate in
distribution boards, busbar chambers, motor starters, cable ducts, boxes or similar
termination points. The item at which the conduit terminates shall be drilled with an
unthreaded clearance hole to receive a brass male bush; the bush shall be screwed
into the coupler from the inside of the item in such a manner that the surface of the
item is gripped between the coupler and the bush. The threads shall be at least half
the length of the coupler.

5/10
January 2011
13.3.4
13.3.5
Protection of conduit systems

(a)
Concealed electrical conduit systems shall have special arrangements

designed by the Contractor to permit movement of conduits to take place on
each side of movement joints in structures. A separate circuit protective
conductor shall be installed to maintain effective electrical continuity across
the joint. The protective conductor shall have a cross-sectional area rated to
suit the largest live conductor to be drawn into the conduit.
(b)
Steel conduit systems laid in contact with or adjacent to other metal work shall
have efficient and permanent metallic connection made between the conduit
and the metal work.
(c)
Underground steel conduits and conduits in contact with soil shall be painted
with two coats of bituminous paint before installation.
(d)
Exposed threads and damage to protective coatings of conduit systems shall

be painted with two coats of anti-rust paint.
(e)
Conduits shall be laid in such a manner that accumulation of condensed

moisture in the conduit system is prevented; measures shall be taken to
prevent water from entering the system.
(f)
Water, moisture and deleterious material shall be prevented from entering

permanent and temporary terminations in concealed electrical conduit
systems, including conduit boxes, by using conduit stopping plugs of a type
reviewed without objection by the Project Manager; paper or rags shall not be
used.
Cleaning of conduit systems

After installation, concealed electrical conduit systems shall be swabbed out with
draw-in tapes and absorbent cloth of a type reviewed without objection by the
Project Manager; all obstructions shall be removed and draw wires shall be
installed. After cleaning, exposed conduit ends shall be sealed as stated in Clause
13.3.4(f).
13.3.6
Installation of cable duct systems

(a)
Changes in direction in cable duct systems shall be constructed in such a

manner that the cables in the duct will have radii of curvature of at least 800
mm. Ducts entering draw-in pits shall be on the same horizontal plane as the
draw-in pit.
(b)
UPVC cable ducts shall be jointed in accordance with the manufacturer's

recommendations.
(c)
Steel cable ducts shall be jointed using screwed galvanized sockets and spun
yarn such that the jointed pipes abut; the threads shall be painted with two
coats of bituminous paint. Internal rags and burrs shall be removed to provide
a smooth bore through joints in the cable duct system.
(d)
Surface mounted cable ducts shall be secured by galvanised steel clamps or

saddles at spacings not exceeding 3 m.

6/10
January 2011
(e)
Ducts laid in the ground shall be kept at least 150 mm clear of gas and water
mains and all other utility services. In the case of any type of electricity supply
the following minimum separating distance shall be provided:(i)
High Voltage single core cables (exceeding 650 Volts) ..............450 mm
(ii)
High Voltage multi-core cables (exceeding 650 Volts) ................300 mm

In cases where it is not possible to provide the required clearance, a
layer of concrete not less than 50 mm thick shall be provided between
the duct and the electricity supply cable.
(iii)
Low and Medium Voltage cables (not exceeding 650 Volts) .......150 mm
where the duct and electricity supply cable cross with minimum separation a
layer of concrete 50 mm thick shall be provided.
(f)
13.3.7
13.3.8
To ensure the correct alignment of ducts, a wooden mandrel shall be drawn

forward as the ducts are laid.
Protection of cable duct systems

(a)
After jointing, exposed bare metal in cable duct systems shall be cleaned and
painted with two coats of zinc chromate primer and two coats of galvanizing
paint.
(b)
Surface mounted galvanized steel cable ducts shall be cleaned and painted
after fittings and jointing have been completed.
Cleaning of cable duct systems

After jointing, cable duct systems shall be cleaned internally by scrubbing with a
cylindrical brush of a type reviewed without objection by the Project Manager. The
ends of ducts, including ends of ducts in draw-in pits and spare ducts, shall be fitted
with tapered hardwood plugs to prevent water, moisture and deleterious material
from entering the system and a 6 mm diameter nylon draw line shall be installed.
The plugs shall be centrally drilled for the draw line and the draw line shall be
secured by a knot tied on the outer face of the plug to leave at least 1500 mm of
surplus line at each plug.
13.3.9
Electrical earthing systems

(a)
Pits and trenches for electrical earthing systems shall be excavated at

positions and at the times directed by the Project Manager.
(b)
After the electrical earthing systems have been installed fill material shall be
deposited and compacted in the pits and trenches to a depth of 300 mm
above the electrical earthing system. Fill material shall be sand or fine fill
material which has been selected from the excavated material, and which is
free from stones retained on a 20 mm BS test sieve. Fill material shall be
compacted by handrammers in a manner reviewed without objection by the
Project Manager.

7/10
January 2011
(c)
The Contractor shall supply and install 1 no. 16mm diameter copper earth rod,
with sufficient length for the pillar box, to ensure earth continuity complete with
concrete lined pits with removable lids to enable access to the connection
between the earthing electrode and earth lead to be obtained. The earth pits
shall be at ground level sited as close as possible to the pillar box and the
earth lead shall be 25 x 3mm copper tape.
13.3.10 Grouting for electrical and mechanical installations

(a)
Grouting to structural steelwork, machine bases, crane rails, electrical and

mechanical equipment and other electrical and mechanical installations shall
comply with the requirements stated in Clause 13.3.10(b) to (g).
(b)
The Contractor shall notify the Project Manager before items or equipment are
grouted.
(c)
Concrete surfaces shall be scabbled to remove laitance and loose material

and to expose the aggregate before the item or equipment is installed in
position.
(d)
The voids to be grouted shall be cleaned and thoroughly wetted immediately

before grouting. Excess water shall be removed by using a compressed air
jet.
(e)
Grout shall be mixed and placed by methods reviewed without objection by

(f)
If grouting is to be carried out in two operations, holding down bolts shall be

grouted into preformed pockets and sufficient time shall be allowed for the
grout to cure and for the bolts to be tensioned before the remaining voids are
grouted.
(g)
Exposed grout surfaces shall have a uniform, dense and smooth surface free
from trowel marks and which is produced by steel trowelling the surface under
firm pressure. The exposed surfaces shall be cured by either:
(i)
using a liquid curing compound applied to the surface by a low-pressure

spray until a continuous visible covering is achieved; or
(ii)
covering the surface with hessian or sacking; the hessian or sacking

shall be lapped and securely held in position and shall be kept damp for
at least 4 days.
13.3.11 Completion of work for electrical and mechanical installations

(a)
Unless otherwise stated in the Contract work shall be completed to the

conditions stated in Clause 13.3.11(b) to (g) inclusive before structures are
made available to Other Contractors for electrical and mechanical
installations.
(b)
Structures shall be clean, dry and free from dust. Work which will produce
large quantities of dust shall be complete.

8/10
January 2011
(c)
Holes and recesses, concealed electrical conduit systems and cable duct
systems required for the installation shall be complete. Concrete surfaces on
which items and equipment are to be installed shall be scabbled.
(d)
Plinths, trenches, louvres, openings and similar work shall be complete and
shall have hardened sufficiently to allow the installation to proceed.
(e)
Floors and slabs shall be complete to the specified finishes except that floor
tiles shall not be laid until after the installation is complete.
(f)
Plant rooms shall be complete, including fixtures and fittings, to a secure and
weatherproof condition. Two sets of door keys for each plant room shall be
provided for the Project Manager.
(g)
Paintwork and similar finishes in plant rooms shall be complete to undercoat

level; final coats shall not be applied until after the installation is complete.
13.3.12 Protection of work for electrical and mechanical installations

(a)
Structures in which electrical and mechanical installations are being carried

out shall be maintained in a clean, dry condition, free from dust, during the
installation.
(b)
The dust level in plant rooms shall be kept to a minimum by using industrial
dust extractors of a type reviewed without objection by the Project Manager
during and after the installation. Temporary screens shall be installed to
separate dust-affected areas from the installations or temporary covers shall
be installed around the installation.
13.4
13.4.1
Inspection of work for electrical and mechanical installations

(a)
(b)
The Contractor shall allow the Project Manager to inspect the following work
for electrical and mechanical installations:
(i)
completed concealed electrical conduit systems, cable duct systems,

electrical earthing systems and items and equipment which are to be
grouted or covered up;
(ii)
items and equipment which are to be tested; and
(iii)
structures which are to be made available for electrical and mechanical

installations.
The Contractor shall notify the Project Manager three days, before work is
covered up, tested or made available.

9/10
January 2011
13.4.2
Testing: earthing continuity

(a)
13.4.3
Concealed electrical conduit systems shall be tested to determine the earthing

continuity. The system shall be tested:
(i)
before the system is cast in concrete or covered up;
(ii)
after the system is cast in concrete or covered up; and
(iii)
after electrical wiring which is installed by the Contractor is complete.
(b)
The method of testing shall be in accordance with the 16th Edition of IEE
Wiring Regulations issued by the Institution of Electrical Engineers.
(c)
The results of tests for earthing continuity shall comply with the 16th Edition of
IEE Wiring Regulations issued by the Institution of Electrical Engineers.
Testing: load tests on beams and joists

(a)
Load tests shall be carried out on lifting beams, rolled steel joists, lifting
hooks, eyes and anchorage points which are installed by the Contractor for
electrical and mechanical work or other Permanent Works.
(b)
Testing shall be carried out by an independent testing authority reviewed

without objection by the Project Manager and by using methods reviewed
(c)
A certificate showing the results of the load tests and signed by the testing
authority shall be submitted to the Project Manager for review without
objection within 7 days of the test.
(d)
The results of tests on lifting beams, rolled steel joists, lifting hooks, eyes and
anchorage points shall comply with the Factories and Industrial Undertakings
(Lifting Appliances and Lifting Gear) Regulations, 1978 issued by the Labour
Department.

10/10
January 2011
SECTION 14 WATER SUPPLY PIPEWORKS
14.1
GENERAL
14.1.1
(a)
Drainage works shall comply with Section 6.
(b)
(c)
(d)
14.2
14.2.1
Fitting
Fitting is a component fitted to a pipe for jointing or connecting or for changing the
direction or bore of a pipe.
14.2.2
Flexible joint
Flexible joint is a connection between pipes and fittings which provides angular
deflection or axial movement or a combination of both in service without impairing
the efficiency of the connection.
14.2.3
Mechanical joint
Mechanical joint is a flexible joint in which an elastomeric joint ring is located in the
socket and the joint sealed by applying pressure to the joint ring by means of a
gland bolted to the socket.
14.2.4
Nominal size
Nominal size is a numerical designation of size which is common to all components
in a pipework system. The nominal size is stated as a convenient round number in
millimetres and is related to, but not normally the same as, the actual internal
diameter of the pipework; dn designates the nominal size of tees and tapers which
are less than DN.
14.2.5
Push-in joint
Push-in joint is a flexible joint in which an elastomeric joint ring is located in the
socket and the joint is effected by entering the spigot through the joint ring into the
socket.

Section 14 Water Supply Pipeworks
1/23
January 2011
14.2.6
Special fitting
Special fitting is a fitting which is made from a manipulated or fabricated pipe.
14.2.7
Thin walled pipe

Thin walled pipe is a pipe, including pipes of DN 1200 or greater, which has a ratio
of nominal size to wall thickness, excluding linings and coatings, exceeding 125.
14.2.8
Nominal outside diameter of a polyethylene pipe

Nominal outside diameter of a polyethylene pipe shall mean the minimum mean
outside diameter of the pipe as described in Clause 3.1 of ISO 161-1.
14.2.9
Nominal wall thickness of a polyethylene pipe

Nominal wall thickness of a polyethylene pipe shall mean the minimum wall
thickness of the pipe as described in Clause 3.4.5 of BS ISO 11922-1.
14.2.10 Standard Dimension Ratio

The Standard Dimension Ratio (SDR) of a polyethylene pipe shall mean the ratio of
its nominal outside diameter to its nominal wall thickness as described in Clause 3.8
of ISO 161-1.
14.2.11 WIS
WIS shall mean the Water Industry Specification produced and published by WRC.
14.3
MATERIALS
14.3.1
Materials for water supply pipeworks

Materials for water supply pipeworks for potable water shall be non-toxic, shall not
promote microbial growth and shall not impart a taste, odour, cloudiness or
discolouration to the water after disinfection and washing out of the pipelines as
stated in Clause 14.6.8.
Water supply pipework shall be either ductile iron or polyethylene unless otherwise
14.3.2
DI pipes and fittings

(a)
DI pipes and fittings shall comply with BS 4772. Pipes and fittings other than
collars, caps and blank flanges shall be lined internally with cement mortar in
accordance with BS 4772, Clause 3.2. Linings shall be made with
sulphate-resisting Portland cement complying with BS 4027.

2/23
January 2011
(b)
14.3.3
14.3.5
(i)
bitumen based hot applied coating material

Clause 23.22 and BS 4147 : Type I, Grade C; or
complying
with
(ii)
bitumen based cold applied coating

Clause 23.22 and BS 3416 : Type II.
complying
with
material
Flanges
(a)
14.3.4
Pipes shall be externally coated with metallic zinc in accordance with

BS 4772, Clause 3.1. Fittings shall be externally coated with zinc rich paint in
accordance with BS 4772, Clause 3.1.5(b). After zinc coating pipes and
fittings shall be externally coated with a finishing coat of one of the following
materials as stated in BS 4772, Clause 3.3:
DI flanges shall be cast-on or welded-on standard flanges complying with

BS 4772.
Bolts and nuts

(a)
Bolts and nuts for flanged joints shall comply with BS 4504 : Section 3.1,
Section 6.
(b)
Bolts and nuts shall be compatible with the type of joint and shall be obtained
from the same manufacturer as the joint.
(c)
Bolts shall be sufficiently long and shall be suitably threaded for jointing the
relevant flanges.
Elastomeric joint rings

Elastomeric joint rings for DI pipes and fittings shall comply with BS 4772,
Clause 2.3.4. The dimensions of rings for use with flanged joints shall comply with
BS 4865 : Part 1. The rings shall be compatible with the type of joint and shall be
obtained from the same manufacturer as the joint.
14.3.6
Polyethylene Pipes
(a)
Polyethylene pipes shall be either PE80 or PE100 grade pipes in accordance

with Clauses 14.3.6 (b) to (h)
(b)
PE80 pipes with nominal outside diameter from 20mm to 63mm inclusive and
PE100 pipes with nominal outside diameter from 90mm to 180mm inclusive
shall conform to ISO 4427.
(c)
PE80 and PE100 pipes shall have a SDR of 11 and have nominal pressure
rating as follows:
(i)
PE80 12.5 bar (PN12.5); and
(ii)
PE100 16 bar (PN16).

3/23
January 2011
(d)
The colour for polyethylene pipes shall be blue within the range below:
Nominal Outside Diameter
14.3.7
14.3.8
Colour Range
20mm 63mm
18E51 to 18E53 of BS 4901
90mm 180mm
20D44 to 20D45 or 20E53 to 20E56 of BS 5252
(e)
The tolerance on the nominal outside diameter of polyethylene pipes shall be

in accordance with Grade B of BS ISO 11922-1.
(f)
The end of the pipe shall be cut cleanly and square to the axis of the pipe to
within the tolerances given below:
Nominal Outside Diameter
Maximum Tolerance (mm)
90mm and below
125mm
180mm
(g)
Standard length of polyethylene pipes supplied shall be 6 m. For pipes of

nominal outside diameter from 20 mm to 63 mm, 50 m coils may be specified.
No reduction in the specified length shall be allowed unless reviewed without
(h)
Melt flow rate of PE80 and PE100 pipes tested at a temperature of 190C
under a nominal load of 5 kg shall be within the range of 0.2 g/10 min to 1.3
g/10 min.
Fittings for Polyethylene pipes

(a)
All fittings for polyethylene pipes shall have a pressure rating the same as or
higher than the nominal pressure rating of the pipes. The fittings shall be
supplied with complete set of accessories including insert, liners, joint rings,
flange gaskets, studs, bolts and nuts, etc. whatever appropriate.
(b)
The flanges of all fittings shall be constructed in such a way that they may be
attached to flanges designated PN16 whose dimensions conform to Table 9
of BS EN 1092-2. One complete set of bolts and nuts and one gasket shall
be supplied with each flange of flanged fittings. The strength of bolts shall be
Grade 4.8 and the strength of nuts shall be Grade 4 complying with BS 4190.
The bolts and nuts shall be hot dip galvanized or have other protective
coatings reviewed without objection by the Project Manager.
Polyethylene Electrofusion Fittings

(a)
Polyethylene electrofusion fittings including couplers, reducers, socket ends

tees, caps and elbows, self tapping tee saddles and other electrofusion fittings
shall comply with WIS 4-32-14. Polyethylene spigot fittings for electrofusion
jointing including the spigot stub flange assembly shall comply with WIS 4-3215. Stub flanges shall comply with WIS 4-24-01.
(b)
Melt flow rate of PE80 and PE100 electrofusion fittings tested at a

temperature of 190C under a nominal load of 5kg shall be within the range of
0.2 g/10 min to 1.3 g/10 min.

4/23
January 2011
(c)
Notwithstanding Clause 5.1.6 of WIS 4-32-14, the fittings shall be capable of

being fused in the tropics.
(d)
The design for fitting terminals and shrouds shall be similar to that stated in
Clause 5.2.3 of WIS 4-32-14. Other designs of terminals will only be
considered if the Contractor can demonstrate that appropriate lead adaptor is
readily available such that electrofusion of their fittings can be conducted
using common electrofusion control units available in the market.
Unless otherwise reviewed without objection by the Project Manager, all
electrofusion fittings shall be blue in colour within the range as specified in
Clause 14.3.6(d).
(e)
14.3.9
Compression Fittings for Polyethylene Pipes

(a)
Compression fittings for polyethylene pipes in a range of nominal outside

diameter 20 mm to 63 mm inclusive, shall be Class 1 end-load bearing fittings
conforming to ISO 14236.
(b)
Compression fittings with external and/or internal threads shall be compatible

with pipes and fittings threaded to BS 21.
14.3.10 Mechanical Fittings for Polyethylene Pipes

(a)
Mechanical fittings for polyethylene pipes of nominal outside diameter 90 mm

and above shall be Type 1 fittings conforming to WIS 4-24-01.
(b)
Mechanical fittings shall be coated with a minimum thickness of 250 microns

of epoxy or plastic based coating complying with the performance requirement
of WIS 4-52-01.
14.3.11 Markings on Polyethylene Pipes and Fittings

(a)
Markings on the polyethylene pipes and fittings shall be in accordance with

the relevant Clauses in the ISO or WIS appropriate to the pipes and fittings
supplied.
(b)
Notwithstanding Clause 8 of ISO 4427, the pipes series in SDR shall be

marked on the pipes.
(c)
Notwithstanding Clause 10 of ISO 14236, the designation of the material

(PE80 or PE100) and the number ISO 14236 shall also be marked on the
compression fittings.
14.3.12 Anticorrosion tape

(a)
Anticorrosion tape shall be a propriety type reviewed without objection by the

Project Manager. The tape shall either be a petrolatum tape with fabric
reinforcement or a bituminous tape with PVC backing. Petrolatum tape shall
be used for valves, flanged joints, slip-on type couplings and flange adaptors
of all sizes. Bituminous tape shall be used in buried or non-exposed condition
for welded joints of steel pipe, repair of steel pipe sheathing and other
applications as specified on the Employers Drawings.

5/23
January 2011
(b)
Anticorrosion tapes shall have a high resistance to cathodic disbondment,

acids and alkalis. Colour of bituminous tape shall be black. Anticorrosion
tapes shall have as a minimum the properties stated in Table 14.1.
(c)
Primer and mastic filler for use with anticorrosion tape shall be compatible
with the tape and shall be a type recommended by the manufacturer of the
tape and reviewed without objection by the Project Manager.
(d)
Bituminous tapes shall be stored in a cool dry place away from the suns rays.
The tape shall be free of dirt or grit immediately prior to application.
Table 14.1: Properties of Anticorrosion Tape

Properties
Petrolatum Tape
Bituminous Tape
0.75
Thickness of PVC backing (mm)

Total thickness (mm)
1.1
1.65
Mass (kg/m )
1.4
2.0
Tensile strength (N/mm)
10
Adhesion strength
Self
0.5
2.5
(180 peel)
Steel
0.5
2.5
Dielectric strength (2 layers) (kV)
15
30
260
Wrapping
-5 to +45
+5 to +50
Service
-5 to +45
-20 to +75
Elongation (at break) (%)

Temperature range (C)
14.3.13 Bituminous coatings

(a)
Bituminous coatings shall comply with the following:

(i)
Bitumen based hot applied coating

material for protecting iron and steel
including suitable primers where required
: BS 4147, Type I, Grade C
(ii)
Black bitumen coating solutions for cold

application
: BS 3416, Type II.
(b)
Bituminous coatings used for repairing joints and coatings shall be compatible
with the adjacent coating.
(c)
Bituminous coatings shall be made from petroleum or asphaltic bitumen.
14.3.14 Zinc-based paint

(a)
Zinc-based paint shall be a proprietary type reviewed without objection by the

Project Manager.
(b)
Primers for zinc-based paint shall comply with BS 4652.
(c)
Rust inhibitor shall be a chemical agent which is capable of converting rust

into iron phosphate.

6/23
January 2011
14.3.15 Joint filler and compressible padding

(a)
Joint filler for joints in concrete bed, haunch and surround shall be a
be a firm, compressible, single thickness, non-rotting filler. The thickness of
the filler shall be as stated in Table 14.2.
(b)
Compressible padding between pipes and supports shall be bitumen

damp-proof sheeting complying with BS 743.
Table 14.2: Joint Filler for Concrete Bed, Haunch and Surround
Nominal diameter of Pipe
Thickness of joint filler (mm)
less than 450 mm
18
450 mm 1200 mm
36
exceeding 1200 mm
54
14.3.16 Polyethylene sheeting

0.125 mm.
14.3.17 Extension keys
Extension keys and clamps for valves shall be Grade 43A steel complying with
BS 4360 and shall be hot-dip galvanised in accordance with BS 729 after
fabrication.
14.3.18 Transport, handling and storage of pipes, joints and fittings
(a)
Pipes, joints and fittings for water supply pipeworks shall be transported,
handled and stored in accordance with the manufacturers' recommendations
and in a manner which will not result in damage or deformation to the pipes,
joints and fittings or in contamination of the pipes, joints and fittings.
(b)
Pipes, joints and fittings shall be protected from damage and damaged pipes,
joints and fittings shall not be used in the Permanent Works. Pipes, joints and
fittings shall be securely packed and supported to prevent movement when
being transported.
(c)
Bolts and nuts shall be packed in sealed metal containers.
(d)
Elastomeric joint rings shall be packed in bags and lubricant for joints shall be
stored in sealed containers marked to identify the contents. The rings and
lubricant shall be protected from exposure to conditions which may affect the
material.
(e)
Boxed or crated materials or those in sealed containers shall remain in their

original boxes, crates or containers.

7/23
January 2011
14.3.19 Handling of pipes and fittings

(a)
Pipes and fittings other than thin walled pipes shall be handled by manual
methods or by using lifting appliances or chains, wire rope or canvas slings of
a type recommended by the pipe manufacturer and reviewed without
objection by the Project Manager. Hooks shall not be used.
(b)
Slings shall be placed around the pipes and fittings and padding shall be
provided at points of contact between pipes and fittings and metal lifting
appliances or slings. Pipes and fittings shall not be handled by means of
metal slings passed through the pipes.
(c)
Pipes and fittings shall not be subjected to rough handling, shock loading or
dropping.
14.3.20 Storage of pipes

(a)
Pipes other than thin walled pipes shall be stored horizontally at least 75 mm
above the ground on wedged timber bearers. The pipes shall be securely
wedged to prevent sideways movement.
(b)
Socket and spigot pipes shall be stored with the sockets alternating and in
such a manner that loads are not applied to the sockets.
(c)
The height of stacks of pipes other than thin walled pipes shall not exceed the
maximum height recommended by the pipe manufacturer.
(d)
Pipes shall not be strung out along the route of the pipeline.
14.3.21 Transport of thin walled pipes

When being transported, thin walled pipes shall be supported on three rubber
covered saddles shaped such that the pipes are supported over at least one-quarter
of the circumference. The pipes shall be securely fixed in position at each saddle
by straps tightened by turnbuckles. One saddle shall be placed at the mid-point of
the length of the pipe and the other two saddles shall be placed at distances of
one-fifth of the length of the pipe from each end of the pipe.
14.3.22 Handling and storage of thin walled pipes
(a)
When being handled and stored, thin walled pipes shall be protected from
deformation by means of at least two screw jack cruciform struts with rubber
padded ends shaped to fit the circumference of the pipes. The struts shall be
fitted inside the pipes; any temporary struts fixed by the manufacturer shall be
left in position until the cruciform struts have been fixed.
(b)
Thin walled pipes shall be handled by using two reinforced canvas slings at
least 300 mm wide. The slings shall be suspended from a lifting beam and
shall be placed at a distance of one-fifth of the length of the pipe from each
end of the pipe.
(c)
Thin walled pipes shall not be rolled.

8/23
January 2011
(d)
Thin walled pipes shall be stored on timber bearers padded with hessian or
straw to provide continuous support over at least one-third of the
circumference of the pipe. The pipes shall be securely fixed in position with
wedges placed at a distance of one-fifth of the length of the pipe from each
end of the pipe.
(e)
Thin walled pipes shall not be stacked on top of each other.
14.4
SUBMISSIONS
14.4.1
Particulars of independent inspection authority

Particulars of the proposed independent inspection authority for pipes, joints, fittings
and valves for water supply pipeworks, including name and address, previous
experience, and names of inspectors, shall be submitted to the Project Manager for
review without objection.
14.4.2
Particulars of pipes, joints and fittings

(a)
The following particulars of the proposed pipes, joints and fittings for water
supply pipeworks shall be submitted to the Project Manager for review without
objection:
(i)
manufacturer's literature, including details of:

manufacturing process;
pressure and temperature ratings;
permissible values of straight draws and angular deflection of
flexible joints;
re-commendations for handling, storage, laying, jointing and repair;
and
drilling and tapping equipment for connections to pipes;
(ii)
a certificate for each material showing the manufacturer's name, the

date and place of manufacture and showing that the material complies
with the requirements stated in the Contract and including results of
tests required in accordance with the relevant British Standard;
(iii)
three copies of Contractors Drawings showing details of the pipes,

joints and fittings, including the materials used and the mass of each
item; and
(iv)
a certificate of inspection of the manufacture and testing signed by the

independent inspection authority reviewed without objection by the
Project Manager.

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January 2011
14.4.3
Particulars of pressure tests

(a)
14.4.4
The following particulars of the proposed procedures for pressure tests on

pipelines for water supply pipeworks shall be submitted to the Project
(i)
test equipment and method of setting up the equipment;
(ii)
calibration certificates for pressure gauges;
(iii)
procedure for carrying out the test; and
(iv)
programme for testing.
Particulars of Anticorrosion tape

The following particulars of the proposed anticorrosion tape for water supply
pipeworks shall be submitted to the Project Manager:
(a)
manufacturers literature for anticorrosion tape; and
(b)
certificate for anticorrosion tape showing the manufacturers name, the date
and place of manufacture and showing that the material complies with the
requirements stated in the Contract and including results of tests in
accordance with the Contract.
14.5
WORKMANSHIP
14.5.1
Access to pipelines
14.5.2
(a)
Rubber wheeled trolleys shall be provided to obtain access inside pipelines

exceeding DN 500 for water supply pipeworks in order to joint pipes, repair
joints, coatings and linings and inspect the pipeline. Persons entering
pipelines shall wear clean soft-soled footwear.
(b)
Mechanical fans shall be provided to ensure that an adequate air supply is

available to those entering pipelines for inspection. Engine driven fans shall
be fitted with a flexible exhaust or other methods of keeping exhaust fumes
clear of the fresh air intake.
Laying pipes
(a)
The Contractor shall notify the Project Manager before pipelaying starts in any
part of the Permanent Works.
(b)
The Contractor shall inspect pipes, joints, fittings and valves, including internal
and external coatings, immediately before and after pipelaying; valves shall
be inspected to ensure that they are in working order and are capable of
being fully opened and closed. Deleterious material shall be removed and
damage shall be repaired immediately before and after pipelaying; potable
water shall be used for washing.

10/23
January 2011
14.5.3
(c)
The inside of pipelines shall be kept clean and free from water, dirt, stones,
debris and deleterious material. Except when pipes are being jointed, the
open ends of pipelines shall be sealed with a wooden plug or stopper.
(d)
Measures shall be taken to prevent flotation of pipes.
(e)
Pipelaying shall follow closely on excavation of the trench. Lengths of trench

which in the opinion of the Project Manager are excessive shall not be left
open.
(f)
Pipelines with a gradient steeper than 1 in 20 shall be laid in an uphill

direction with sockets facing uphill.
(g)
Pipes shall be laid in such a manner that water will not pond in locations with
either zero or shallow gradients, and the line and level of pipes shall comply
with the specified tolerances.
Laying pipes with flexible joints

The degree of the curve of pipes for water supply pipeworks with flexible joints
which are to be laid to a curve shall be equally distributed over all joints within the
curved section. The deflection at a completed joint shall not exceed 3 or
three-quarters of the maximum deflection recommended by the manufacturer
whichever is less.
14.5.4
14.5.5
14.5.6
Installation of valves
(a)
Operating gear and associated fittings shall be installed and fixed at the same
time as valves, for water supply pipework, are installed. After installation,
valves shall be cleaned inside and outside and left in a closed position.
(b)
Extension keys and clamps shall be fixed to valves in valve chambers if the
vertical distance between the top of the valve spindle and the finished ground
level exceeds 600 mm. The length of extension keys shall be such that the
top of the extension key is not more than 300 mm below the finished ground
level.
Bedding pipes
(a)
Surfaces on which pipes for water supply pipeworks will be laid shall be
cleaned and objects which may damage the pipes shall be removed before
pipes are laid.
(b)
The bottom of trenches on which pipes will be laid directly shall be shaped to
support the pipes uniformly along the length of the barrel; holes shall be dug
to prevent pipes resting on the sockets and to allow the pipes to be jointed.
Cutting pipes
(a)
Pipes for water supply pipeworks shall be cut and the ends shall be prepared
in accordance with the manufacturer's recommendations. Pipes shall be cut
using purpose made equipment recommended by the manufacturer and

11/23
January 2011
14.5.7
(b)
Cut ends of pipes shall be square and even, without damage to the pipe or
coating. Cut ends, including cut ends of the piece not immediately required,
shall be trimmed and chamfered to suit the type of joint and in such a manner
that elastomeric joint rings will not be damaged by the cut end.
(c)
Pipes requiring to be cut to form closing lengths shall not be cut until adjacent
pipes have been laid and jointed and the length to be cut can be accurately
measured.
Drilling pipes
Drilling in water pipelines for pipe connections shall be prohibited..
14.5.8
Jointing pipes
(a)
Pipes for water supply pipeworks shall be jointed in accordance with the
manufacturer's recommendations and using jointing equipment and jointing
materials recommended by the manufacturer and reviewed without objection
(b)
The Contractor shall inspect pipes, joints, fittings and valves, including internal
and external coatings, immediately before and after jointing. Deleterious
material shall be removed and damage shall be repaired immediately before
and after jointing; potable water shall be used for washing. Surfaces which
are to be jointed and jointing materials shall be cleaned immediately before
jointing.
(c)
All joints in pipelines shall be watertight.
(d)
The widths of gaps at joints shall be in accordance with the manufacturer's

recommendations and shall be achieved by marking the outside of the pipe or
by using metal feelers. The position of elastomeric joint rings shall be
checked by using metal feelers after jointing.
(e)
Gaps at joints in pipes shall be protected after jointing by methods reviewed

without objection by the Project Manager to prevent dirt, stones or other
material entering the joint.
(f)
Bolt holes in flanged joints and joints incorporating bolted components shall
be correctly orientated before the bolts are tightened. The correct size of bolts
and nuts shall be used. Bolt threads shall be lubricated and bolts shall be
tightened using the correct size of spanner. Bolts shall be tightened in
diametrically opposite pairs working around the bolt circle until all bolts are
tightened to the torque recommended by the manufacturer.
(g)
Bolt holes in flanged joints shall be orientated symmetrically about the vertical
diameter with no bolt holes on the vertical diameter. Elastomeric joint rings
shall be the correct size and shall not protrude into the bore of the pipe. The
rings may be temporarily fixed to the face of the flange using a minimum
amount of adhesive of a type recommended by the manufacturer; jointing
compound or paste shall not be used.

12/23
January 2011
14.5.9
DI pipes with push-in joints

DI pipes with push-in joints for water supply pipeworks shall be jointed by smearing
the spigot end of the pipe with lubricant and placing the elastomeric joint ring in
position inside the groove of the socket end of the laid pipe. The spigot end of the
pipe shall be placed in the socket end of the laid pipe and pushed home.
14.5.10 DI pipes with mechanical joints

(a)
DI pipes with mechanical joints for water supply pipeworks shall be jointed as
stated in Clauses 14.5.10(b) to (d).
(b)
The elastomeric joint ring and the ends of the pipe shall be smeared with
lubricant over a distance recommended by the manufacturer.
(c)
The gland and the elastomeric joint ring shall be placed in position on the
spigot end of the pipe.
(d)
The spigot end of the pipe shall be placed in the socket end of the laid pipe
before the bolts are tightened.
14.5.11 Repairs to joints, coatings and linings

(a)
Joints and damage to coatings and linings of pipes, joints and fittings for water
supply pipeworks shall be repaired as stated in Clauses 14.5.11 to 14.5.13.
(b)
Repairs to joints, coatings and linings shall be carried out using materials of
the same type and grade as in the pipe, joint or fitting.
(c)
External repairs shall be completed before internal repairs are carried out.
(d)
Internal repairs and adjacent areas shall be washed with potable water after
the repair is complete.
14.5.12 Repairs to DI pipes with bitumen coatings

Internal and external repairs to joints and coatings of DI pipes with bitumen coatings
shall be carried out using bituminous paint. The area to be repaired shall be
cleaned to bare metal and dried. The area to be repaired shall be painted with
bituminous paint to the same thickness as the adjacent coating; the paint shall be
finished to a smooth uniform surface.
14.5.13 Internal repairs to DI pipes with cement mortar lining
(a)
Internal repairs to joints and linings of DI pipes with cement mortar linings
shall be carried out as stated in Clause 14.5.13(b) to (d).
(b)
The area to be repaired shall be cut back to leave clean, bright metal. The
area surrounding the area to be repaired shall be wetted.

13/23
January 2011
(c)
The cement mortar shall be worked into the area to be repaired and
compacted to the same thickness as the adjacent lining; the cement mortar
shall be finished to a smooth uniform surface. The repaired area shall be
cured with curing compound as stated in Clause 20.5.6.
(d)
The inside of pipe sockets and the faces of flanges shall be kept free from
cement mortar.
14.5.14 Thrust and anchor blocks

(a)
The bearing face, and other faces stated in the Contract, of concrete thrust
and anchor blocks for water supply pipeworks shall be cast directly against
undisturbed ground; the faces of excavations shall be trimmed to remove
loose material before concreting. Excess excavation and working space shall
be filled with concrete of the same grade as the block.
(b)
Internal pressure shall not be applied to the pipeline until thrust and anchor
blocks have developed the specified grade strength.
14.5.15 Concrete bed, haunch and surround

(a)
Concrete bed, haunch and surround to pipelines for water supply pipeworks
shall be constructed as stated in Clause 14.5.15(b) to (e).
(b)
Pipes shall be supported at the required level by Grade 20 precast concrete

wedges, blocks or cradles. One support shall be placed adjacent to each end
of each pipe and the spacing between supports shall not exceed 3 m.
Compressible sheeting shall be placed between the pipes and supports.
(c)
Flexible joints shall be formed in concrete bed, haunch and surround at

flexible joints in pipelines. Joint filler shall be placed next to the flexible joint in
the pipeline and shall extend for the complete thickness of the bed, haunch
and surround.
(d)
Polyethylene sheeting shall be placed on the trench bottom before concreting.
(e)
Concrete shall be placed evenly over the complete width of the bed and over
the complete length of the pipe being concreted up to a level of 25 mm below
the underside of the pipe. Concrete shall then be placed on one side of the
pipe only and worked under the pipe until the concrete spreads under the
pipe. Concrete shall then be placed equally on both sides of the pipe to the
specified level.
14.5.16 Tolerances : pipelines

The line and level of pipelines for water supply pipeworks shall be within 25 mm of
the specified line and level.
14.5.17 Tolerances : manholes and chambers
The finished level of manholes and chambers shall be within 5mm of the specified
level.

14/23
January 2011
14.6
14.6.1
Inspection of manufacture and testing
14.6.2
14.6.3
14.6.4
(a)
The manufacture and testing of pipes, joints, fitting and valves for water
supply pipeworks shall be inspected by an independent inspection authority
(b)
The inspections shall be carried out at the manufacturer's works or at other

locations stated in the Contract or directed by the Project Manager. The
facilities and equipment required for inspections shall be provided by the
Contractor.
Pipe jointing trials

(a)
Trials shall be carried out to demonstrate that the pipes, joints and fittings for
water supply pipeworks fit correctly.
(b)
The trials shall be carried out at least 6 weeks before the materials are
proposed to be incorporated in the Permanent Works.
(c)
The Contractor shall notify the Project Manager before carrying out trials.
(d)
The Contractor shall immediately notify the Project Manager of any pipes,
joints or fittings which do not fit correctly. Modifications shall be made to
pipes, joints and fittings which do not fit correctly or replacements shall be
provided as directed by the Project Manager.
Trials for drilling and tapping

(a)
Trials shall be carried out to demonstrate that the proposed equipment and
methods of drilling and tapping pipes for water supply pipeworks will produce
connections which comply with the specified requirements.
(b)
The trials shall be carried out at least 14 days before drilling and tappingis
programmed to commence.
(c)
The Contractor shall notify the Project Manager before carrying out trials.
Polyethylene pipe manufacturing quality control

(a)
For quality control on manufacturing of the pipes, the following tests listed in
ISO 4427 shall be subject to inspection by the independent inspection
authority:
(i)
Clause 3.3;
(ii)
Clause 3.7 melt flow rate test only;
(iii)
Clauses 4.1 and 4.2;
(iv)
Clause 5.1 100 hour at 20C and 165 hour at 80C only; and
(v)
Clause 6.3(b).

15/23
January 2011
(b)
(c)
14.6.5
14.6.6
For quality control on manufacturing of the compression fittings, the following

tests listed in ISO 14236 shall be subject to inspection by the independent
inspection authority:
(i)
Clause 6.1; and
(ii)
Clauses 8.3.4.2 and 8.3.4.3.
Polyethylene materials for both PE80 and PE100 shall be tested in

accordance with the Chlorine Water Test specified in Clause 9.8 of the
Japanese Industrial Standard (JIS) K6762 and the performance of the
polyethylene materials shall comply with the chlorine-water resistance for
single wall pipe specified in Clause 5 of the JIS K6762. Test certificates shall
Sampling polyethylene pipes

(a)
Sampling procedures for inspection shall be in accordance with BS6001 : Part

1 unless specified otherwise and shall meet the following requirements:
(b)
Sample size for dimensional, appearance, casting quality and BS21 threading
checks on pipe materials shall be determined in accordance with BS6001 :
Part 1 at Inspection Level II for single sampling plan. Materials from different
sources shall be sampled as isolated batches. Normal inspection shall be
used at the start of inspection. Inspection may be switched to tightened or
reduced inspection and switched back to normal inspection in accordance
with the procedures stipulated in Clause 9.3 of BS6001:Part 1. Acceptable
Quality Level (AQL) shall be 4.0.
(c)
For material and marking checks, one sample shall be selected from each
type and size of pipe materials in each batch. Materials from different sources
shall be sampled as isolated batches.
Testing Polyethylene Pipes

(a)
Water/Hydrostatic Pressure Test

(i)
Notwithstanding Clause 6.1 of BS6001 : Part 1, each batch shall, as far

as practicable, consist of units of pipes of a single type, grade, class and
composition, of different sizes, manufactured under essentially the same
conditions, and at essentially the same time. Two samples shall be
selected from each size of the pipes in each batch.
(ii)
Duration of tests shall be in accordance with the relevant specification.
(iii)
Tests shall be witnessed before any finishing treatment.
(iv)
Acceptance criteria shall be no failure of witnessed water/hydrostatic

pressure tests.

16/23
January 2011
14.6.7
Testing Polyethylene Fittings

(a)
14.6.8
Water/Hydrostatic Pressure Test

(i)
Notwithstanding Clause 6.1 of BS6001 : Part 1, each batch shall, as far

as practicable, consist of units of pipes of a single type, grade, class and
composition, of different sizes, manufactured under essentially the same
conditions, and at essentially the same time. Two samples shall be
selected from each size of the pipes in each batch.
(ii)
Duration of tests shall be in accordance with the relevant specification.
(iii)
Tests shall be witnessed before any finishing treatment.
(iv)
Acceptance criteria shall be no failure of witnessed water/hydrostatic

pressure tests.
Cleaning and sterilisation of pipelines

(a)
Fresh water and potable water pipelines for water supply pipeworks shall be
cleaned and flushed through with potable water. Cleaning and flushing shall
be carried out:
(i)
(ii)
before and after the complete pipeline, or part thereof permitted by the
Project Manager, has been tested;
after the Temporary Works required for testing have been removed; and
(iii)
after parts of the pipeline removed for testing have been reconnected.
(b)
The pipeline shall be completely filled with water that has been dosed with a
homogeneous solution of sterilising chemicals such that the final
concentration of free chlorine in the water is at least 30 ppm. The water shall
be left in the pipeline for at least 24 hours.
(c)
After the 24 hour period, the pipeline shall be drained down and the sterilising
water shall be flushed out using potable water until the concentration of the
remaining chlorine is less than 1 ppm.
(d)
Pipelines shall be cleaned and sterilised not more than 7 days before the
application for Completion Certificate.
(e)
Swabbing shall be carried out to the pipes not exceeding DN600.

17/23
January 2011
(f)
Swabs shall be of a proprietary brand obtained from a manufacturer reviewed

without objection by the Project Manager and used in accordance with the
manufacturer's instructions. They shall be of a compressible hard grade
polyurethane foam in cylindrical shape and shall have the following diameters:
DN OF PIPE
Diameter of Swab
Up to 300 mm
Pipe DN + 25%
Above 300 mm
Pipe DN + 75 mm
Swabs shall be suitable for clearing out new pipelines and removing dirt and
materials inadvertently left in the pipeline during construction. Swabs may be
fitted with a signalling device to enable the swab to be located within the
pipeline.
(g)
The Contractor shall be responsible for the supply of water to the place where
swabbing work is required and if necessary, pressurize the water to a level
sufficient for the swabbing work.
(h)
The swab shall be inserted into a short plain ended pipe at ground level
adjacent to the trench and the pipe shall then be fitted, by means of flange
adaptors, into position in the pipeline between two gate valves which shall then
be opened to allow the swab to pass through the pipeline.
(i)
The swab shall be fully immersed in water during the entire operation using
water as the driving medium. Foam swabs shall not be air driven and the water
must not drain away from the swab on downhill sections. The velocity of the
swab, which shall be controlled by the rate of flow of water downstream of the
swab, shall be kept within a range of 300 mm/sec to 1200 mm/sec.
(j)
All air valves and valves on tees/branches from the pipeline shall be closed
before swabbing work commences.
(k)
At least 14 days before the swabbing operation is to be carried out, the

Contractor shall submit the following information for review without objection by
the Project Manager:
(i)
Name and address of supplier of swab,
(ii)
Place and name of manufacturer,
(iii)
Type and grade of swab,
(iv)
Manufacturer's recommended instructions for use,
(v)
Details of previous applications of the proposed type of swab,
(vi)
Programme and details of swabbing operation, and
(vii)
Means of recovering swab from pipeline at the end of the swabbing run.

18/23
January 2011
14.6.9
Testing: pressure pipelines for water supply pipeworks

(a)
Pressure pipelines for water supply pipeworks shall be tested as stated in

Clause 14.6.9(b) to (f).
(b)
The pipeline shall be tested in sections as stated in the Contract unless

otherwise permitted by the Project Manager; if testing in sections other than
those stated in the Contract is permitted, the section to be tested shall be as
long as practicable provided that the specified test pressure will not be
exceeded. Final tests on complete pipelines which have been tested in
sections shall not be carried out unless stated in the Contract.
(c)
The test pressure shall be as stated in the Contract. If the test pressure is not
stated in the Contract, the test pressure shall be:
(i)
1.5 times the maximum working pressure if the maximum working

pressure does not exceed 1.5 Mpa; or
(ii)
1.3 times the maximum working pressure if the maximum working

pressure exceeds 1.5 MPa.
(d)
Unless otherwise permitted by the Project Manager, pressure tests shall not
be carried out until fill material has been deposited and compacted over the
complete length of the pipeline to be tested; if permitted, sufficient fill material
shall be deposited to restrain the pipeline in position during the test.
(e)
Tests shall not be carried out simultaneously on pipelines in the same trench.
(f)
(g)
The pipeline shall be left charged with water at a head of at least 15 m after
testing and until the pipeline has been sterilized.
14.6.10 Compliance criteria: pressure pipelines for water supply pipeworks

The results of tests on pressure pipelines for water supply pipeworks shall comply
with the following requirements:
(a)
the leakage of water from the pipeline determined by the pressure test shall
not exceed the permitted leakage calculated in accordance with
Clause A14.1.4 in Appendix A14.1; and
(b)
there shall be no discernable leakage of water from the pipeline or from any
joint during the pressure test.
14.6.11 Non-compliance: pressure pipelines for water supply pipeworks

If the result of any test on pressure pipelines for water supply pipeworks does not
comply with the specified requirements for the test, the Contractor shall investigate
the reason. Remedial or replacement work reviewed without objection by the
Project Manager shall be carried out and the pipeline shall be retested.

19/23
January 2011
14.6.12 Testing: water sterilisation

After the pressure test on fresh water and potable water pipelines have been
completed, samples of the water in the pipelines shall be taken by the Contractor in
the presence of the Project Manager. The number of samples and locations of
sampling shall be as directed by the Project Manager. Testing shall be carried out
as stated in Clauses 24.6.11 to 24.6.12 for water sterilisation of water retaining
structures. The colour, odour, appearance, turbidity, conductivity, free residual
chlorine, E.Coli, total coliforms, total bacterial count and pH values of the water
samples shall be tested to demonstrate the quality of each sample of water is
comparable to that drawn from the supply point and the results shall be reviewed

20/23
January 2011
APPENDIX A14.1
PRESSURE TESTS ON PIPELINES
A14.1.1 Scope
This method covers the determination of the leakage of water from pipelines for
water supply pipeworks by means of a pressure test.
A14.1.2 Equipment
The following equipment is required:
(1)
blank flanges or caps;
(2)
struts and wedges;
(3)
temporary concrete blocks or other anchors;
(4)
force pump and pump feed tank;
(5)
pressure gauge, readable and accurate to 0.01 m head; and
(6)
continuous pressure recorder and purpose made charts.
A14.1.3 Procedure
(1)
pipes and valves shall be checked for cleanliness and the operation of valves
shall be checked;
(2)
blank flanges or caps shall be fixed to the ends of the pipeline, or section of
the pipeline, to be tested. Tests shall not be made against valve gates;
(3)
the blank flanges and caps shall be secured with struts and wedges against
temporary concrete blocks or other anchors. The blocks and anchors shall be
completed and shall have hardened sufficiently before testing starts;
(4)
thrust and anchor blocks, pipe straps and other devices required to prevent
movement of pipes and fittings shall be completed before testing starts;
(5)
the pipeline shall be filled with water and all air shall be removed;
(6)
the pipeline shall remain filled for 3 days before testing starts to allow
absorption to take place and to achieve conditions which are as stable as
practicable;
(7)
the pressure in the pipeline shall be increased slowly to the specified test
pressure by pumping water into the pipeline using a force pump;
(8)
the pressure in the pipeline shall be maintained within +0% and -5% of the
specified test pressure for a test period of at least 2 hours;

21/23
January 2011
(9)
at the beginning and end of the test period and at 30 minute intervals during
the test period, readings shall be taken from the pressure gauge and the
pressures (p) shall be recorded. The pressure shall be adjusted to the
specified test pressure each time a reading is taken;
(10) the pressure shall be adjusted to within the specified tolerances for the test
pressure at any time during the test period if the pressure falls outside the
specified tolerances;
(11) the pressure shall be monitored during the test by means of a continuous
pressure recorder with purpose made charts; and
(12) the leakage of water from the pipeline shall be measured as the amount of
water required to maintain the specified test pressure in the pipeline; the
amount of water shall be determined from the fall in level of water in the pump
feed tank.
A14.1.4 Calculation
(1)
The average test pressure (P) shall be calculated as the average of the
pressures (p) recorded during the test.
(2)
The permitted leakage of water from the pipeline during the pressure test
shall be calculated from the equation:
t
P
Permitted leakage = 0.02 x d x l x
x
litre
24
10
where:
- d is the nominal diameter of the pipe (mm)
- l is the length of pipeline tested (km)
- t is the test period (hr)
- P is the average test pressure (m)

(1)
the internal diameter of the pipe to the nearest 1 mm;
(2)
the length of pipeline tested to the nearest 1 m;
(3)
the test period to the nearest 0.01 hr;
(4)
the pressures recorded during the test to the nearest 0.01 m;
(5)
the average test pressure to the nearest 0.01 m;
(6)
the leakage and permitted leakage of water to the nearest 0.1 litre;

22/23
January 2011
(7)
details of any discernable leakage of water from the pipeline during the test;
(8)
charts obtained from the continuous pressure recorder; and
(9)

23/23
January 2011
SECTION 15
NOT USED

Section 15 Not Used
1/1
January 2011
SECTION 16
NOT USED

Section 16 Not Used
1/1
Janaury 2011
SECTION 17 PILING WORKS
17.1
GENERAL
17.1.1
(a)
(b)
(c)
(d)
Materials for grout for piling works shall comply with Section 20.
(e)
Grouting for piling works shall comply with Section 21.
(f)
Prestressing shall comply with Section 21.
(g)
17.2
17.2.1
Barrette
A barrette is a pile formed by excavation using grabs and chisels through a
thixotropic suspension of bentonite or other agent which supports the sides of the
shaft as excavation proceeds, and which is concreted in one continuous operation.
17.2.2
Bored Piles
Bored piles are cast-in-situ concrete piles formed by boring or grabbing. Piles with a
diameter 600 mm or less are commonly referred to as small diameter piles, while
piles with a diameter greater than 600 mm are referred to as large diameter piles.
17.2.3
Minipiles
A minipile is a pile with a diameter of less than 400 mm in which the load bearing
element consists of one or more steel reinforcement bars. Permanent steel casing
above rockhead level is used to contain the grout.
17.2.4
Rock-Socketted Steel H-piles

A rock socketted steel H-pile is a pile formed by inserting a steel H-pile in a prebored hole sunk into Grade III or better rock, with a temporary steel casing above
the rock head level and subsequent filling of the holes with cement grout.
17.2.5
Driven Steel H-piles

A driven steel H-pile is a H-section steel pile installed by percussive methods.
Materials & Workmanship Specification

Section 17 Piling Works
1/40
January 2011
17.2.6
Continuous Flight Augur Piles

A continuous flight augur pile is a pile formed by a flight augur and subsequent
pressurized injection with cement-sand grout through the augurs stem as it is being
withdrawn.
17.3
17.3.1
Regulations, Codes of Practice, Design and Quality Supervision Guidelines

and Site Safety Supervision
Piling works shall comply with the Building (Construction) Regulations of Hong
Kong, Practice Notes for Authorised Persons and Registered Structural Engineers
(PNAP) and other codes and standards set out below.
17.3.2
Pile Caps
Pile caps shall comply with the Hong Kong Code of Practice for the Structural Use of
Concrete in respect of all materials and workmanship for reinforced concrete pile
caps and for structural concrete above piles. Where BS 8110 is used, specific
requirements as specified in PNAP 187 shall be followed. Editions of BS 8110 other
than the 1985 version shall not be used unless otherwise reviewed without objection
17.3.3
Safety of Piling Works

Piling works shall comply with the following;
17.3.4
(a)
Code of practice for site safety supervision
(b)
Technical memorandum for site safety
(c)
BS 8004: Code of practice for foundations
(d)
BS 5573: Code of practice for safety precautions in the construction of large

diameter boreholes for piling and other purposes
Specialist Foundation Contractor

All piling works shall be carried out by a Registered Specialist Contractor
(Foundation Works) under the Buildings Ordinance except where exempted in
PNAP 214.
17.4
MATERIALS
17.4.1
Steel Piles
(a)
Steel bearing piles shall be of a proprietary section reviewed without objection

(b)
Steel sheet piles shall be of a proprietary section reviewed without objection


2/40
January 2011
17.4.2
17.4.3
(c)
Steel bearing piles and steel sheet piles shall be manufactured from Grade
50B steel and comply with BS 4360 and BS 5950:Part 2.
(d)
Steel pipe piles shall comply with BS 3601 or BS 6232:Parts 1 and 2, except
for the requirements of hydraulic pressure tests.
(e)
All steel piles shall be free from loose scale and rust.
Pile Shoes
(a)
Pile shoes for driven cast-in-place piles shall be manufactured from durable
materials capable of withstanding driving stresses without damage. The shoes
shall be designed to provide a watertight joint with permanent casings.
(b)
Cast steel pile shoes for steel bearing piles shall be manufactured from steel
complying with BS 3100, Grade A.
(c)
Welded fabricated pile shoes for steel bearing piles shall be manufactured
from steel complying with BS 4360, Grade 43A.
Epoxy Paint
Epoxy based paint for epoxy coatings to steel piles shall be a proprietary type
17.4.4
Bituminous Coating Material

Bituminous coating material for steel piles shall be hot-applied filled or unfilled
bituminous material complying with BS 4147.
17.4.5
Grout for Piling Works

(a)
Grout for piling works shall consist of OPC and water. Sand, PFA and
admixtures may be used subject to review without objection by the Project
Manager.
(b)
The minimum cementitious content of grout shall be 600 kg/m3.
(c)
Grout used to fill core holes shall be non-shrink grout and have a minimum
characteristic compressive strength of not less than the specified grade
strength of the concrete surrounding the core hole.
(d)
Grout used to fill minipiles and pre-bored rock socketted steel H-piles shall be
non-shrink grout and have a minimum characteristic compressive strength of
30 MPa at 28 days.
(e)
Water used in the grout must be clean and fresh with a temperature not
exceeding 30C nor less than 5C.
(f)
The maximum amount of bleeding of grout shall not exceed 2% in the first 3
hours and shall not exceed 4% in total; the water shall be reabsorbed by the
grout during the 24 hours after mixing.
(g)
Free expansion of grout shall not exceed 10% at the ambient temperature.

3/40
January 2011
17.4.6
(h)
The chloride ion content of admixtures for concrete containing embedded

metal or for concrete made with SRPC shall not exceed 2% by mass of the
admixture or 0.03% by mass of the cementitious content, whichever is less.
(i)
The maximum total chloride content of grout, expressed as a percentage

relationship between the chloride ion and the cementitious content by mass in
the grout, shall not exceed 0.1%.
(j)
Admixtures shall be chloride free and comply with BS 5075 and shall be
submitted for review without objection by the Project Manager before use.
Reinforcement Connectors
(a)
Reinforcement connectors shall be of a proprietary type reviewed without

(b)
Connectors shall be capable of transmitting the total pile load in tension or

compression as appropriate.
(c)
Connectors for tension joints shall be:
(d)
17.4.7
17.4.8
(i)
cold swaged or threaded type;
(ii)
capable of developing the full tensile strength of the parent bar; and
(iii)
comprised of high tensile studs and seamless steel tubes fitted with
protective plastic caps.
Connectors for compression joints, shall be wedge locking, bolted sleeve type.
Surface Treatment of Steel Piles

(a)
Surface preparation and application of protective coatings other than

bituminous coatings to steel piles shall be carried out in a fully enclosed wellventilated workshop.
(b)
The method of application of protective coatings to steel piles, the ambient

temperature and humidity at the time of application and the time interval
between the application of successive coats shall be in accordance with the
manufacturer's recommendations. The complete coating shall be applied in
and around clutches.
Surface Preparation of Steel Piles

The surfaces of steel piles to which protective coatings will be applied shall be
prepared by blast cleaning to either:
(a)
second quality of surface finish in accordance with BS 4232; or
(b)
Sa21/2 in accordance with Swedish Standard SIS 05 59 00.

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17.4.9
Epoxy Coatings to Steel Piles

(a)
Epoxy coatings to steel piles shall consist of three coats of epoxy based paint,
each coat having a minimum dry film thickness of 75 m. The first coat shall
be applied within two hours of blast cleaning.
(b)
The finished surface of epoxy coatings shall be smooth with a dense and
uniform texture and shall be free from sharp protuberances and pinholes. The
thickness and continuity of completed epoxy coatings shall be measured using
a magnetic thickness gauge.
(c)
Damaged areas of epoxy coatings shall be repaired by cleaning the damaged

areas to bare metal, feathering back the adjacent areas with coarse grade
sand-paper and re-applying the coatings.
17.4.10 Bituminous Coatings to Steel Piles

(a)
Bituminous coating material, or primer if the bituminous coating consists of a

built-up system, to steel piles shall be applied within two hours of blast
cleaning. The thickness of bituminous coatings shall be at least 300 m.
(b)
Damaged areas of bituminous coatings shall be cleaned back and overcoated

with the same bituminous coating material to restore the specified thickness.
(c)
Steel H-piles shall be protected with a bituminous coating for eight (8) metres
below cut-off level.
17.4.11 Surface Treatment of Extended Steel Piles

The splice areas of steel piles which are extended in-situ shall be prepared by blast
cleaning prior to splicing. The protective coating shall be re-applied to the splice
area before the piles are driven.
17.4.12 Removal of Protective Coatings to Steel Piles
Protective coatings shall be removed from the heads of steel piles which will be
encased in concrete by blast cleaning or flame cleaning. The coatings shall be
removed to a level of 75 mm above the underside of the concrete into which the pile
will be encased.
17.4.13 Handling and Storage of Piles
(a)
The identification number, grade of steel and length of pile shall be marked on
steel piles.
(b)
Piles shall be stored horizontally off the ground on level supports and in a
manner which will not result in damage to the coatings. Bituminous coated
piles shall not be stacked.
(c)
Different types and sizes of piles shall be stored separately.

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17.4.14 Handling and Storage of Bentonite

Bentonite shall be handled and stored in a manner which will not result in spillages
on Site. It shall be stored in cool dry conditions and particular care shall be taken
with bulk storage to prevent balling of the bentonite powder due to damp, or
deterioration of properties due to damp and heat.
17.5
SUBMISSIONS
17.5.1
Particulars of Piling Works

(a)

construction for piling works shall be submitted to the Project Manager for
(i)
details of Contractor's Equipment;
(ii)
methods and sequence of installation of piles, including methods of

avoiding damage to adjacent piles, structures and utilities and measures
to be taken to deal with hard material and obstructions;
(iii)
details of material for steel piles, including mill certificates;
(iv)
calculations of driving stresses;
(v)
methods of jointing and lengthening piles;
(vi)
details of reinforcement splices;
(vii) methods of controlling groundwater, or groundwater treatment;

(viii) anticipated ground vibration, ground movement and groundwater
drawdown, methods of instrumentation and monitoring, and details of
monitoring and measurement instrumentation;
(ix)
methods and sequence of excavation, including methods of supporting

excavations and of cleaning the excavation;
(x)
methods of concreting or grouting;
(xi)
details of protective coatings to steel piles, including manufacturers'

literature;
(xii) details of preliminary piles; and

(xiii) methods of testing , including details of the specialist firm, independent
from the Contractor, proposed to carry out non-destructive testing of
welds and the programme for integrity testing.

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17.5.2
Particulars of Construction using Bentonite Slurry

(a)

construction using slurry containing bentonite or other similar agent shall be
(i)
a certificate for bentonite showing the type, the manufacturer's name,

the date and place of manufacture and including details of the apparent
viscosity range in Pa.s and the gel strength range in N/m2 for solids in
water;
(ii)
characteristics of the bentonite slurry in a freshly mixed condition and in

the excavation immediately before concreting;
(iii)
methods of quality control, sampling, testing, mixing, storing,

recirculating, removing silt and sand, preventing spillages and disposal
from Site;
(iv)
head of bentonite slurry, including stability calculations;
(v)
details of guide walls;
(vi)
methods of placing concrete by tremie; and
(vii) sequence of construction.

17.5.3
Particulars of Minipiles
(a)

construction for minipiles shall be submitted to the Project Manager for review
without objection:
(i)
details of pile head, reinforcement and permanent steel casing including

spacers and couplings;
(ii)
details of grout mix as stated in Clause 21.4.3 including fine aggregate

and admixtures as appropriate;
(iii)
sequence and timing of grouting, including details of secondary pressure

grouting;
(iv)
method of installation including equipment to be used, sequence of

operations, drilling methods, casing installation and time of grouting; and
(v)
minimum length of rock socket for each pile.

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17.5.4
Particulars of Rock-Socketted Steel H-piles in Pre-Bored Holes

(a)
17.5.5

construction for rock-socketted steel H-piles shall be submitted to the Project
(i)
details of pile head, steel H-pile and the external casing, including splice
joint and welding details;
(ii)

(iii)

grouting;
(iv)

(v)
minimum length of rock socket for each pile.
Particulars of Continuous Flight Auger Piles

(a)

construction for continuous flight auger piles shall be submitted to the Project
Manager for review:
(i)
details of reinforcement including spacers and couplings;
(ii)

(iii)

grouting;
(iv)

(v)
length of piles when designed as friction piles or rock socket detail when
designed as end bearing piles.
17.6
WORKMANSHIP
17.6.1
Commencement of Piling Works

Piling works, including groundwater control and ground treatment for piling works,
shall not commence until:
(a)
Site Safety Supervision Plan and Quality Supervision Plan as stipulated in

the PNAP 242 are submitted to the satisfaction of the Buildings Department
and the Project Manager;

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17.6.2
(b)
consent to the commencement of piling works has been given by the Buildings
Department; and
(c)
proposed materials and methods of construction, including construction and

testing of preliminary piles, have been reviewed without objection by the
Project Manager.
Prevention of Damage due to Piling Works

(a)
Piling works shall not damage any structure, utility service or previously
installed pile. The position of existing utilities shall be determined and
underground utilities adjacent to the piles shall be exposed or otherwise
accurately located before piling works start.
(b)
All necessary measures shall be taken to minimise the settlement of the

ground and adjacent structures and utilities and to prevent the formation of
cavities in the ground resulting from piling works.
(c)
The vibrations due to piling works at previously installed piles measured in

terms of peak particle velocity shall not exceed 25 mm/s.
(d)
The vibrations due to piling works at other structures and installations in terms
of peak particle velocity shall not exceed the values stated in Table 17.1 or
such limits imposed by the Project Manager or the Buildings Department.
(e)
Instruments for monitoring purposes shall be installed as required by the

Project Manager and the Buildings Department prior to commencement of
piling works.
Table 17.1 : Restrictions on Peak Particle Velocity

Type of structure or installation
17.6.3
Peak particle velocity (mm/s)
Water retaining structures
13
Water mains
25
Passenger terminal complex
15
Sha Lo Wan directional beacon
For all other structures
25
Monitoring of Noise, Vibration, Ground Movement and Groundwater Level

(a)
Measurements of noise level, vibration, ground movement and groundwater

level shall be taken when piling works are being carried out, at locations and
time intervals as stated in the Contract or as proposed by the Contractor and
reviewed without objection by the Project Manager. Records of the
measurements shall be kept on Site by the Contractor, and a copy of the
records submitted to the Project Manager for review. The Contractor shall
submit a copy of the records to the Buildings Department as necessary.
Arrangements for installing instruments and taking measurements both inside
and outside the Site shall be made by the Contractor.
(b)
Measurements of noise level and vibration shall be made with instruments of a

type reviewed without objection by the Project Manager.

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17.6.4
(c)
Sufficient numbers of piezometers and survey points shall be installed to allow

the changing groundwater levels and the effects on structures, utilities and
previously installed piles to be measured. Measurements shall be taken at
regular intervals as specified in the Contract when groundwater control is
carried out and until such time as the groundwater has resumed its natural
regime.
(d)
The Contractor shall inform the Project Manager immediately of any

unanticipated change in measurements.
(e)
If the specified limits on vibration, groundwater movement or groundwater

level are exceeded, the work causing the limits to be exceeded shall be
stopped immediately and particulars of proposed changes to the methods of
construction shall be submitted to the Project Manager for review without
objection. Work shall not recommence until the revised methods have been
Ground Investigation for Piling Works

(a)
Prior to the commencement of piling, pre-drilling of boreholes of minimum Nx

size shall be sunk by a Registered Specialist Contractor (Ground Investigation
Field Work) in accordance with PNAP 66, PNAP 132, PNAP 242 and all other
relevant PNAPs to determine the soil and/or rock characteristics and to
determine the appropriate founding level of non-displacement cast-in-situ
piles.
(b)
The Contractor shall ensure that the Registered Specialist Contractor (Ground
Investigation Field Work) (RSC (GIFW)) accurately logs and places cores in
the correct order in specially constructed core boxes. The RSC (GIFW) shall
clearly mark the corehole numbers on the cores and the boxes. Logging of
cores shall be preformed by a suitably qualified person in accordance with
PNAP 132. The Contractor shall notify the Project Manager before the start
and at the completion of core drilling.
(c)
Core logs and photographic records of cores shall be submitted to the Project
Manager for review within 7 days of completion of the drilling and shall be in a
format suitable for submission to Buildings Department.
(d)
The Contractor shall store the cores on Site during the Contract and shall
relocate or dispose of the cores and boxes as directed by the Project
Manager.
(e)
Unless otherwise stated in this section, drilling for ground investigation for
piling works shall be carried out in accordance with the requirements of
(f)
Soil samples and rock samples shall be taken by the Contractor from pile
excavations for visual inspection and testing. The method of sampling and
testing shall be as stated in Section 8 of this General Materials and

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17.6.5
Founding Levels and Obstructions

(a)
Prior to commencement of piling founded on rock, pre-boring should be

carried out by a RSC (GIFW), such that the quality of the founding rock can be
identified and the appropriate founding levels can be determined.
(b)
Pre-boring
(i)
The RSC (GIFW) shall pre-bore each pile location in accordance with
PNAP 66 and the cores shall be minimum Nx size.
(ii)
The RSC (GIFW) shall accurately log and place the cores in the correct
order in properly constructed core boxes supplied by the RSC (GIFW)
and clearly mark the corehole numbers on the cores and boxes. The
logging of the core shall be carried out by a suitably qualified person in
accordance with PNAP 132 and the Contractor shall notify the Project
Manager before the start and at the completion of core drilling.
(iii)
Core logs and a photographic record of all cores shall be submitted to

the Project Manager for review without objection within seven (7) days of
completion of core drilling, in a format suitable for submission to
Buildings Department.
The Contractor shall store the cores on Site during the Contract and
shall relocate or dispose of these cores and boxes as directed by the
Project Manager.
(iv)
(c)
Pile shafts shall be excavated to founding levels in accordance with founding

criteria shown on the Employer's Drawings. This shall be established at each
pile location by means of the site investigation pre-bore as specified in Clause
17.6.5(b)(i).
(d)
Unless otherwise stated in the Contract, the pile base shall be levelled and
shall fully penetrate the founding stratum in the case where it is on an inclined
plane.
(e)
The Contractor shall notify the Project Manager immediately the pile founding
level is reached. The Contractor shall also submit, for the Project Managers
review, a sample of the material taken from the arisings at the proposed pile
founding level.
(f)
Unless otherwise stated in the Contract, bored cast-in-situ piles shall be

founded on and continue into rock in accordance with the founding criteria
shown on the Employers Drawings, or for a minimum depth of 800 mm,
whichever is the greater.
(g)
Obstructions are objects encountered during installation of piles that impede

or stop the pile being installed in accordance with the founding criteria shown
on the Employers Drawings or specified strata. Obstructions shall be broken
out or drilled through to enable the pile to be installed in accordance with the
founding criteria shown on the Employers Drawings or specified strata.

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January 2011
17.6.6
Preliminary Piles
(a)
(b)
17.6.7
(i)
drill a borehole adjacent to the proposed location of each preliminary

pile, before it is driven, to determine the geotechnical conditions;
(ii)
install the piles at a location outside the permanent structure and to the
anticipated founding depth;
(iii)
test the preliminary pile by Pile Driving Analyser with CAPWAP

analysis after installation to the founding depth reviewed without
objection by the Project Manager;
(iv)
carry out loading testing on the preliminary piles in accordance with

PNAP 66 and PNAP 242 immediately after driving to determine the
ultimate shaft friction and end bearing capacity of each of the piles; and
(v)
cut off each preliminary pile two metres below the finished ground level,
or as directed by the Project Manager, after completion of the loading
test.
The relevant piling works shall not commence until the construction, testing
and records of the preliminary piles have been reviewed without objection by
Support for Driven Piles

(a)
(b)
17.6.8
Preliminary piles shall be constructed using the materials and methods of

construction proposed for the working piles and which have been submitted to
the Project Manager for review without objection.
The installation of
preliminary piles shall be as follows:
Driven piles shall be supported and restrained by means of leaders, trestles,

temporary supports or other guide arrangements in such a manner that :
(i)
the piles are maintained in position and alignment;
(ii)
the piles are not loosened in the ground; and
(iii)
damage resulting from oscillation, vibration or movement of freestanding piles does not occur.
The supports and restraints shall be maintained at all times during driving and
until the piles are self supporting.
Followers
(a)
Followers or long dollies shall not be used unless reviewed without objection
by the Project Manager and permitted by the Buildings Department. If
permitted, the set shall be revised by the Contractor and submitted to the
Project Manager in a format suitable for submission to the Buildings
Department for review, to allow for the reduction in effectiveness of the
hammer blows.
(b)
Whenever followers are used, the Contractor shall assess the energy
reduction factor of each follower for each pile size and submit the calculations
to the Project Manager, in a format suitable for submission to the Buildings
Department, for review without objection.

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January 2011
(c)
The energy reduction factor of the follower shall be taken as :-
(d)
17.6.9
Energy imparted to the pile immediately

after the introduction of follower
Energy imparted to the pile immediately
before the introduction of follower
The energy reduction factor for every combination of follower and pile size
shall be determined by averaging the results of 5 sets of dynamic pile tests
performed at or near to the set of 5 different piles of the same size.
Marking of Piles
Piles, including temporary and permanent casings, shall be marked at 1 m intervals
before pitching.
17.6.10 Driving Piles

(a)
Each pile, other than sheet piles, shall be driven without interruption until the
required depth or set has been achieved. If a minimum depth of penetration is
stated in the Contract, the Contractor shall submit to the Project Manager for
review his proposals for achieving this requirement. The Contractor shall
ensure that the minimum penetration and set are achieved without causing
damage to the pile.
(b)
The sequence and method of driving piles shall minimise the detrimental
effects of heave and lateral displacement of the ground and cause the least
possible displacement to previously installed piles. The Contractor shall drive
piles from the centre of the pile group and work outwards. Piles, including
casings, shall not be driven within a centre to centre distance of 3 m or five
times the diameter of the pile or casing, whichever is less, from an unfilled
excavation or from an uncased concrete pile which has been cast for less than
48 hours.
(c)
The Contractor shall inform the Project Manager without delay of any sudden
change in driving characteristics. The Contractor shall investigate the cause of
any sudden change in driving characteristics and further driving shall not
continue until these investigations have been completed and the results
reviewed without objection by the Project Manager
17.6.11 Precast Concrete Piles

The use of precast concrete piles is not permitted.
17.6.12 Displaced Piles
Piles which have been displaced as a result of driving adjacent piles shall be
corrected. Particulars of the method of correction and measures to be taken to avoid
displacement in subsequent driving shall be submitted to the Project Manager for
review without objection.

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January 2011
17.6.13 Re-drive Checks

(a)
Re-drive checks shall be carried out on all preliminary piles and as directed by
the Project Manager. The pile driving formula proposed by the Contractor shall
be revised if the final set on re-driving is more than the final set achieved
during the initial driving.
(b)
Preliminary piles which fail the re-drive check shall be deemed unacceptable.
Additional preliminary piles shall be proposed together with the revised pile
driving formula for the review without objection of the Project Manager.
(c)
No re-drive checks shall be carried out within 24 hours of completion of first

driving.
17.6.14 Lengthening Driven Piles

(a)
Pile Joints
The strength of piles at joints shall not be less than the strength at any normal
section of the pile. Lengthened piles shall not be driven until the joint has
developed the designed strength. Pile joints shall be tested as stated in the
Contract.
(b)
Splicing and Welding

(i)
Splicing of H-piles shall be carried out in accordance with the

requirements shown on the Employers Drawings.
(ii)
Welding for splicing of H-piles shall be carried out in accordance with

Testing of welding for splicing of H-piles shall be carried out in
accordance with Sections 17.7.8(a) and 17.7.8(b).
(iii)
(iv)
Piles shall be accurately located and aligned during welding. The

Contractor shall ensure that the straightness of the complete pile shall
not deviate by more than 3 mm along a 3 m straight edge or by 1 in
1,000 overall.
17.6.15 Measurement of Set and Working Load Capacity of Driven Piles

(a)
(b)
Set shall be measured for each driven pile in the presence of the Project
Manager and reviewed without objection by the Project Manager. The final set
shall be measured as either:
(i)
penetration per 10 blows; or
(ii)
the number of blows required to produce 25 mm penetration.
If driving is interrupted for more than 30 minutes, set shall not be measured
after driving restarts until at least 20 blows of the same driving energy as at
final set have been struck.

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January 2011
(c)
When final set is measured:

(i)
the exposed part of the pile shall be in good condition without damage or
distortion;
(ii)
the dolly and packing shall be in sound condition;
(iii)
the final hammer blows shall be in line with the axis of the pile and the
impact surfaces shall be flat and at right angles to the axes of the pile
and hammer; and
(iv)
the hammer shall be in good condition and operating correctly.
(d)
The temporary compression of each driven pile shall be measured.
(e)
The Contractor shall notify the Project Manager at least 1 hour before final set
and temporary compression are to be measured.
(f)
Piles shall be driven by hydraulic hammer. The Contractor shall assess the
pile working load capacity according to a pile-driving formula (e.g. the modified
Hiley Formula with the adoption of a single efficiency factor for hydraulic
hammer, Kh, multiplied by the impact energy. The value of Kh shall be
reviewed without objection by the Project Manager and the Buildings
Department). The factor of safety shall not be less than two (2) for ultimate
driving resistance against working load.
(g)
The pile-driving formula shall be calibrated against load tests carried out on
preliminary piles and checked as other piles are tested. The pile-driving
formula and correlation with test loading data shall be submitted to the Project
Manager for review without objection prior to carrying out piling works other
than preliminary piles
(h)
The pile shall not be considered to have attained the theoretical calculated
safe loading capacity should the penetration at final set be in excess of the
value reviewed without objection by the Project Manager.
The temporary compression of the driving cap shall be taken as not less than
7.5 mm when hardwood packing at the pile head and in the dolly are 100 mm
thick.
(i)
17.6.16 Excavation for Cast-In-Situ Piles

(a)
Excavation for cast-in-situ concrete piles shall be carried out by mechanical

methods; blasting and compressed air shall not be used.
(b)
The stability of excavation for cast-in-situ concrete piles shall be maintained

where necessary by:
(c)
(i)
temporary casings;
(ii)
permanent casings; or
(iii)
a thixotropic slurry containing bentonite or other similar agent reviewed

The bottom of casings shall be kept sufficiently deep to prevent the flow of soil
into the casing.

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January 2011
(d)
Permanent casings shall not be used within temporary casings.
(e)
Drilling fluids shall not be used.
(f)
Where an enlarged base of a cast-in-situ concrete pile is required, this shall be

formed by under-reaming with reverse circulation heads.
17.6.17 Excavation for Barrettes

(a)
Excavation for barrettes shall be carried out by mechanical methods; blasting

shall not be used.
(b)
The stability of excavations for barrettes shall be maintained by a thixotropic

slurry containing bentonite or other similar agent reviewed without objection by
(c)
The height of guide walls for barrettes shall be such that the head of slurry
shall ensure the stability of excavations and prevent movement of the adjacent
ground in excess of that specified in the Contract. The position, alignment and
level of guide walls shall be checked at regular intervals and submitted for
review without objection by the Project Manager.
17.6.18 Excavation for Minipiles

The Contractor shall install minipiles without the use of bentonite slurry or other
drilling muds. The stability of excavations for minipiles shall be maintained where
necessary by permanent casings which shall :
(a)
be manufactured from Grade 43 mild steel;
(b)
have a minimum thickness of 4.5 mm;
(c)
have an internal diameter of not less than the finished pile diameter shown or
as scheduled on the Employers Drawings;
(d)
be free from distortion and internal projections throughout the whole length
which might prevent the proper formation of the piles; and
be of uniform cross-section throughout the whole length.
(e)
17.6.19 Design and Construction of Minipiles

The design and construction of minipiles shall be in accordance with guidelines
provided in PNAP 66, PNAP 242 and all other relevant PNAPs.
17.6.20 Grouting Trials for Minipiles
Grouting trials shall be carried out to demonstrate accurate control of water/cement
ratio, consistency of mixing, satisfactory workability and achievement of strength
requirements. The trial shall be carried out on one minipile which is considered
representative of those which are to be constructed in the Permanent Works and at
a location reviewed without objection by the Project Manager.

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17.6.21 Inclination of Piles

The Contractor shall check the inclination of every inclined pile at each stage, during
installation. The Contractor shall arrange for a number of piles, as directed by the
Project Manger, to be checked by the use of an inclinometer or other method
reviewed without objection by the Project Manager, before grouting. The Contractor
shall record the inclination and orientations of the holes and submit the records to
the Project Manager for review.
17.6.22 Excavation for Socketted Steel H-piles
(a)
The prebored holes shall be large enough to allow a minimum cover of 40 mm

to the steel H-piles.
(b)
A temporary casing, the quality of which has been reviewed without objection,
shall be provided in the pre-boring process down to at least 500 mm or such
depth as required, below rockhead level, to prevent soil from falling into the
pre-bored hole.
(c)
Before the steel H-pile is inserted in the pre-bored hole, the hole should be
cleaned with air flushing to ensure that is free from debris and soil.
(d)
Extraction of the temporary casing shall be carried out while the grout is
sufficiently workable to ensure that the grout is not lifted with the casing. A
vibratory extractor, which has been reviewed without objection by the Project
Manager, may be used.
17.6.23 Construction using Bentonite Slurry

(a)
(b)
Excavation using bentonite slurry

(i)
Excavations for piles using bentonite slurry shall be filled with slurry from
the time that excavation commences until concreting is complete. The
slurry shall be maintained at a level of at least 1 m above the level of the
external groundwater and such that the slurry pressure exceeds the
pressure exerted by the soil and ground water.
(ii)
If there is a loss of bentonite slurry from the excavation which is

sufficient to result in a lack of stability, the excavation shall be
immediately filled with material previously reviewed without objection by
the Project Manager. The cause of the loss of slurry shall be
investigated and excavation shall not recommence until remedial action,
reviewed without objection by the Project Manager, has been taken.
Mixing of bentonite slurry

(i)
Bentonite shall be thoroughly mixed with water in a colloidal mixer. The

water for bentonite shall be clean, uncontaminated and from a source
reviewed without objection by the Project Manager. The Contractor shall
test the water in accordance with the requirements of Section 20.8.3.
The water shall be at a temperature of at least 5oC. The temperature of
the bentonite slurry shall be at least 5oC when supplied to the
excavation.

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January 2011
(ii)
(c)
If the groundwater is excessively saline or chemically contaminated, the

bentonite shall be pre-hydrated or the bentonite slurry shall be modified
such that the slurry is suitable to support the excavation.
Disposal of benetonite slurry

Any remaining bentonite slurry shall be removed from the Site and disposed in
accordance with Section 7.
17.6.24 Fixing Reinforcement for Piles

(a)
Fixing reinforcement for large diameter bored piles and continuous flight augur
piles
Prefabricated reinforcement cages for piles shall be marked and fitted with
spacers to ensure that the cage is correctly orientated and positioned within
the pile.
(b)
Fixing reinforcement to minipiles

Reinforcement shall be lengthened by staggering the couplers using methods
reviewed without objection by the Project Manager. Each reinforcement bar
shall be separated by spacers at regular intervals.
17.6.25 Cleaning and Drying Excavations for Piles

(a)
The bases of excavations for piles shall be cleaned by air lifting before
concrete is placed. If excavation is carried out under water, cleaning shall
continue until the water is clear and free from particles of soil. Measures shall
be taken to prevent the accumulation of silt and other material at the base of
the excavation.
(b)
If the excavation for piles is supported by bentonite slurry:
(c)
(i)
the Contractor shall take measures to remove all silt or other material at
the base of the boring. The Contractor shall remove heavily
contaminated bentonite suspension, which could impair the free flow of
concrete from the pipe of the tremie, from the bottom of the hole; and
(ii)
the Contractor shall take a sample of the bentonite suspension from the
base of the boring using a sampling device reviewed without objection
by the Project Manager. If the specific gravity of the suspension exceeds
1.25 the placing of concrete shall not proceed, and the bentonite shall be
replaced.
Provided the rate of ingress of water does not exceed 0.3 l/s, the base of
excavations for piles shall be dried immediately before concrete is placed.

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January 2011
17.6.26 Placing Concrete in Piles

(a)
Each pile shall be concreted as soon as practicable. Concrete shall be placed

without interruption until the complete pile is concreted.
(b)
In the event that excavations for piles are supported by bentonite slurry or if
the rate of ingress of water exceeds 0.3 l/s, the Contractor shall comply with
the following :
(i)
concrete shall be placed by tremie;
(ii)
the hopper and pipe of the tremie shall be clean and watertight
throughout. The pipe shall extend to the base of the boring and a sliding
plug or barrier shall be placed in the pipe to prevent direct contact
between the first charge of concrete in the pipe of the tremie and the
water or drilling fluid. After the first charge of concrete the pipe shall at
all times penetrate the concrete which has previously been placed and
shall not be withdrawn from the concrete until completion of the
concreting. Sufficient concrete shall be maintained within the pipe to
ensure that the pressure from it exceeds that from the water or drilling
fluid. The internal diameter of the pipe of the tremie shall be not less
than 150 mm for concrete made with 20 mm aggregate. It shall be so
designed that external projections are minimized, allowing the tremie to
pass through reinforcing cages without causing damage. The internal
face of the pipe of the tremie shall be free from projections;
(iii)
the minimum cement content of the concrete shall be 375 kg/m3;
(iv)
the level of the top of the concrete in piles shall be at least 1 m above
the specified cut-off level; and
(v)
if the top of the guide wall of barrettes is at the specified cut-off level,
concrete shall continue to be placed until the top of the pile is free from
contamination.
(c)
Operations which in the opinion of the Project Manager are likely to disturb or
affect the concrete or placing of the concrete shall not be carried out.
(d)
For piles concreted in dry conditions, the concreted level shall be not less than
150 mm and not more than 500 mm above the specified cut-off level. For piles
cast using tremie concrete, the concrete level shall be not less than 1 m and
not more than 2 m above the specified cut-off level.
(e)
The Contractor shall trim back the concrete of all piles to final cut-off level.
Trimming back shall be carried out at least 7 days after placing the concrete.
17.6.27 Grouting for Piling Works

(a)
Grout material shall be mixed by weight batching. The amount of water used
shall be measured by a calibrated flowmeter or a measuring tank. The mixing
time in high speed mixers shall be suitable for the type of mixer used. After
mixing, the grout shall be continuously agitated in a holding tank and screened
before injection.
(b)
Before grouting, the bottom of the hole shall be flushed by high pressure air.

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January 2011
(c)
The grout intake volume should be measured with a flowmeter accurate to 1

litre. The Contractor shall calibrate the flowmeter and submit a calibration
report to the Project Manager 7 days before trial mix of grout is made. Each
pile shall be cast-in one continuous operation and under no circumstances
shall a pile be left partially grouted.
17.6.28 Removal of Temporary Casings to Piles

(a)
A sufficient quantity of concrete shall be maintained within temporary casings

being withdrawn to ensure that the pressure from external water or soil is
exceeded and that the pile is not reduced in section or contaminated.
(b)
Temporary casings in contact with concrete and not withdrawn before the
initial set of the concrete shall be left in place.
(c)
The Contractor shall take precautions reviewed without objection by the

Project Manager in all cases where excess heads of water or drilling fluid
could be caused as the casing is withdrawn due to the displacement of water
or fluid by the concrete as it flows into its final position against the walls of the
shaft.
(d)
Where two or more discontinuous lengths of casing (double casing) are used
in the construction, the proposed method of working shall be reviewed without
17.6.29 Empty Bores above Piles

Empty bores and shafts which remain above the pile after concrete has been placed
shall be temporarily protected or filled with material, of a type which has been
reviewed without objection by the Project Manager as soon as practicable.
17.6.30 Tolerances: Steel Bearing Piles
Dimensional tolerances of steel bearing pile sections shall comply with the BS 4360,
BS 5950 and BS 5400 as stated in Section 22.3.1. Fabrication tolerances for steel
bearing piles and related steelwork shall comply with BS 5950:Part 2.
17.6.31 Tolerances: Pile Installation
(a)
Piles, including mini-piles, shall be installed to within the tolerances stated in

Table 17.2.
(b)
Piles which do not comply with the specified tolerances shall not be forcibly
corrected.
Table 17.2: Tolerances of Installed Piles

Description
Deviation from specified position in plan, measured at cut-off level
Tolerance
75 mm
Deviation from vertical

(a)
all piles except bored piles
1 in 75
(b)
bored piles
1 in 300
Deviation of raking piles from specified batter

Deviation from specified cut-off level
1 in 25
-25 mm, +0
The diameter of cast in-situ piles shall be at least 97% of the specified diameter at
all points.
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January 2011
17.6.32 Remedial Works to Out of Tolerance Piles

(a)
In the event that one or more piles are identified as being outside the
tolerances for installed piles, the Contractor shall submit proposals for
remedial works to the Project Manager for review without objection, in a format
suitable for submission to the Buildings Department, within 10 days of the
completion of the piling work survey.
(b)
The Contractors remedial works proposals shall include design calculations

and Contractors Drawings prepared by a registered structural engineer. The
proposals shall show the extent of additional reinforcement necessary such
that stresses in the pile and related structure are within acceptable limits.
(c)
Remedial works shall be carried out upon approval and consent by the
Buildings Department and review without objection by the Project Manager,
prior to commencing any works over the affected pile.
17.7
INSPECTION TESTING AND COMMISSIONING
17.7.1
Quality Supervision for Piling Works

The Contractor shall comply with the requirements for quality supervision in
accordance with PNAP 242.
17.7.2
17.7.3
Inspection of Piling Works

(a)
Where pile bores or excavations are retained by bentonite slurry, the

Contractor shall arrange Koden tests to be carried out on each pile by an
independent testing body reviewed without objection by the Project Manager.
The Contractor shall submit the test report to the Project Manager prior to
placing concrete in piles.
(b)
The Contractor shall notify the Project Manager before placing concrete in
piles.
Inspection of Installed Piles

(a)
(b)
(c)
If directed by the Project Manager, installed piles shall be exposed for

inspection or testing. Excavations for exposing piles shall be of a depth
reviewed without objection by the Project Manager, and the face of the
excavation shall be at least 750 mm from the face of the pile. The excavation
shall be maintained in a stable condition and kept free from water.
The surface of the pile shall be washed clean of all silt, mud or other adhering
materials to permit inspection.
After inspection, excavations for exposing piles shall be filled using suitable fill
material, of a type reviewed without objection by the Project Manager, which
shall be compacted to obtain a relative compaction of at least 95% above the
groundwater table.

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January 2011
17.7.4
17.7.5
Post Construction Proof Drilling

(a)
Post construction proof drilling shall be carried out after the construction of
piles in accordance with PNAP 66, PNAP 132 and PNAP 242.
(b)
For large diameter bored piles and barrettes where core-drilling at the
concrete/rock interface is to be carried out at each pile, the concrete shall be
in contact with rock at the interface. If imperfections such as a thin layer of
sediment, segregated concrete, honeycomb are found, the Contractor shall
submit remedial proposals to the Project Manager, for review without
objection, in a format suitable for submission to the Buildings Department.
Testing: Load Tests on Piles

(a)
(b)
Testing: load tests on piles

(i)
The number of piles to be tested by load testing shall be as stated in the

Contract or as required by the Buildings Department, whichever is the
greater.
(ii)
The piles shall be tested to determine the settlement of the pile under
load. Testing shall be carried out in accordance with the method of
testing as stated in PNAP 66 and requirements imposed by the Buildings
Department.
(iii)
Piles shall not be tested until the concrete or grout has attained sufficient
strength to withstand the tests. The Contractor shall notify the Project
Manager 7 days prior to the commencement of the test.
(iv)
Records of pile load tests shall be kept by the Contractor and submitted
to the Project Manager within 24 hours of each test completion. The
records shall be kept on the standard forms as shown in Appendix
A17.6.
Compliance criteria: load tests on piles

Unless otherwise stated in the Contract, the results of load tests on piles shall
comply with criteria described in PNAP 66 and requirements imposed by the
(c)
Non-compliance: load tests on piles

If the result of any load test on piles does not comply with the specified
requirements for settlement, the Contractor shall submit remedial proposals to
the Project Manager for review without objection. In the event the remedial
proposal involves any change of design, the design calculations and
Contractors Drawings shall be prepared by a registered structural engineer
and shall be submitted to the Project Manager for onward submission to
Buildings Department for approval. No remedial works shall be undertaken,
before review without objection by the Project Manager and approval by the

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January 2011
17.7.6
Testing: Concrete Cores from Piles

(a)
(b)
(c)
Samples : concrete cores from piles

(i)
The number of concrete cores to be provided for testing from concrete

piles shall be the larger of, the number required to satisfy the Buildings
Department, and the number stated in the Contract. The positions from
which the cores are taken shall be as directed by the Project Manager.
(ii)
Concrete cores shall be 100 mm diameter.
(iii)
The method of taking concrete cores shall be in accordance with CS1.
(iv)
Holes formed by taking concrete cores from piles shall be reinstated

using non-shrink concrete or grout, of the same characteristic
compressive strength as the concrete of the pile and reviewed without
Testing: concrete cores from piles

(i)
Each concrete core from a pile shall be inspected for evidence of

segregation of the constituents and for the presence of voids.
Specimens selected from each core shall be tested to determine the
compressive strength.
(ii)
The method of preparing, inspecting and testing concrete cores shall be

as stated in Section 20.8.17.
Compliance criteria: concrete cores from piles

The compliance criteria for concrete cores from piles shall be as stated in
PNAP 66 and Section 20.8.18.
(d)
Non-compliance: concrete cores from piles

(i)
If the result of any test on a concrete core from a pile does not comply
with PNAP 66 and/or Clause 20.8.18, additional cores shall be taken
from the same pile and additional tests shall be carried out.
(ii)
Additional concrete cores shall be 100 mm diameter for concrete of 20

mm nominal maximum aggregate size and 150 mm diameter for
concrete of 40 mm nominal maximum aggregate size. The number of
additional cores shall be as directed by the Project Manager.
(iii)
If the result of any additional test does not comply with the compliance
criteria for concrete cores the Contractor shall submit remedial proposals
to the Project Manager for review without objection. The number of
additional piles and additional tests shall be as directed by the Project
Manager.

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January 2011
17.7.7
Testing: Non-destructive Tests on Welds in Piles

(a)
(b)
Testing: non-destructive tests on welds in piles

(i)
The number and type of non-destructive tests on welds in piles shall be

as stated in the Contract or as required by the Buildings Department,
whichever is the greater.
(ii)
Radiographic tests shall comply with BS 2600:Part 1 and ultrasonic tests

shall comply with BS 3923:Part 2.
Non-compliance : non-destructive tests on welds in piles

If the result of any test on a weld in a pile does not comply with the specified
requirements, the complete weld shall be cut out, the joint shall be re-welded
and the weld shall be retested.
17.7.8
Testing: Integrity Tests

(a)
Testing: sonic and vibration tests on piles

(i)
In all bored cast-in-situ piles excavated by machine the Contractor shall

install three 50 mm and one 150 mm internal diameter steel tubes
securely tied to the reinforcement cage. The tubes shall be extended to
the full depth of the pile and terminate above the finished concrete level.
The tubes shall be watertight, corrosion free, continuous with sealed
joints and with the top and bottom sealed with a 2.0 mm thick steel plate
welded to the tube. The tubes shall be equally spaced around the piles.
The Contractor shall submit details of the proposed method of
installation of the tubes for the Project Manager's review without
objection.
(ii)
The Contractor shall carry out sonic tests at cast-in-situ pile at locations
reviewed without objection by the Project Manager to verify the integrity
and homogeneity of the pile.
(iii)
The Contractor shall carry out vibration tests at all cast-in-situ piles
which have not been sonic tested to verify the integrity and homogeneity
of these piles.
(iv)
Sonic and vibration testing shall be carried out by an independent testing

company.
(v)
The Contractor shall submit the details of the proposed independent

testing company and the proposed procedures for sonic and vibration
testing to the Project Manager for review without objection.
(vi)
All reports, and photographic traces from sonic and vibration tests shall
be submitted to the Project Manager for review without objection within
48 hours of completion the test.
(vii) All tubes shall be cut-off flush with the concrete and filled with non-shrink
grout having the same characteristic compressive strength as the
concrete on completion of all testing.

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January 2011
(b)
Non-compliance : sonic and vibration testing

If the results of any sonic or vibration test indicate that the pile does not
comply with the specified requirements or indicate any weakness or
discontinuity in the pile, additional tests shall be carried out by the Contractor
to confirm that the quality and bearing capacity of the pile satisfy the
requirements of the Contract and the Buildings Department. In the event that
the additional tests show that the pile does not comply, the Contractor shall
propose remedial measures for review without objection by the Project
Manager.
17.7.9
Testing: Bentonite Slurry

(a)
(b)
(c)
Samples: bentonite slurry

(i)
Samples of bentonite slurry shall be provided for testing at a frequency

reviewed without objection by the Project Manager. Samples for testing
to determine the density of the slurry shall be provided each day. A
sample of bentonite slurry taken from the base of the excavation shall be
tested to determine the density of the slurry before placing of concrete.
(ii)
The method of sampling and the sampling apparatus shall be reviewed

Testing: bentonite slurry

(i)
Each sample of bentonite slurry shall be tested to determine the density,

viscosity, shear strength and pH value.
(ii)
The method of testing shall be as stated in Table 17.3.
(iii)
The measuring device for testing density shall be readable and accurate
to 0.005 g/mL.
(iv)
Samples to be tested for viscosity using the Fann viscometer shall be

screened before testing using a 300 m BS test sieve.
Compliance criteria : bentonite slurry

(i)
The results of tests on bentonite slurry shall be as stated in Table 17.3.
(ii)
Tests to determine the shear strength and pH value shall be

discontinued if the results of tests indicate that a consistent working
pattern has been established, taking account of the mixing process,
blending of freshly mixed and previously used slurry and processes used
to remove impurities from previously used slurry. If there is a subsequent
change in the established working pattern, the tests to determine shear
strength and pH value shall be re-introduced.

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January 2011
(d)
Non-compliance : bentonite slurry

If the results of tests for density and viscosity do not comply with the specified
requirements, or if the results of tests for shear strength or pH value do not
indicate a consistent working pattern, the bentonite slurry shall be deemed
unsuitable for the work and concrete shall not be placed in the slurry. The
slurry shall be replaced or its composition adjusted before concrete is placed.
Table 17.3: Properties of Bentonite Slurry and Methods of Testing

Property at 20C
Density as supplied to excavation
Test Results
Method of Testing
1.10 g/mL
Mud density balance
Density at base of excavation before

placing concrete
1.25 g/mL
Mud density balance
30 50 seconds
Marsh cone method or

Fann viscometer
Viscosity
Shear strength
(10 minute gel strength)
pH value
0.02 Pa.s
1.4 10 N/m2
4 40 N/m2
8 12
Shearometer or
Fann viscometer
pH indicator paper strips or
electrical pH meter
17.7.10 Testing of Grout

(a)
Definition of batch
A batch of grout is any quantity of grout used for grouting in one continuous
operation in one day.
(b)
(c)
Test for bleeding and free expansion

(i)
One sample of grout from each batch shall be provided for testing not
more than 30 minutes after mixing and protected from changes in
moisture content before tests are carried out.
(ii)
Each sample shall be divided into 3. Each third shall be placed in a

covered cylinder with a diameter of 100 10 mm to a depth of 100 5
mm and the amount of bleeding and free expansion shall be measured
by a scale fixed to the outside of the cylinder.
(iii)
If the result of any test for the amount of bleeding or free expansion of
the grout does not comply with the specified requirements, proposed
changes to the materials, grout mix or method of production shall be
Flow cone efflux test

(i)
One sample from each batch shall be taken and tested in accordance
with ASTM C939-94 to determine the Flow Cone Efflux time.
(ii)
Grout mixes containing additives with an efflux time of less than 15

seconds shall be rejected.

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January 2011
(d)
Test for crushing strength

(i)
One sample of the grout shall be taken from each grouting operation
after mixing and protected from changes in moisture content before
making test cubes.
(ii)
Cubes shall be prepared using 100 mm cube moulds.
(iii)
Strength compliance requirements shall comply with Section 20.8.14.
17.7.11 Testing: Dynamic Pile Test

(a)
Testing: dynamic pile test

(i)
In addition to load tests on piles, dynamic testing on driven piles shall be

carried out by the Contractor. The dynamic pile test is a test applied to
the pile by means of a falling weight, hammer or other percussive
device. The response of the pile to the impact force is measured in
terms of pile strain, acceleration and displacement. The results of the
dynamic pile test shall allow a determination to be made by the
Contractor on the load capacity of the pile. The Contractor shall take
measurements at one level on the pile surface near the pile cap.
(ii)
The dynamic pile testing method shall be reviewed without objection by

the Project Manager prior to carrying out testing.
(iii)
The number of dynamic pile tests shall be as stated in the Contract and
the tests shall be carried out on piles selected by the Project Manager.
17.7.12 Records of Piling Works

(a)
Records of piles delivered

Records of prefabricated piles shall be kept by the Contractor on Site and
submitted to the Project Manager for review at the time the piles are delivered
to Site. The records shall include test certificates, analyses and mill sheets for
steel piles and proprietary piles.
(b)
Records of pile installation

Records of pile installation shall be kept by the Contractor on Site and
submitted to the Project Manager for review without objection within 24 hours
after the driving or installation of each pile has been completed. The records
shall be kept on standard forms as shown in Appendices A17.2 to A17.4. The
records and Form BA 14 shall be submitted to the Project Manager for onward
submission to the Buildings Department upon completion of piling works.
(c)
Records of bentonite slurry

Records of tests of bentonite slurry shall be kept by the Contractor on Site and
a report shall be submitted to the Project Manager at frequencies reviewed
without objection by the Project Manager. The records shall be kept on
standard forms as shown in Appendix A17.5.

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January 2011
(d)
Records of load tests on piles

Records of load tests on piles shall be kept by the Contractor on Site and a
report shall be submitted to the Project Manager for review without objection
within 48 hours after the test has been completed. The records shall be kept
on standard forms as shown in Appendix A17.6. The records shall include
graphs showing load and settlement versus time, plotted in the format shown
in BS 8004, Figure 15(a).
(e)
Records of integrity tests on piles

Records of integrity tests on piles shall be prepared by an experienced
engineer reviewed without objection by the Project Manager and shall be kept
by the Contractor on Site and a report shall be submitted to the Project
Manager for review without objection within 48 hours after the test has been
completed. The records shall be available to the Project Manager for
inspection at all times. The report shall contain the following details:
(i)
pile reference numbers;
(ii)
measured pile length;
(iii)
defects such as cracks, fractures or discontinuities; and
(iv)
pile stiffness.
The Contractor shall submit the records to the Project Manager for onward
submission to the Buildings Department.
17.7.13 Record Drawings
(a)
Record drawings of installed piles shall be prepared by the Contractor and

four copies shall be submitted to the Project Manager for review within 14
days of completing each group of the piles.
(b)
The drawings shall include a plan showing characteristic features of the Site,
the as-constructed co-ordinates of the centre of each pile at cut-off level, the
final depth and cut-off level and size of each pile as constructed and other
information to the satisfaction of the Buildings Department and the Project
Manager.
(c)
The Contractor shall submit record drawings and Form BA 14 to certify

completion of piling works, to the Project Manager for onward submission to
the Buildings Department. For the avoidance of doubt, these record drawings
are in addition to the as-constructed drawings required under the Contract.

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January 2011
APPENDIX A17.1
DETERMINATION OF THE LOAD DEFLECTION CHARACTERISTICS
OF PILES BY LOAD TEST
A17.1.1 Scope
This method determines the load deflection characteristics of piles.
A17.1.2 Equipment
(a)
Kentledge, anchor piles or other anchorages supported or installed at suitable

locations to provide adequate reactions against jacking.
(b)
A load measuring device which shall consist of a load column, pressure cell,
or other appropriate system, calibrated before and after each series of tests,
or whenever adjustments are made to the device, or at time intervals
recommended by the manufacturer of the equipment.
(c)
Four deflectometers accurate to 0.025 mm.
(d)
Precision levelling equipment accurate to 0.25 mm.
(e)
A reference frame for supporting deflectometers and providing a datum for

deflectometer measurements.
(f)
Working platforms.
(g)
Screens and protection from exposure to conditions which may affect the test.
(h)
Hydraulic loading equipment.
A17.1.3 Procedure: Before Testing

The procedure before testing shall be as follows:
(a)
The kentledge, anchor piles or other anchorages shall be installed. The

centre of each anchor pile shall be at least 2 m or three times the pile
diameter, whichever is greater, from the centre of the pile to be tested and
from the centre of any adjacent pile.
(b)
If required, the pile to be tested shall be extended from cut-off level to ground
level. The strength of piles at joints shall not be less than any normal section
of the pile.
(c)
A temporary square pile cap designed by the Contractor shall be constructed.
(d)
Working platforms, screens and protection shall be installed.
(e)
The reference frame shall be set up on supports which are at least 2 m or

three times the pile diameter, whichever is greater, from the test pile and
anchor pile. The four deflectometers shall be mounted on the reference frame
to measure the deflection of the four corners of the temporary pile cap.

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January 2011
A17.1.4 Procedure : Load Test

The procedure for the load test shall be as follows:
(a)
Preliminary piles shall be tested to not less than twice the working load of the
pile. Working piles shall be tested to not less than 1.8 times working load.
Reductions for group or boundary effects shall not be made in determining the
test loads.
(b)
Test loads shall be applied and removed in three stages as stated in Table
A17.1.1.
(c)
The test loads shall be applied in increments, and removed in decrements, of

25% of the working load. Increments of load shall not be applied until the rate
of settlement of the pile is less than 0.1 mm in 20 minutes.
(d)
The full test loads for Stage I, defined in Table A17.1.1, shall be applied in
increments and shall then be maintained for at least 24 hours after the rate of
settlement has reduced to less than 0.1 mm per hour. The test loads shall be
removed in decrements and the recovery of the pile determined before
loading is resumed.
(e)
The procedure stated in Clause A17.1.4 (d) shall be repeated for Stage II,
defined in Table A17.1.1, loading.
(f)
The procedure stated in Clause A17.1.4 (d) shall be repeated for Stage III,
defined in Table A17.1.1, loading unless the Project Manager directs the
loading to be maintained for a longer period.
(g)
The settlement of the pile shall be measured at hourly intervals. The

settlement of the pile under each increment and decrement of loading shall be
measured. The exact times at which increments are applied and decrements
are removed shall be recorded. Settlements shall be measured and times
shall be recorded in the presence of the Project Manager.
(h)
The level of the reference beam shall be checked at regular intervals, as

reviewed without objection by the Project Manager during the test.
Table A17.1.1 : Test Loading Stages

Stages
Test load
25% of max. test load
II
III
A17.1.5 Procedure: After Testing

After testing, equipment shall be removed, temporary pile caps shall be demolished
and pile extensions shall be removed to cut-off level. Anchor piles shall be
withdrawn.

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January 2011

(a)
The loads applied to the nearest 0.05 t.
(b)
The settlement of the pile to the nearest 0.05 mm at hourly intervals and
under each increment and decrement of loading.
(c)
The exact times at which increments were applied and decrements removed.
(d)
The levels of the reference beam, to the nearest 0.05 mm.

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January 2011
APPENDIX A17.2
PILE DRIVING RECORD
(Prefabricated Steel and Driven Cast-in-place Piles)
Contract No.
Title
Contractor
Pile data
Reference No.
Location
Type
Size
Rake
For steel piles; Length ____________________________________

Drive system data
Hammer: type
mass
kg drop (at set)
Helmet, dolly & anvil : type

Packing : type
mm rated energy kJ
mass
condition
kg
thickness
mm
Levels
Commencing ground/sea bed* level (PD/CD)*
Depth of overburden/height of working platform above ground/sea bed level
Reference working level/platform level*
Date
&
Time
+
++
Drop
(m)
Depth
penetrated
(m)
No. of
blows+
Cumulative
No. of
blows
Length of individual
segments, location of
splices and tests
carried out
Remarks (State details

of obstruction, delays,
interruptions and
location of concrete
samples++)
per 0.25 m for top 3.0 m of pile

for cast in place piles
(*delete as appropriate)

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January 2011
PILE DRIVING RECORD

(Prefabricated Steel and Driven Cast-in-place Piles)
Temporary compression record (on graph paper graduated in millimetres to be pasted in
space below)
Final penetration depth
mm
Top of pile level
Temporary compression
mm
Cut off level
Final set
or
mm/last 10 blows
Pile head level
blows/25 mm
Final toe level
Deviation from plumb or rake 1 in
Deviation at cut-off level x-x

y-y
mm
mm
For driven cast-in place piles:

Length of temporary
casing
Length of permanent
casing
Concrete grade
Date of concreting
Length of cage
reinf.
Theoretical volume of concrete required
Actual volume of concrete placed
Reported by
Contractor's Representative
Verified by
Date
Date
Project Manager's Representative
(* delete as appropriate)

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January 2011
APPENDIX A17.3
PILE RECORDS
(Bored Cast-in-place Piles)
Contract No.
Title
Contractor
Pile data
Reference No.
Type
Location
Diameter
mm
Design Length
mm
Rake 1 in
Bore hole record

Commencing ground/sea bed* level (P.D./C.D.)*
Depth of overburden/height of working platform above ground/sea bed level
Casing/drilling fluid* type

Reference working level/platform level*
Date
&
Time
Depth
penetrated
Details of strata
penetrated/ground
water level
Details of soil testing,

proving of bedrock and
under-ream
Deviation from plumb or rake 1 in

Length of temporary casing
Remarks (State details

of obstruction, delays
interruptions, and
location of concrete
samples)

y-y
m
Length of permanent casing
mm
mm
m

34/40
January 2011
PILE RECORDS
(Bored Cast-in-place Piles)
Bore hole condition prior to concreting
Bottom visible/invisible*Measured depth of bore
Depth of water/drilling fluid*
Damage and debris observations

Concrete record
Concreting in dry/by tremie*
Water inflow rate
Concrete grade
Slump
Actual concreted level
Cut off level
Lt
Overall __ =
La
Length of cage reinforcement
Date
&
Time
Delivery
note No./
Truck load
No.
Quantity
(m3)
Theoretical
length
filled
Lt(m)
Actual
Length
Placed
La (m)
Lt
%
La
Reported by
Verified by
Date
Date
Note :
Cumulative
length
placed (m)
litres/second
Remarks
(Interruptions in placing,
cause of excessive
Lt
%, Location of
La
concrete samples,
Ref. No. of cubes taken,
etc.)
The Project Manager shall be informed of any deviation greater than 10%
from the expected (theoretical) level of concrete placed.

35/40
January 2011
APPENDIX A17.4
PILE RECORDS
(Barrettes)
Contractor No.
Title
Contractor
Pile data
Reference No.
Location
Size of barrette
Shape
Design Length
Excavation data
Commencing ground level (PD)
Depth of overburden
Guide wall levels: top
bottom
Date
Depth
reached
(m)
Details of Strata
penetrated/surrounding
ground water level
Deviation from plumb 1 in
Details of soil testing,

proving of bedrock,
and under-ream
Remarks
(State details of
obstructions, interruptions
and delays)

y-y
Base level of excavation
mm
Depth of base from top of guide wall

mm
36/40
January 2011
PILE RECORDS
(Barrettes)
Concrete record
Concrete grade
Slump
Actual concreted level
Cut off level
Lt
Overall __ =
La
Length of cage reinforcement

Date
&
Time
Delivery
note No./
Truck load
No.
Quantity
3
(m )
m
Theoretical
length
filled
Lt (m)
Actual
Length
Placed
La (m)
Report by
Verified by
Date
Note
Lt
%
La
Cumulative
length
placed (m)
Remarks
(Interruptions in placing,
cause of excessive
Lt
%, Location of
La
concrete samples,
Ref. No. of cubes
taken, etc.)
Date
The Project Manager shall be informed of any deviation greater than 10% from the
expected (theoretical) level of concrete placed.

37/40
January 2011
APPENDIX A17.5
BENTONITE SLURRY RECORDS
Title
Contract No.
Contractor
Sample data
Ref. No. of pile
Location
Sources of test sample: (a) freshly mixed slurry*

(b) as supplied to excavation*
(c) from bottom of excavation prior to placing concrete*
Date & time of sampling
Test Method and
Apparatus Used
Test Result
Density (g/mL)
Viscosity (seconds)
pH
Sand Content (%)
Fluid Loss (mL)
Temperature (C)
Remarks : -
Reported by
Verified by
Date

Date

38/40
January 2011
APPENDIX A17.6
PILE LOAD TEST RECORD
(Test Result)
Contract No.
Title
Contractor
Pile data
Reference No.
Location
Type
Size
Pile dia/diagonal width (D)
Gross pile length (Lp)
Sectional area (A)
Young's modulus (E)
Testing data
Design working load (P)
Test load (Q) = 2 (P)
Pressure gauge No.
Calibration Certificate ref.
Dial gauge number

Serial number
Calibration certificate ref.
Date of calibration
Date
3
Level of fixed point on load reaction system:

before testing ___
after testing
ground settlement =
Date
&
Time
Load
(kN)
Pressure
Gauge
Reading
Dial Gauge Readings

Dial 1

Dial 2
Dial 3
39/40
Dial 4
Average
Cumulative
Settlement
(mm)
Remarks
January 2011
PILE LOAD TEST RECORDS

(Test Result)
Load in kN
1000
Settlement
in
mm
--
--
10
--
15
--
20
--
25
--
30
--
35
--
40
--
Maximum settlement at working load:
2000
3000
4000
5000
6000
(Allowable = 20 mm for buildings and 10 mm for all

other structures)
Actual =
Settlement at maximum test load (S1):
(Allowable = S1 less than twice settlement at 90% of

maximum test load (2S2).)
Actual S1 =
2S1 =
Reported by
Verified by
Date

Date
(delete as appropriate)

40/40
January 2011
SECTION 18 FORMWORK AND FINISHES TO CONCRETE
18.1
GENERAL
18.1.1
The works and materials specified herein shall comply with the Sections stated,
unless otherwise stated in this Section:
(a)
surface finish to concrete carriageways shall comply with Section 10;
(b)
cover spacers for steel reinforcement shall comply with Section 19; and
(c)
materials for cement mortar shall comply with Section 20.
18.2
18.2.1
Class
Class is a term used to identify the different types and standards of formed,
unformed and treated finishes.
18.2.2
Falsework
Falsework is a temporary structure used to support formwork and the permanent
structure until the permanent structure is self-supporting.
18.2.3
Formed finish
Formed finish is the finish of the concrete surface produced by the use of formwork.
18.2.4
Formwork
Formwork is the mould against which concrete is cast and which gives the shape
and finish to the concrete surface.
18.2.5
Permanent formwork
Permanent formwork is formwork designed to remain in position as part of the
Permanent Works.
18.2.6
Profiled formwork, trough moulds and waffle moulds

(a)
Profiled formwork is formwork designed to produce a ribbed or patterned

finish on the concrete surface.
(b)
Trough mould is the mould used with complementary moulds to create an

elongated recess in the underside of a slab.
(c)
Waffle mould is the mould used with complementary moulds to create square
recesses in a concrete slab.

Section 18 - Formwork & Finishes to Concrete
1/19
January 2011
18.2.7
Sealed plywood
Sealed plywood is plywood which has been sealed with a factory-applied film of
phenolic resin or plastic material.
18.2.8
Spatterdash
Spatterdash is a mixture of cement, coarse sand, granite fines and water, used as a
rendering on concrete surfaces.
18.2.9
Treated finish
Treated finish is the finish of the concrete surface produced by a treatment applied
to a formed or unformed finish.
18.2.10 Unformed finish

Unformed finish is the finish of the concrete surface produced without formwork and
by working the concrete surface before the concrete has hardened.
18.3
18.3.1
Design of falsework and formwork

(a)
Falsework and formwork shall be designed, in accordance with the

Specification, to maintain the position and shape of the formwork such that
the hardened concrete surface complies with the characteristics of finish
stated in Table 18.1.
(b)
Falsework and formwork shall be capable of being dismantled and removed

without shock, disturbance, damage or loading to the concrete and in such a
manner that the specified requirements for removing or leaving in position
side formwork, soffit formwork and falsework will be achieved without
disturbing other formwork or falsework.
(c)
Formwork shall be used to form the top surface of concrete inclined at a slope
exceeding 15 to the horizontal unless it can be demonstrated that the
specified finish will be produced without the use of formwork. Formwork to
top surfaces shall be anchored to prevent floatation.
18.4
MATERIALS
18.4.1
Formwork
(a)
Formwork shall be timber, metal, plastic, fibreglass or other material which will
produce the specified finish. Materials used as formers for profiled formwork,
chamfers, splays, rebates and other features shall be such that they produce
the same finish as the main formwork.
(b)
Plywood for formwork shall have a close, uniform grain and the edges shall be
sealed with barrier paint, polyurethane varnish or other impermeable material.

2/19
January 2011
18.4.2
18.4.3
(c)
The faces of formwork for Class F3, F4, F5 and F6 finishes shall have a
uniform texture and a matt, not a shiny or polished, surface. The edges of the
formwork shall be straight and square.
(d)
The formwork used for F3, F4 and F5 finished surfaces shall be formed of one
material only. All make up pieces shall be of that material to ensure the same
finish is obtained across the whole surface.
(e)
All concrete to receive a waterproof membrane shall have a surface finish

either formed or unformed that is compatible with the membrane to be
applied.
(f)
The surface finish of floor slabs in toilet and kitchen areas where the
waterproofing is to be laid by others shall be unformed finish type U3 unless
shown otherwise.
Formwork class of finish

(a)
The characteristics of each class of finish shall be as stated in Tables 18.1,

18.2 and 18.3.
(b)
Formwork of the type stated in Table 18.1 shall produce a concrete surface
which complies with the characteristics of finish stated in Table 18.1.
(c)
Unless otherwise shown on the Employer's Drawings, the class of formed and
unformed finish required for different concrete surfaces shall be as stated in
Table 18.4. The higher class of finish shall start at least 150 mm below the
finished ground level for concrete surfaces which are partly buried.
Release agents
(a)
Release agents shall be a proprietary type reviewed without objection by the

Project Manager. Release agents containing mineral oils shall not be used.
Barrier paint, polyurethane varnish, wax or other materials shall not be used
instead of a release agent.
(b)
Release agents shall not:

(i)
stain or colour the concrete;
(ii)
affect the bond between the concrete and subsequent coverings; or
(iii)
have an adverse effect on any finishes to be applied to the concrete.
(c)
Release agents other than those which incorporate a surface retarder to

produce a Class T1 finish shall not affect the hardening of the concrete.
(d)
Release agents used on formwork for water retaining structures for potable
and fresh water shall be non-toxic and shall not impart a taste to the water.
(e)
Release agents used on steel formwork shall contain a rust-inhibiting agent.
(f)
Release agents used on formwork for Class F4, F5 and F6 finishes shall be a
chemical release agent.

3/19
January 2011
(g)
On areas of formwork which are likely to be affected by pedestrian traffic, rain

or dust, release agents for Class F4, F5 and F6 finishes shall be a type which
evaporates to leave a dry film on the formwork, unless protection from such
effects is provided.
Table 18.1 : Formed Finishes

Characteristics of finish
Type of
formwork
normally
used
Formwork
pattern
Abrupt
irregularities
permitted
Gradual
irregularities
permitted
F1
Sawn timber
Not required
< 10 mm
< 15 mm in 2 m
No specific
requirements
F2
Plywood
< 5 mm
< 10 mm in 2 m
Even surface
No grout runs
F3
Sealed
plywood
or fibreglass
or steel
Pattern of
formwork
joints and tie
holes as
stated in
Clause
18.6.4 (a)
and (b)
< 3 mm
< 5 mm in 2 m
Even surface
No grout runs
No grain pattern
No fins or other
projections
F4
Sealed
plywood or
fibreglass or
steel
< 2 mm
< 5 mm in 2 m
F5
Sealed
fibreglass or
Steel
< 1 mm
< 5 mm in 2 m
Uniform, dense
and smooth
surface
No grout runs
No grain pattern
No crazing
No major
blemishes
No staining or
discolouration
No fins or other
projections
Blowholes up to 5
mm dia.
Uniform, dense
and smooth
surface
No grout runs
No grain pattern
No crazing
No blemishes
No staining or
discolouration No
fins or other
projections
Blowholes up to 3
mm dia.
No holes or
embedded metal
parts
F6
Sealed
plywood
< 3 mm
< 5 mm in 2 m
Class
of
finish
Pattern of
formwork
stated in
Clause
18.6.4.(a)

4/19
Specific
requirements
As F4 but no
internal ties and/or
embedded metal
parts allowed
January 2011
Table 18.2 : Unformed Finishes

Class
of
finish
Method of
producing
finish
U1
Levelling the surface of the

compacted concrete with a
screed board
U2
U3
U4
U5
Abrupt
irregularities
permitted
Screed marks
< 5 mm
Gradual
irregularities
permitted
< 10 mm in 2 m
Specific
requirements
Forming a Class U1 finish

and tamping the surface
Tamp marks
< 10 mm
Not applicable
Ridged surface

and wood floating, steel
trowelling or power floating
the surface
and brushing the surface
with a stiff brush
and steel trowelling the
surface under firm
pressure or power floating
the surface
Float marks
< 3 mm
< 10 mm in 2 m
Uniform, dense and

smooth surface
Brush marks
< 3 mm
< 10 mm in 2 m
Rough texture
Nil
< 5 mm in 2 m
Uniform, dense and

smooth surface, free
from trowel marks
No staining or
discolouration
No specific
requirements
Table 18.3 : Treated Finishes

Class
of
finish
T1
Type of
finish
Exposed
aggregate
Method
of
producing finish
Washing and brushing
the concrete surface
Cement matrix removed and coarse
aggregate exposed to a depth not
exceeding one-third of the nominal
maximum coarse aggregate size
T2
Point tooled
Point tooling the

concrete surface
Cement matrix and aggregate surface

removed sufficiently to expose the
aggregate with a minimum penetration into
the matrix between aggregates
T3
Bush
hammered
Bush hammering the

concrete surface
T4
Broken rib
Hammering or chiselling
the edges and faces of
the concrete surface
Cement matrix and aggregate surface

removed
Fragments of concrete ribs removed
T5
Light
blasting
Blasting the concrete

surface by abrasives

aggregate exposed to a minimum depth
T6
Heavy
blasting
and compressed air or

by water jetting

aggregate exposed to a depth not
exceeding one-third of the nominal
maximum coarse aggregate size

5/19
January 2011
Table 18.4 : Class of Finish

Class of finish
Description of surface
Formed
F2
F2
F4
Unformed
U2
U3
U5
F3
U3
U4
Construction joints (for Class T1

finish)
F2
U3
Movement joints
F3
U3
Benching, screeds
F3
U5
Blinding, foundations, pile caps
F1
U1
Surfaces to be covered
screeded
rendered, plastered
tiled
painted
Surfaces for treated finishes

Surfaces for pedestrian traffic
Piers, blocks, pipe surrounds
- below FGL
- above FGL
F1
F2
U1
U3
Manholes, chambers
- external below FGL

- external above FGL
- internal
F1
F2
F2
U1
U3
U3
Culverts, channels

- internal
F1
F2
F4
U1
U3
U5
Water retaining structures

- internal
F2
F4
F4
U3
U5
U5
Buildings

- internal and external surfaces not
exposed to view
- exposed to view in plant rooms
- exposed to view in non-public
areas
- exposed to view in public areas
F1
F2
U1
U3
F3
F4
U3
U5
F5
U5
F1
F4
U1
U5
F5
U5
F2
U1
Bridges, retaining walls, walls
- below FGL
- above FGL, not exposed to direct
public view
- above FGL, exposed to direct
public view
- internal, not exposed to direct
public view

6/19
January 2011
18.4.4
18.4.5
18.4.6
Formwork ties
(a)
Formwork ties shall not be used in any structure which bears against the
ground or retains water.
(b)
Formwork ties and components shall be a type such that any removable part
can be removed without damaging the concrete; any part left in the concrete
shall be at least 40 mm or the specified nominal cover to the reinforcement,
whichever is greater, from the concrete surface.
(c)
Formwork ties and components used with profiled formwork shall be a type
such that holes left by the ties and components are small enough to be
located completely within the recesses in the concrete surface.
Cement mortar for concrete surfaces

(a)
All formwork ties and component holes including blowholes shall be filled.
(b)
Cement mortar for filling blowholes shall consist of cement and fine aggregate
together with the minimum amount of water necessary to achieve a
consistency suitable for completely filling the blowholes.
(c)
Cement mortar for filling holes left by formwork ties and components shall
consist of 1 part of cement to 3 parts of fine aggregate together with the
minimum amount of water necessary to achieve a consistency suitable for
compacting the mortar into the holes. The mix shall contain a non-shrink
admixture.
(d)
Cement mortar for filling blowholes and holes left by formwork ties and
components in concrete surfaces with Class F4, F5 and F6 finishes shall be
the same colour as the hardened concrete; light-coloured sand or white
cement may be used for this purpose.
Surface retarder
Surface retarders shall be a proprietary type reviewed without objection by the
Project Manager and shall not stain or colour the concrete.
18.4.7
Abrasives
Abrasives for blasting shall be grit and shall not contain any silica, iron, clay or other
materials which will stain or colour the concrete.

7/19
January 2011
18.5
SUBMISSIONS
18.5.1
Particulars of formwork and finishes to concrete and samples of materials

(a)
(b)
(c)
Particulars and samples of the proposed materials and methods of

construction for Class F3, F4, F5, F6, U5 and T finishes shall be submitted to
the Project Manager for review without objection as marked 'x' in Table 18.5.
The same particulars shall be submitted for other classes of finish if required
by the Project Manager. For formwork Class F5 and F6, the extent of each
pour shall be proposed by the Contractor and reviewed without objection by
the Project Manager so that no visible difference occurs in concrete surfaces
in the same general plan.
The particulars and samples submitted for formed, unformed and treated
finishes shall include details for trial panels.
Design calculations for formwork and falsework, in accordance with the
requirements of Section 2 of this General Materials and Workmanship
Specification, shall be submitted to the Project Manager for review without
objection.
Table : 18.5 : Particulars to be Submitted

Particulars to be submitted
Formwork drawings
Panel/trough/waffle construction
- Layout
and
pattern
of
panels/troughs/waffles, joints,
rebates and formwork ties
Column construction
- Layout and pattern of column
moulds, joints rebates and
formwork ties
Formed
finishes
Unformed
finishes
Treated
finishes
Design calculations
Check on formwork, falsework,

Permanent Works
Method statement
Samples
Method statement of formwork

and falsework erection, including
sequence for floor slab and
columns
Formwork, F3, F4 and F5
Formwork ties
Cover spaces
Release agent
Curing compound
Surface retarder
Removing formwork
Applying treated finishes
X
X
X
X
X
X
-
X
-
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Brand name
manufacturer's
literature
Programme
Details
and
:
:
Sources of formwork, formwork

ties and cover spacers
Curing method
Filling blowholes
Filling formwork tie holes
Protecting finishes

8/19
January 2011
18.6
WORKMANSHIP
18.6.1
Trial panels
18.6.2
(a)
A trial panel shall be constructed for each Class F4, F5, F6, U5 and T finish to
demonstrate that the proposed materials, mix design, methods of production
and methods of construction, including curing and removal of formwork, shall
produce the specified finish.
(b)
Trial panels for Class F4, F5 and F6 finishes shall be constructed before the
relevant formwork for the Permanent Works is erected, and trial panels for
Class U5 and T finishes shall be constructed before the relevant Permanent
Works is concreted. The trial panels shall be completed at least 4 weeks
before the relevant Permanent Works are programmed to commence.
(c)
The Contractor shall notify the Project Manager before constructing trial
panels.
(d)
Trial panels shall be constructed using the materials, mix design, methods of
production and methods of construction, including curing and removal of
formwork, submitted to and reviewed without objection by the Project
Manager.
(e)
Trial panels shall be horizontal, vertical or inclined as appropriate and shall be

constructed at locations reviewed without objection by the Project Manager.
Unless otherwise stated in the Contract each trial panel shall be not less than
2 m by 2 m by 300 mm thick, and shall contain reinforcement representative
of the most congested reinforcement which will be used in the Permanent
Works. Trial panels shall incorporate formwork ties and components,
horizontal joints, vertical joints, chamfers, splays, rebates and other features
representative of those which will be used in the Permanent Works, including
the filling of formwork ties, components and blowholes.
(f)
The Contractor shall submit the trial panels to the Project Manager for review
without objection. When the Project Manager has issued a notice of no
objection for the trial panels, they shall become a benchmark against which all
subsequent finishes of concrete surfaces shall comply. Benchmarks shall be
protected from damage and shall be left in position until the Project Manager
directs their removal.
Non-compliance: trial panels

If the Project Manager determines that the specified finish has not been produced in
the trial panel, particulars of proposed changes to the materials, mix design,
methods of production or methods of construction shall be submitted to the Project
Manager for review without objection and further trial panels shall be constructed
until the specified finish is produced in the trial panel. Further trial mixes shall be
made unless the Project Manager directs otherwise.
18.6.3
Commencement of formwork and concreting

Formwork for Class F4, F5 and F6 finishes shall not be erected and elements with
Class U5 and T finishes shall not be concreted until the Project Manager has
determined that the specified finish has been produced in the trial panel.

9/19
January 2011
18.6.4

The materials, mix design, methods of production or methods of construction,
including curing and removal of formwork, used to produce the specified finish in
the benchmarks shall not be changed unless reviewed without objection by the
Project Manager.
18.6.5
18.6.6
Storage of formwork
(a)
Formwork shall be stored off the ground on level supports and in a manner
which will not result in damage, deformation or contamination of the
formwork.
(b)
Formwork for Class F3, F4, F5 and F6 finishes shall be covered and protected
from exposure to conditions which may affect the formwork.
Storage of release agents and surface retarders

Release agents and surface retarders shall be stored in sealed containers marked
to identify the contents and protected from exposure to conditions which may affect
the material. The materials shall be stored in accordance with the manufacturers'
recommendations and shall not be used after the recommended shelf life has been
exceeded.
18.6.7
Construction of formwork
(a)
Formwork shall not have any splits, cracks or other defects. The faces and
edges of formwork shall be clean and formwork faces shall be free of
projections.
(b)
Formwork which has been previously used shall be repaired and the edges
resealed before it is erected.
(c)
Formwork shall be firmly supported and individual panels shall be rigid. Joints
between formwork panels, stop ends and adjoining concrete shall be tight and
shall not permit grout loss.
(d)
Formwork shall be cut in such a manner that reinforcement and built-in

components passing through the formwork are maintained in position; the
joints shall be tight and shall not permit grout loss.
(e)
Formers for profiled formwork, chamfers, splays, rebates and other features
shall be rigidly and evenly fixed to the formwork along the complete length
and shall not permit grout loss.
(f)
Formwork ties and components shall be fixed in such a manner that they do
not touch reinforcement or built-in components.
Formwork ties and
components shall fit tightly against formwork faces and shall not permit grout
loss.
(g)
If required for compaction, cleaning or inspection, temporary openings shall

be provided in the formwork.

10/19
January 2011
18.6.8
Construction of formwork for Class F2, F3, F4, F5 and F6 finishes

(a)
Formwork panels for Class F2, F3, F4, F5 and F6 finishes shall be the same
size and shall form a regular pattern as shown on the Employer's Drawings
and/or reviewed without objection by the Project Manager. The lines of joints
between panels shall be straight and continuous, horizontal and vertical, or
inclined to suit the pattern of profiled formwork, and shall be coincident with
construction joints and other joints and with recesses in the concrete surface.
The number of make-up pieces shall be kept to a minimum and shall be the
same material as the formwork system.
(b)
Holes left by formwork ties and components in concrete surfaces with

Class F2, F3 and F4 finishes shall be in line horizontally and vertically and
shall form a regular pattern reviewed without objection by the Project
Manager. Holes in profiled formwork shall be located in such a manner that
the holes are completely within recesses in the concrete surface.
(c)
Chamfers shall be provided for all external angles of 90 or less in concrete

surfaces with Class F2, F3, F4, F5 and F6 finishes.
Formwork for curved concrete surfaces with Class F2, F3, F4, F5 and F6
finishes shall not be made up of a series of flats or straights.
(d)
18.6.9
Construction of formwork for Class F3, F4, F5 and F6 finishes

(a)
Each type of formwork for either Class F3, F4, F5 and F6 finishes shall be
obtained from one source and different types of formwork shall not be mixed.
Damaged formwork shall not be used. Parts of steel formwork which will be in
contact with concrete shall be free from rust.
(b)
For concrete surfaces with Class F3, F4, F5 and F6 finishes, joints between
formwork panels shall be sealed with foamed rubber strips. The foamed
rubber strips shall be sufficiently compressible to form a grout-tight joint. The
width of the resulting gap between the panels shall not be greater than 1 mm
and the sealing strips shall not protrude proud of the surface of the formwork
panels. Joints between formwork panels shall not be sealed by tape fixed to
the formwork faces.
(c)
For concrete surfaces with Class F3, F4, F5 and F6 finishes, joints between
the formwork and its ends, adjoining concrete and built-in components shall
be sealed with gaskets of rubber or flexible foamed polyurethane; the gaskets
shall be fixed firmly and evenly to the formwork. The joints shall not be sealed
by tape fixed to the formwork faces, putty or other sealants.
(d)
Formwork for Class F3, F4, F5 and F6 finishes shall be protected from
spillages, rust marks and stains.
(e)
For concrete surfaces with Class F3, F4 and F5 finishes, the formed face at
all joints between formwork panels and moulds shall be flush.

11/19
January 2011
18.6.10 Built-in components

(a)
Built-in components, void formers and box-outs shall be fixed in position

before concreting. Void formers and box-outs shall not be used instead of
built-in components. Polystyrene shall not be used for void formers and boxouts.
(b)
Hardened concrete shall not be cut or broken to provide holes or chases

without being reviewed without objection by the Project Manager.
(c)
Pipe sleeves, inserts and ducts shall be securely and correctly located within
the specified tolerances.
(d)
Formwork for openings, chases and holes shall not interfere with the
reinforcement.
(e)
Cast-in items shall be temporarily sealed where necessary to ensure that no

unintended seepage of grout occurs into channels or recesses of the cast-in
item.
18.6.11 Application of release agents

(a)
(b)
A release agent shall be used on all formwork other than permanent formwork
and formwork on which a surface retarder is used to produce a Class T1
finish. The release agent shall be applied by the method and at the rate of
application recommended by the manufacturer or as demonstrated to be
satisfactory by use in the trial panel.
Formwork faces shall be cleaned before release agents are applied.
Concrete, reinforcement and built-in components shall not be contaminated
by release agents.
(c)
Each type of release agent used on formwork for Class F3, F4, F5 and F6
finishes shall be obtained from one manufacturer and different types of
release agent shall not be used on formwork for the same element.
(d)
Release agents shall be applied to formwork for Class F3, F4, F5 and F6
finishes after the formwork has been erected and before the reinforcement is
fixed or, if this is not practicable, immediately before the formwork is erected.
The release agent covering shall be complete and uniform.
18.6.12 Times for removal of falsework and formwork

(a)
Falsework and formwork shall not be loosened or removed before the

minimum times stated in Table 18.6 have elapsed. The times stated are for a
minimum ambient temperature of 15C, for elements without superimposed
loads and for concrete containing OPC, PPFAC or both OPC and PFA.
(b)
For the purpose of determining the minimum times for loosening or removing
falsework and formwork, copings at the top of columns in water retaining
structures shall be classified as slabs and roof slabs in water retaining
structures shall be classified as beams.
(c)
For the purpose of Table 18.6, props left in shall include a minimum of 4
props over any one span in each orthogonal direction.

12/19
January 2011
(d)
Concrete which has a durability exposure of Very Severe as indicated on the

Employers Drawings, shall have the formwork left in place for a minimum
period of seven days.
Table 18.6 : Minimum Times for Loosening or Removing Falsework

Class F1, F2, F3, F4 and F6 finishes
Class F5 finish
Type of falsework or formwork
Concrete
without PFA
Concrete
with PFA
Concrete with or
without PFA
Vertical (non-profiled)
(profiled)
12 hours
7 days
15 hours
7 days
48 hours
7 days
Inclined to top surfaces
12 hours
15 hours
48 hours
Soffits of slabs and ribs

(props left in)
4 days
4 days
7 days
Soffits of beams
(props left in)
7 days
7 days
14 days
Props to slabs and ribs

(unloaded)
10 days
10 days
14days
Props to beams
(unloaded)
14 days
14 days
14days
Props to cantilevers
28 days
28 days
28 days
18.6.13 Removal of falsework and formwork

(a)
Formwork shall be removed without hammering or levering the concrete and

in such a manner that there is no shock, disturbance, damage or loading to
the concrete or damage to the specified finish. Side formwork shall be
removed without disturbing soffit formwork. Soffit formwork shall be removed
without disturbing props except where the Contractor has previously
submitted a method statement, reviewed without objection by the Project
Manager, that demonstrates that the intended prop removal or replacement
sequence can be achieved without overstressing the structure, giving due
consideration to the strength of the concrete at the time.
(b)
Falsework and formwork shall be loosened and removed in a continuous

operation and in accordance with a method reviewed without objection by the
Project Manager. All formwork shall be loosened before individual panels are
removed. Individual panels or make-up pieces shall not be left in position.
(c)
Formwork shall be thoroughly cleaned to remove all traces of concrete and

made good to the original standard before any reuse.
(d)
Unless formwork has been left in place for curing requirements it must be fully
removed immediately after initial loosening so that curing may be carried out.

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January 2011
18.6.14 Unformed finishes

(a)
Unformed finishes shall be produced by the methods stated in Table 18.2.
(b)
Brushing to produce a Class U4 finish shall be carried out in straight lines in a

direction reviewed without objection by the Project Manager. Brushing shall
be carried out when the concrete has hardened sufficiently for the float marks
to be removed and for the ridges to be formed without displacing the
aggregate.
(c)
Floating and trowelling shall not be carried out until the concrete has
hardened sufficiently to allow the specified finish to be produced with the
minimum amount of floating and trowelling. Excess laitance shall not be
produced.
18.6.15 Treated finishes

(a)
Treated finishes shall be produced by constructing a concrete surface with a

Class F3 or U3 finish as appropriate and applying the treatment to the surface
by the methods stated in Table 18.3. Abrupt irregularities in the concrete
surface shall be removed before the treatment is applied.
(b)
The treatment shall be applied in a continuous operation in accordance with a

programme reviewed without objection by the Project Manager.
18.6.16 Class T1 finish

(a)
Washing and brushing to produce a Class T1 finish shall not be carried out
until the concrete has hardened sufficiently for the cement matrix to be
removed without disturbing the coarse aggregate. After washing and
brushing have been completed and the concrete surface has hardened, the
surface shall be cleaned.
(b)
The cement matrix shall not be removed or the aggregate exposed by

mechanical methods.
(c)
Class T1 finishes may be produced by using a surface retarder applied to the

formwork or to the concrete surface. The surface retarder shall be applied by
the method and at the rate of application recommended by the manufacturer,
or as demonstrated to be satisfactory by use on the trial panel.
(d)
Plywood to which a surface retarder is to be applied shall be sealed with

barrier paint or polyurethane varnish. The formwork shall be removed in small
sections and the coarse aggregate exposed by washing and brushing the
concrete surface.
(e)
Formwork to which a surface retarder has been applied shall not be re-used
unless a surface retarder is to be used again on the formwork. Formwork to
which a surface retarder has been applied and which is to be re-used shall be
cleaned before the retarder is reapplied.
18.6.17 Class T2 and T3 finishes

Point tooling to produce Class T2 finishes and bush hammering to produce
Class T3 finishes shall be carried out evenly in small areas and not in distinct lines.
Tooling and hammering shall not start until at least 7 days after concreting.
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January 2011
18.6.18 Class T4 finish

Hammering or chiseling to produce a Class T4 finish shall be applied from only one
direction and only either hammering or chiseling shall be applied, on any one face.
Hammering and chiseling shall not start until at least 14 days after concreting.
18.6.19 Class T5 and T6 finishes
(a)
Blasting to produce Class T5 and T6 finishes shall not be carried out until the
concrete has hardened sufficiently for the cement matrix to be removed
without disturbing the coarse aggregate. Adjacent surfaces shall be protected
from blasting and dust shall be controlled by screens and by water-spraying.
18.6.20 Remedial and repair work on concrete surfaces

(a)
Remedial or repair work shall not be carried out on concrete surfaces unless
(b)
Prior to any mechanical work being carried out to any concrete surface, a trial
repair panel shall be offered to the Project Manager for review without
objection.
(c)
Abrupt irregularities shall be removed from concrete surfaces which will be

painted or to which tiles will be fixed with adhesives.
(d)
For slipformed surfaces, as the concrete emerges from the shutter, any drag
cracks shall immediately be closed by means of a wooden float. The surface
of the concrete shall then be gently brushed horizontally to produce a light
uniform texture. Any necessary cutting out of concrete shall be carried out
immediately and made good as soon as possible thereafter using concrete
taken from the slipforming mix with the coarse aggregate sieved out as
necessary.
18.6.21 Filling blowholes and formwork tie holes

(a)
Blowholes exceeding 3 mm in size in water retaining structures and watertight

structures, and blowholes exceeding 10 mm in size in other structures shall
be filled with cement mortar. The size of blowholes shall be the maximum
dimension measured across the hole on the concrete surface. If the number
and size of blowholes in concrete surfaces with Class F3 and F4 finishes is
greater than in the trial panel the blowholes shall be filled.
(b)
Holes left by formwork ties and components shall be cleaned and filled by
ramming cement mortar into the holes in layers. Holes in concrete surfaces
with a Class F4 finish shall be filled to a level slightly below the concrete
surface; the holes shall not be overfilled and rubbed down.
(c)
Filling of blowholes and holes left by formwork ties and components shall be
carried out as soon as practicable after the Project Manager has inspected
the finish and with the minimum interruption to curing. Filling of blow holes in
Class F5 finish shall not be permitted.

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January 2011
18.6.22 Spatterdash and bonding agents

(a)
Spatterdash shall consist of cement and coarse sand or granite fines in the
proportions 1:2 by volume mixed with the minimum amount of water
necessary to achieve the consistency of a thick slurry. Spatterdash shall be
thrown with a hand trowel onto the surface to a thickness not exceeding 6 mm
and shall cover at least 60% of the area which is to be plastered or rendered.
Spatterdash shall be wetted one hour after application and shall be allowed to
cure and harden before under coats are applied.
(b)
Spatterdash shall be applied as soon as practicable after the Project Manager

has inspected the finish and after the concrete surface has been cleaned and
wetted.
(c)
Bonding agents for attaching finishes to concrete surfaces shall be a

be applied by the method and at the rate recommended by the manufacturer.
18.6.23 Construction Tolerances

(a)
Except where otherwise specified in the Contract, deviation of concrete

surfaces from the specified lines, grades and dimensions shown on the
Employer's Drawings shall comply with the tolerances set-out in this subsection. The dimensions shown on the Employers Drawings show the
required as-constructed position after deflections due to self weight and
superimposed dead loads.
(b)
Final measurements to confirm that the Works are within the specified
tolerances shall be made at 28 days after casting for in-situ construction.
(c)
The specified tolerances shall not be cumulative.

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January 2011
(d)
The permitted deviations for in-situ concrete construction shall be as follows :

(i)
Variation in equivalent positions, in plan, of a

concrete surface of a column or wall, between
two successive pours at floor level
+5 mm in any direction
(ii)
Variation from the vertical:

- In the lines and surfaces of concrete
columns and walls
No more than 1:300, up

to 15 mm maximum
measured horizontally
from true vertical
- In the lines and surfaces of conspicuous

items such as corners of columns,
architectural rebates, etc.

to 10 mm maximum,
from true vertical
5 mm
(iii)
Variation in normal level of floor slab, as

shown on the drawings
(iv)
Variation from the horizontal (Refer Table

18.2 for unformed surfaces other than slab
surfaces)

to +10 mm, -5 mm
maximum for upper
slab surfaces
No more than shown in
Table 18.1, up to
-10 mm, +0 mm
maximum for slab and
rib soffits, measured
vertically from true level
(v)
Variation from true plan position and from

correct lines

to 15 mm maximum
from true plan position
(vi)
Variation in cross section and linear

dimensions
Members up to 1500
mm dimension; +5 mm,
-0 mm
Members over 1500
mm; +10 mm, -0 mm
(vii)
(viii)
Openings, sleeves and embedded fixtures:

-
Variation of location
6 mm
Variation of size
3 mm
Variation in steps:
-
In a flight, maximum accumulative

tolerance,
rise 3 mm
tread 6 mm
In consecutive steps,
rise 2 mm
tread 3 mm

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January 2011
(e)
The permitted deviation for in-situ concrete items associated with mechanical
and electrical plant shall be as follows:
(i)
(ii)
(iii)
(iv)
(v)
Variation from verticality:

-
Plinths and machine bases
3 mm in 8 m
( 3 mm max)
Cable and pipe trenches
6 mm per 8 m
( 6 mm max)
Variation from level or specific gradient or batter:

-
3 mm in 8 m
( 3 mm max)
6 mm per 8 m
( 6 mm max)
Variation from specified centre lines or setting out lines:

-
3 mm
6 mm
Variation from specified cross-sectional dimensions:

-
3 mm
6 mm
Variation from specified position for bolt

boxes
6 mm
Variation from
foundation bolts
6 mm
specified
position
for
The plan distance between ends and sides of escalator and moving walkway
voids and pits shall be within +10mm/-0mm.
(f)
Notwithstanding the maximum tolerances specified in the preceding subsections, there shall be no misalignment at vertical or horizontal joints on
exposed faces. Also, any exposed concrete face which shows an undulating
or irregular surface, even though it may be within the stated tolerances, will
not be accepted.
(g)
Note that where a tolerance is related to a given length, the tolerance for any
lesser length shall be in linear proportion thereto, subject to review without
objection by the Project Manager. For verticality, the tolerance for each lift of
concrete shall be calculated on the same basis with a normal maximum of 3
mm deviation from true vertical.
(h)
The Contractor shall determine the amount of pre-set deflection and/or precamber that may be necessary in formwork to ensure that the as constructed
position of the concrete is within the specified tolerances.

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January 2011
18.6.24 Temporary fixings left in

Temporary fixings left in the completed concrete structure shall be left with a
minimum of 40mm cover and filled over with a polymer modified mortar, reviewed
without objection by the Project Manager. Temporary fixings shall not be left in on
concrete surfaces that are exposed to public view or in water retaining structures.
18.7
INSPECTION, TESTING & COMMISSIONING
18.7.1
Inspection of formwork and reinforcement
18.7.2
18.7.3
(a)
The Contractor shall allow sufficient time for the Project Manager to inspect
the completed formwork and reinforcement, including trial panels, before
carrying out any work, including fixing reinforcement adjacent to formwork and
erecting formwork adjacent to reinforcement, which will make access to the
formwork faces or reinforcement difficult.
(b)
The Contractor shall allow sufficient time for the Project Manager to inspect
formwork for Class F3, F4, F5 and F6 finishes before it is erected and shall
notify the Project Manager before erecting the formwork.
Inspection of finishes
(a)
Before any subsequent work is carried out on a concrete surface, the surface
will be inspected by the Project Manager to determine if the specified finish
has been produced. Formed finishes shall be inspected as soon as the
formwork has been removed.
(b)
Blowholes or holes left by formwork ties and components shall not be filled
and spatterdash or other coverings shall not be applied before the inspection.
Compliance of finishes
(a)
Concrete surfaces shall have the characteristics stated in Tables 18.1 and
18.2 for the different classes of formed and unformed finish before any
subsequent work is carried out on the concrete surface and shall have the
characteristics stated in Table 18.3 for the different classes of treated finish.
(b)
The Project Manager will determine if the specified finish has been produced
and will use the trial panels as a benchmark.
(c)
Abrupt irregularities shall be measured by direct measurement. Gradual

irregularities shall be measured using a 2 m long straight edge on surfaces
intended to be flat and by a method reviewed without objection by the Project
Manager on other surfaces.
(d)
All exposed in-situ and pre-cast concrete surfaces shall match for colour and
surface texture.

19/19
January 2011
SECTION 19 STEEL REINFORCEMENT
19.1
19.1.1
Reinforcement Connector
Reinforcement connector is a coupler or sleeve designed to transmit the force
between two bars in tension or compression.
19.1.2
Bar Reinforcement
Bar reinforcement is hot rolled steel bar or cold worked steel bar or cold reduced
wire reinforcement.
19.1.3
Fabric Reinforcement
Fabric reinforcement is a mesh or grid of bar reinforcement welded in the factory in
accordance with BS 4483.
19.1.4
Batch: Reinforcement
A batch of bar reinforcement, fabric reinforcement or reinforcement connectors for
tension joints is any quantity of bar reinforcement, fabric reinforcement or
reinforcement connectors for tension joints of the same type, size and grade,
manufactured by the same mill, covered by the same mill and testing certificates
and delivered to Site at any one time. In addition, for epoxy coated reinforcement
and galvanized reinforcement, the coatings shall have been applied at the same
coating factory and shall be covered by the same testing certificates.
19.2
MATERIALS
19.2.1
Bar Reinforcement and Fabric Reinforcement

(a)
Except where noted on the Employer's Drawings, bar reinforcement and

fabric reinforcement shall comply with the following:
Hot rolled steel bars
: Construction Standard CS2
Cold worked steel bars
: BS 4461
Steel fabric
: BS 4483
Cold reduced steel wire
: BS 4482
Deformed high yield steel bars : BS 4449, Type 2 bond classification

(b)
All reinforcement shall comply with the requirements of Practice Note for
Authorised Persons and Registered Structural Engineers (PNAP) 122 issued
by the Buildings Department.

Section 19 Steel Reinforcement
1/14
January 2011
19.2.2
19.2.3
19.2.4
19.2.5
Epoxy Coatings to Reinforcement

(a)
Epoxy coatings to reinforcement and patching material for epoxy coatings

shall comply with ASTM A775M except as stated in Sections 19.2.2 (b),
19.4.5, 19.5.3, 19.5.4 and 19.5.8. The coatings shall be applied by the
electrostatic spray method in accordance with ASTM A775M at a factory
(b)
The film thickness of the coating after curing shall be at least 0.15 mm and
shall not exceed 0.25 mm over the complete periphery including deformations
and ribs. The bond classification of coated bars determined in bond
performance tests shall not be less than that of uncoated bars.
Galvanizing to Reinforcement
(a)
Galvanizing to reinforcement shall comply with BS 729.

Galvanized
reinforcement shall be chromate passivated as part of the galvanizing process
by quenching the bars immediately after galvanizing in a solution containing at
least 0.2% sodium dichromate in water. The galvanizing shall be applied after
cutting and bending of the reinforcement.
(b)
Metallic zinc-rich priming paint for repairs to galvanized reinforcement shall

comply with BS 4652.
Reinforcement Connectors
(a)
Reinforcement couplers shall be of proprietary type, accepted by the Buildings

Department and reviewed without objection by the Project Manager.
(b)
Reinforcement connectors for tension joints shall be a cold swaged or

threaded type. The connectors shall develop the full tensile strength of the
parent bar and shall comprise high tensile steel studs and seamless steel
tubes fitted with protective plastic caps.
(c)
Reinforcement connectors for compression joints shall be wedge locking or

bolted sleeve type.
(d)
The concrete cover to reinforcement connectors shall not be less than the
specified minimum.
(e)
Reinforcement connectors shall not be used with galvanized or epoxy coated

reinforcement.
Cover Spacers
(a)
Cover spacers for reinforcement shall be concrete blocks or a proprietary

plastic or concrete type. Proprietary cover spacers shall be reviewed without
(b)
Cover spacers for Class F3, F4, F5 and F6 finishes shall be a proprietary
plastic or concrete type. Cover spacers for epoxy coated reinforcement and
galvanized reinforcement shall be a proprietary plastic type.

2/14
January 2011
(c)
Cover spacers shall be as small as practicable consistent with their purpose

and shall be designed to maintain the specified cover to reinforcement. Cover
spacers shall be capable of supporting the weight of reinforcement and
construction loads without breaking, deforming or overturning.
(d)
The strength and durability of concrete blocks and proprietary concrete cover
spacers shall not be less than that of the surrounding concrete.
(e)
Cover spacers for Class F3, F4, F5 and F6 finishes shall be of a colour similar
to that of the surrounding concrete and shall not cause indentations in the
formwork.
The use of Site manufactured concrete spacer blocks will only be permitted if
the Project Manager has reviewed without objection the method of
manufacture and quality of the block.
(f)
19.2.6
Chairs, Supports and Spacers

Chairs, supports and spacers other than cover spacers for reinforcement shall be
steel. The steel shall be coated with nylon, epoxy, plastic or other dielectric
material for epoxy coated reinforcement and shall be galvanized for galvanized
reinforcement.
19.2.7
Tying Wire
Tying wire for reinforcement adjacent to and above Class F4, F5 and F6 finishes
shall be 1.2 mm diameter stainless steel wire. Tying wire for epoxy coated
reinforcement shall be 1.6 mm diameter soft annealed steel wire coated with nylon,
epoxy, plastic or other dielectric material. Tying wire for galvanized reinforcement
shall be 1.6 mm diameter galvanized soft annealed steel wire. Tying wire for other
reinforcement shall be 1.6 mm diameter soft annealed steel wire.
19.2.8
Tying Devices and Clips

Tying devices and clips for reinforcement shall be a proprietary steel type reviewed
without objection by the Project Manager. Tying devices and clips for reinforcement
adjacent to and above Class F4, F5 and F6 finishes shall be stainless steel. Tying
devices and clips for epoxy coated reinforcement shall be coated with nylon, epoxy,
plastic or other dielectric material. Tying devices and clips for galvanized
reinforcement shall be galvanized.
19.3
SUBMISSIONS
19.3.1
Particulars of Bar Reinforcement and Fabric Reinforcement

The following particulars of the proposed bar reinforcement and fabric
reinforcement shall be submitted to the Project Manager for review:
(a)
for Class 1 bar reinforcement, a mill certificate from the quality assured
stocklist in accordance with CS2 Cl.4.1.3 and a copy of the manufacturer's
third party certificate;
(b)
for Class 2 bar reinforcement, a mill certificate from the quality assured
stocklist in accordance with CS2 Cl.4.1.4 and a copy of the manufacturers
third party certificate;

3/14
January 2011
19.3.2
(c)
for Class 3 bar reinforcement, a mill certificate from the supplier in accordance
with CS2 Cl.4.2;
(d)
Upon delivery of bar reinforcement the Contractor shall submit a test report
containing the details specified in CS2, Cl.3.3.3 and Cl.3.3.5; and
(e)
for fabric reinforcement, a certificate form the manufacturer showing the

manufacturer's name, the date and place of manufacture and showing that
the reinforcement complies with the requirements stated in the Contract
including details of:
(i)
bond classification of deformed bar reinforcement and of fabric

reinforcement;
(ii)
cast analysis;
(iii)
carbon equivalent value;
(iv)
results of tensile, bend and rebend tests, including the effective

cross-sectional area for tensile tests;
(v)
results of bond performance tests for deformed bar reinforcement and

for fabric reinforcement; and
(vi)
results of weld tests for fabric reinforcement.
Particulars of Epoxy Coatings to Reinforcement

The following particulars of the proposed epoxy coatings to reinforcement shall be
(a)
name and location of the coating factory;
(b)
coating material and method of application; and
(c)
a certificate from the manufacturer showing the date and place of application
of the coating and showing that the epoxy coatings comply with the
requirements stated in the Contract and including results of tests for:
(i)
thickness of coating;
(ii)
chemical resistance;
(iii)
resistance to applied voltage;
(iv)
chloride permeability;
(v)
adhesion of coating;
(vi)
bond strength to concrete;
(vii) abrasion resistance;

(viii) impact strength; and
(ix)
hardness.

4/14
January 2011
19.3.3
Particulars of Galvanized Coatings to Reinforcement

The following particulars of the proposed galvanized coatings to reinforcement shall
be submitted to the Project Manager for review:
19.3.4
(a)
name and location of the coating factory; and
(b)
a certificate from the manufacturer showing the date and place of application
of the coating and showing that the galvanized coatings comply with the
requirements stated in the Contract and including results of tests for:
(i)
weight of coating; and
(ii)
uniformity of coating.
Particulars of Reinforcement Connectors

Particulars of the proposed materials and methods of installation for reinforcement
connectors, including the manufacturer's literature, and tensile test results, shall be
19.3.5
Particulars Suitable for Submission to Buildings Department

All submissions under Clauses 19.3.1 19.3.4 shall be in a form suitable for
submission to the Buildings Department.
19.3.6
19.3.7
Bending Schedules
(a)
Unless otherwise stated in the Contract, for works designed in detail by the
Employer, any bending schedules by the Employer are provided for the
information of the Contractor but are not guaranteed correct. The Contractor
shall check the schedules and submit to the Project Manager for review
without objection, any amendments, additions or deductions as may be
necessary to conform to the Employer's Drawings and the Specification at
least 28 days before bending of the reinforcement commences.
(b)
Should any alterations to the bending schedules be required by the Contractor

to facilitate his sequence of construction, location of construction joints, boxouts, openings and the like, then the revised bending schedules together with
explanatory notes and diagrams shall be submitted to the Project Manager for
review without objection at least 28 days before bending of the reinforcement
commences.

the Project Manager at the same time as particulars of the material are submitted:
(a)
bar and fabric reinforcement;
(b)
epoxy coated bar and fabric reinforcement;
(c)
galvanized bar and fabric reinforcement;
(d)
reinforcement connectors for tension joints and compression joints;

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January 2011
(e)
cover spacers; and
(f)
tying wire, tying devices and clips.
19.4
WORKMANSHIP
19.4.1
Handling of Reinforcement
19.4.2
19.4.3
(a)
Reinforcement shall not be subjected to rough handling, shock loading or

dropping from a height.
(b)
Nylon, rope or padded slings shall be used for lifting epoxy coated
reinforcement and galvanized reinforcement; bundles shall be lifted with a
strongback or with multiple supports to prevent abrasion.
Storage of Reinforcement
(a)
Reinforcement shall be stored off the ground on level supports and in a

manner which will not result in damage or deformation to, or in contamination
of, the reinforcement. Fabric reinforcement shall be stored horizontally.
Where conditions of saline water exist the Contractor shall provide hard
standing reviewed without objection by the Project Manager for steel storage
and bending and shall prevent contact between steel and saline water.
(b)
Different types and sizes of reinforcement shall be stored separately.
(c)
Reinforcement shall not be stored on or adjacent to concrete surfaces which

form part of the Permanent Works or existing structures.
(d)
Epoxy coated reinforcement and galvanized reinforcement shall be stored on

wooden or padded cribbing.
Cutting and Bending Reinforcement

(a)
Reinforcement shall be cut and bent in accordance with BS 4466 to the

specified shapes and dimensions and shall be bent at temperatures of at least
5C and not exceeding 100C.
(b)
Epoxy coated reinforcement shall be bent cold. Bar cutting and bar bending
equipment for epoxy coated reinforcement shall have padded supports and
contact areas shall be fitted with nylon or plastic mandrels.
(c)
Grade 460 reinforcement shall not be rebent or straightened after bending,

with the exception of reinforcement of 20mm diameter (or less) which projects
from hardened concrete or is out of position. Such reinforcement and Grade
250 reinforcement which projects from hardened concrete may be bent aside
and rebent provided that the internal radius of the bend is at least three times
the diameter of the bar for Grade 460 and twice the diameter of the bar for
Grade 250, and that bending is not carried out by levering against the
concrete or by other methods which will damage the concrete.
(d)
The ends of bars to be used with reinforcement connectors for compression

joints shall be sawn square with all burrs removed.

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January 2011
19.4.4
19.4.5
Surface Condition of Reinforcement

(a)
Reinforcement shall be clean at the time of fixing and shall be free from loose
mill scale, loose rust or any substance which is likely to reduce the bond or
affect the reinforcement or concrete chemically. Reinforcement shall be
maintained in this condition until concrete is placed around it.
(b)
If the surface condition of the reinforcement deteriorates such that it does not
comply with the requirements stated in Section 19.4.4(a), the reinforcement
shall be cleaned or dealt with by other methods reviewed without objection by
the Project Manager, prior to being used.
Repairs to Epoxy Coatings and Galvanized Coatings

(a)
If the coating to epoxy coated reinforcement is delaminated or split at any

point or if the coating to epoxy coated reinforcement or galvanized
reinforcement is damaged:
(i)
at any point by an amount exceeding 25 mm in area or 50 mm in

length;
(ii)
at more than three points in a 1 m length by amounts each not

exceeding 25 mm in area or 50 mm in length; or
(iii)
at more than six points in the cut and bent length of a bar by amounts
each not exceeding 25 mm in area or 50 mm in length,
then that part of the reinforcement shall not be used in the Permanent Works.
19.4.6
(b)
Damaged areas not exceeding 25 mm in area or 50 mm in length and cut

ends of epoxy coated reinforcement, other than that rejected under Section
19.4.5(a) shall be repaired using patching material applied in accordance with
the manufacturer's recommendations.
(c)
Damaged areas not exceeding 25 mm in area or 50 mm in length and cut

ends of galvanized reinforcement shall be repaired by applying two coats of
metallic zinc-rich priming paint. Sufficient paint shall be applied to provide a
zinc coating of at least the same thickness as the galvanized coating.
(d)
Repairs to epoxy coatings and galvanized coatings shall be carried out within
8 hours of cutting or damage. Traces of rust shall be removed from the
surface of the reinforcement before the repair is carried out.
Fixing Reinforcement
(a)
Bar reinforcement, fabric reinforcement and reinforcement connectors for

tension joints from each batch shall not be fixed until testing of the batch has
been completed.
(b)
Reinforcement shall be fixed rigidly in position and secured against

displacement.
(c)
A sufficient number of intersecting and lapping bars shall be tied using tying
wire, tying devices or clips to prevent movement of the reinforcement. The
ends of tying wire, tying devices and clips shall not encroach into the cover to
reinforcement.

7/14
January 2011
19.4.7
(d)
Laps and joints in reinforcement shall be made only at the positions specified
on the Employer's Drawings and by the specified methods except where
otherwise reviewed without objection by the Project Manager in accordance
with Section 19.3.5(b).
(e)
Sufficient numbers of cover spacers, chairs, supports and spacers other than
cover spacers shall be provided to maintain the reinforcement in the correct
location and to maintain the specified cover at all positions. Cover spacers,
chairs, supports and spacers other than cover spacers shall be placed at a
maximum spacing of 1.5 m. Chairs, supports and spacers other than cover
spacers shall be positioned adjacent to or above cover spacers and shall
have at least the same cover as that specified for the reinforcement.
(f)
Prefabricated reinforcement cages shall be rigidly supported and braced

before moving.
(g)
Reinforcement which is free-standing shall be secured in position and braced

to prevent movement due to wind and other loads.
Fixing Reinforcement Connectors

Reinforcement connectors shall be fixed in accordance with the manufacturer's
recommendations and using equipment recommended by the manufacturer.
19.4.8
Welding of Reinforcement
Reinforcement shall not be welded.
19.4.9
Exposed Reinforcement
Reinforcement which is to be left exposed shall be protected by coating with cement
slurry. The bars shall be cleaned and recoated by the same method if the original
coating has begun to deteriorate.
19.4.10 Access Over Reinforcement

Reinforcement shall not be contaminated or displaced as a result of access over the
reinforcement; access shall be obtained by using planks and ladders.
19.4.11 Tolerances: Reinforcement
(a)
Tolerances on cutting and bending reinforcement shall comply with BS 4466,

Table 1, 2 and 4.
(b)
Unless otherwise stated on the Employer's Drawings, reinforcement shall not

be out of the designed position by more than 5 mm and shall not encroach
into the minimum specified cover.
(c)
Reinforcement bars may be moved as necessary to avoid interference with

other reinforcing steel or embedded items. If bars are moved more than one
bar diameter or enough to exceed the above tolerance, the resulting
arrangement of bars shall be subject to review without objection by the Project
Manager.

8/14
January 2011
19.5
19.5.1
Inspection of Reinforcement
The Contractor shall allow sufficient time for the Project Manager to inspect the
completed reinforcement before carrying out any work, including erecting formwork
adjacent to reinforcement, which will make access to the reinforcement difficult.
The Contractor shall notify the Project Manager before carrying out such work.
19.5.2
Samples: Reinforcement
(a)
Samples of bar reinforcement, fabric reinforcement and reinforcement

connectors for tension joints from each batch of the material delivered to Site,
at least 14 days before fixing of the reinforcement starts, shall be submitted to
the Project Manager for review without objection. The number of samples to
be provided from each batch shall be as stated in Table 19.1.
(b)
The number of specimens in each sample shall be as follows:

(i)
bar reinforcement (without epoxy coating or

galvanized coating)
in accordance with CS2

Table 9
(ii)
epoxy coated bar reinforcement and

galvanized bar reinforcement
2 additional specimens to
those specified in CS2
Table 9 for bar
reinforcement
(iii)
fabric reinforcement (without epoxy coating

or galvanized coating)
(iv)
epoxy coated fabric reinforcement and

galvanized fabric reinforcement
(v)
reinforcement connectors for tension joints
(c)
The list of bars currently acceptable for abbreviated testing are given in
Construction Standard CS2.
(d)
Each specimen of bar reinforcement shall be 1 m long. Each specimen of

fabric reinforcement shall be 1.2 m long by 1.2 m wide and shall contain at
least three wires in each direction. Each specimen of reinforcement
connectors shall consist of one reinforcement connector joined to two lengths
of bar each 500 mm long; the bars shall be the same type, size, grade and
source of manufacture as the bars to which the reinforcement connector will
be fixed in the Permanent Works. The assembly shall be prepared in the
same manner as that to be used for the Permanent Works.
(e)
Each specimen of bar reinforcement and fabric reinforcement shall be taken

from different bars or sheets in the batch. The ends of specimens shall be cut
square and loose mill scale and rust shall be removed by wire brushing before
delivery to the laboratory.

9/14
January 2011
(f)
For epoxy coated bar reinforcement, two additional specimens shall be

selected from each batch of reinforcement, as directed by the Project
Manager, for epoxy coating tests on thickness, adhesion and continuity in
addition to the requirements of tensile tests, bend tests and rebend tests.
Each specimen shall be a 2 m length piece cut at least 1m from the ends of a
12 m length bar. Specimens shall be selected from different bundles of the
reinforcement batch.
Table 19.1 : Rate of Sampling of Reinforcement

Connectors for Tension Joints
Description
Reinforcement connectors
for tension joints
19.5.3
Reinforcement
No. of samples
Size of Batch
per batch
In accordance with
Bar reinforcement
Fabric reinforcement
and
Table 9 of CS2
0 50 tonnes
exceeding 50 tonnes
1 for each 50 tonnes or part

thereof
less than 100 No.
100 500 No.
exceeding 500 No.
Testing: Reinforcement
(a)
Testing of reinforcement shall be in accordance with Practice Note for

Authorized Persons and Registered Structural Engineers No. 122. All
verification tests shall be carried out by testing laboratories accredited by
HOKLAS
(b)
Each sample of bar reinforcement and fabric reinforcement shall be tested to

determine the yield stress, elongation, tensile strength, bending and
rebending properties and unit mass. Each sample of fabric reinforcement
shall also be tested to determine the weld shear strength. Each sample of
epoxy coated reinforcement shall also be tested to determine the thickness,
adhesion and continuity of the coating.
Each sample of galvanized
reinforcement shall also be tested to determine the weight and uniformity of
coating.
(c)
Each sample of reinforcement connectors for tension joints shall be tested to

determine the tensile strength and the slip between the reinforcement
connector and the parent bars.
(d)
The number of tests on each sample shall be as stated in Table 19.2.

10/14
January 2011
(e)
19.5.4

Hot rolled steel bars
: Construction Standard CS2;
Cold worked steel bars
: BS 4461;
Cold reduced steel wire
: BS 4482;
Steel fabric
: BS 4483; and
Galvanized coating
: BS 729.
(f)
The method of testing epoxy coatings shall be in accordance with ASTM A775
except that the test for adhesion of coating shall be carried out on 180 bends
to design radii in accordance with BS 4466, Table 1. Bends shall be
performed at a uniform rate and shall be capable of being completed within
15 seconds without visual distress to the coating.
(g)
Tests shall be carried out on specimens having a temperature of between 5C

and 30C.
Compliance Criteria: Epoxy Coatings to Reinforcement

The results of tests for thickness, adhesion and continuity of epoxy coatings to
reinforcement shall comply with the following requirements:
(a)
at least 90% of measurements taken to determine the thickness of the coating

shall be within the specified limits. The thickness of the coating shall be at
least 0.10 mm and shall not exceed 0.30 mm at any point, other than at
repaired areas of coating;
(b)
cracking or debonding of the coating shall not be visible to the unaided eye on
any part of the bent bar; and
(c)
the continuity of the coating shall comply with ASTM A775, Clause 7.2.

11/14
January 2011
Table 19.2 :
Number of Tests on Each Sample of Reinforcement

Type and number of tests
Description
Bar
reinforcement
Cold reduced
steel wire
Steel fabric
- fabric sheet
- longitudinal
wire
- transverse
wire
Epoxy coating
Galvanized
coating
Reinforcement
connectors for
tension joints
19.5.5
Yield,
Elongation
and
Tensile
Bend
Rebend
Unit
Mass
Weld
Shear
Stress
Thickness,
Adhesion
and
Continuity
No. of tensile, bend and rebend tests in

accordance with CS2 Table 9 and one
unit mass test accompanied with each
tensile test.
3
1
3
Pitch,
Dimension
Weight and
Uniformity
of
Galvanized
Coating
-
3
-
1
-
2
-
1
-
Non-compliance: Characteristic Strength

(a)
A batch of bar reinforcement or fabric reinforcement shall be considered as

not complying with the specified requirements for characteristic strength if the
yield stress in any tensile test carried out on any sample taken from the batch
is less than 93% of the specified characteristic strength.
(b)
If the yield stress in any tensile test is less than the specified characteristic
strength but equal to or greater than 93% of the specified characteristic
strength, additional samples shall be provided from the same batch and
additional tests for yield stress shall be carried out. The number of samples
shall be as stated in Clause 5.1.4 of the Construction Standard CS2. The
batch shall be deemed to comply with the Specification if the test specimens
meet the requirements of Clause 5.1.2 of the Construction Standard CS2.
(c)
The number of specimens in each additional sample shall be seven.
(d)
The number of tests on each additional sample of bar reinforcement shall be

seven. The number of tests on the longitudinal wires and on the transverse
wires of each additional sample of fabric reinforcement shall be seven.
(e)

requirements for characteristic strength if the yield stress in any additional test
is less than 93% of the specified characteristic strength.

12/14
January 2011
19.5.6
Non-compliance: Elongation, Tensile Strength, Bending, Rebending, Unit

Mass, Weld Shear Strength
If any test specimen fails to meet the tensile strength, elongation, bend or rebend
test requirements as stipulated in Construction Standard CS2, two additional test
specimens may be taken from different bars of the same batch and be subjected to
the test or tests which the original specimen failed. If both additional test
specimens pass the retests the batch from which they were taken shall be deemed
to comply with this Specification. If either of them fails, the batch shall be deemed
not to comply with this Specification.
19.5.7
19.5.8
Non-compliance: Thickness, Adhesion and Continuity of Epoxy Coatings

(a)
If the result of any test for thickness, adhesion or continuity of epoxy coatings
to reinforcement does not comply with the specified requirements for the
property, additional samples shall be provided from the same batch and
additional tests for the property shall be carried out. The number of additional
samples shall be as stated in Table 19.1.
(b)
The number of specimens in each additional sample shall be as follows:

(i)
epoxy coated bar reinforcement
(ii)
epoxy coated fabric reinforcement
(c)
The number of tests on each additional sample shall be four.
(d)

Non-compliance: Weight and Uniformity of Galvanized Coatings

(a)
If the result of any test for weight or uniformity of galvanized coatings to

reinforcement does not comply with the specified requirements for the
property, additional samples shall be provided from the same batch and
additional tests for the property shall be carried out. The number of additional
samples shall be as stated in Table 19.1.
(b)
The number of specimens in each additional sample shall be as follows:

(i)
galvanized bar reinforcement
(ii)
galvanized fabric reinforcement
(c)
The number of tests on each additional sample shall be four.
(d)


13/14
January 2011
19.5.9
Compliance Criteria: Reinforcement Connectors for Tension Joints

The results of tensile tests on specimens of reinforcement connectors for tension
joints shall comply with the following requirements:
(a)
the tensile strength shall not be less than the specified requirements for the
parent bar; and
(b)
the slip between the reinforcement connector and the parent bars shall not
exceed 0.2 mm in 2 minutes at the specified characteristic strength.
19.5.10 Non-compliance: Slip of Reinforcement Connectors

(a)
If the result of any test for slip of reinforcement connectors for tension joints
does not comply with the specified requirements for slip, additional samples
shall be provided from the same batch and additional tests for slip shall be
carried out. The number of additional samples shall be as stated in
Table 19.1.
(b)
The number of specimens in each additional sample shall be six.
(c)
The number of tests on each additional sample shall be six.
(d)

requirements for slip if the result of any additional test does not comply with
the specified requirements for slip.

14/14
January 2011
SECTION 20 CONCRETE AND JOINTS IN CONCRETE
20.1
GENERAL
20.1.1
Sprayed Concrete
Sprayed concrete shall comply with Section 8 except as stated in this section.
20.1.2
Joints in Concrete Carriageways

Joints in concrete carriageways shall comply with Section 10.
20.1.3
20.1.4
Movement Joints
(a)
Movement joints shall be positioned as shown on the Employer's Drawings

and shall comply with this section.
(b)
Movement joint bearings shall be designed by the Contractor.
Prestressed Concrete
Prestressed concrete shall comply with Section 21.
20.2
DEFINITIONS & ABBREVIATIONS
20.2.1
Cementitious Content
Cementitious content or cement content is the mass of cement per cubic metre
of compacted concrete or, if cement and PFA are used as separate constituents,
the combined mass of cement and PFA per cubic metre of compacted concrete.
20.2.2
Grade
Grade is a term used to identify the different concrete mixes in terms of grade
strength or in terms of grade strength and nominal maximum aggregate size.
20.2.3
Grade Strength
Grade strength is the compressive strength of concrete stated in the Contract. For
designed mix concrete, compliance with the grade strength shall be ascertained in
accordance with Clause 20.8.14.
20.2.4
Designation of Concrete Mixes

(a)
Designed mix concrete shall be designated by the grade strength in MPa

followed by the nominal maximum aggregate size in mm and the suffix D.
(b)
Standard mix concrete shall be designated by the grade strength in MPa

followed by the nominal maximum aggregate size in mm and the suffix S.

Section 20 Concrete & Joints in Concrete
1/53
January 2011
(c)
Designed mix concrete or standard mix concrete of the same grade strength
but with different constituents, workabilities or other properties shall be
designated as such by the addition of a suitable description. If the Grade of
concrete is designated by one number only, the number shall be the grade
strength in MPa.
(d)
Prescribed mix concrete shall be designated by the grade strength in MPa

followed by the nominal maximum aggregate size in mm and the suffix P.
20.3
20.3.1
Cement
(a)
20.3.2
Cement shall comply with the following:

(i)
Ordinary and rapid hardening Portland cement
: BS 12:1996
(ii)
Sulphate resisting Portland cement
: BS 4027
(iii)
Portland pulverised-fuel ash cement
: BS 6588.
PFA
PFA shall comply with BS 3892:Part 1 except as specified herein.
20.3.3
20.3.4
Aggregates
(a)
Fine aggregate shall be clean, hard, durable crushed rock, or natural sand,
complying with BS 882 except as specified herein.
(b)
Coarse aggregate shall be clean, hard, durable crushed rock complying with
BS 882.
Admixtures
(a)
Admixtures shall comply with the following:

(i)
Pigments for Portland cement and Portland cement products : BS 1014
(ii)
Accelerating admixtures, retarding admixtures and

water-reducing admixtures
: BS 5075:Part 1
(iii)
Superplasticising admixtures
: BS 5075:Part 3
(iv)
Corrosion inhibitor admixtures
: BS 5075 Part 1
: 1982 or STMC
-494 Type C

2/53
January 2011
20.4
DESIGN & PERFORMANCE CRITERIA
20.4.1
Concrete Mix
(a)
Concrete shall be a designed mix unless the Project Manager reviews without
objection the use of a standard or prescribed mix. Designed mixes shall be
designed by the Contractor. The Contractor shall select the mix proportions
with due regard to workability, strength, durability, temperature control and
other requirements stated in the Specifications and on the Employer's
Drawings. Prescribed mixes shall be in accordance with the requirements of
the Hong Kong Building (Construction) Regulations.
(b)
The minimum design slump value for designed mix concrete for reinforced
elements, after the addition of superplasticiser if used, shall be as shown in
Table 20.1. Should the Contractor wish to use designed mix concrete with a
design slump value less than that shown in Table 20.1 in reinforced elements,
the Contractor shall submit his proposal to the Project Manager for review
without objection to demonstrate that such concrete can be satisfactorily
placed and compacted in trial sections simulating the appropriate sections of
the Works.
(c)
Cement, PFA, aggregates, water and admixtures for concrete shall comply
with Clauses 20.5.1 to 20.5.5. All-in aggregate shall not be used.
(d)
SRPC shall only be used if stated in the Contract. PFA shall not be used with
SRPC.
(e)
PFA shall not be used in addition to PPFAC.
(f)
Microsilica admixtures shall be used in conjunction with water reducing

admixtures.
(g)
Corrosion inhibitor admixtures shall be added separately with other

admixtures.
Table 20.1 : Workability
Degree of
20 mm max.
size
40 mm max.
size
Workability
aggregate
aggregate
Slump (mm)
Slump (mm)
Low
12-25
25-50
Simply reinforced large

sections with vibration
Medium
25-50
50-100
Moderately reinforced sections

with vibration, such as ordinary
beams and slabs
High
50-125
100-175
Sections with heavily

congested reinforcement
where vibration is difficult

3/53
Uses of which Concrete is

suitable
January 2011
20.4.2
Chloride and Sulphate Content of Concrete

(a)
The maximum total chloride content of concrete, expressed as a percentage

the concrete mix, shall be as stated in Table 20.2. If the concrete is of more
than one of the types stated, then the lower value of maximum chloride
content shall apply.
(b)
The total acid-soluble sulphate content of the concrete mix, expressed as

SO3, shall not exceed 4% SO3 by weight of the cement in the mix. The
sulphate content should be calculated as the various constituents of the mix.
The 4% limit does not apply to concrete made with supersulphated cement
Table 20.2: Maximum Total Chloride Content of Concrete

Maximum total
Type of concrete
chloride content (%)
Prestressed concrete.
0.1
Steam-cured structural concrete
20.4.3
Concrete with reinforcement or other

embedded metal and made with
ordinary or rapid hardening Portland
cement.
0.35
Concrete made with SRPC
0.2
Cementitious Content of Designed Mix Concrete

(a)
The minimum cementitious content of designed mix concrete of Grade 20 or

above using 20 mm nominal maximum aggregate size shall be as stated in
Table 20.3, the minimum cementitious content shall be increased by 40 kg/m
for 10 mm nominal maximum aggregate size and decreased by 30 kg/m for
40 mm nominal maximum aggregate size.
(b)
Except as otherwise stated on the Employer's Drawings, the maximum

cementitious content of any mix shall be 550 kg/m and the maximum cement
content of any mix shall be 440 kg/m.
(c)
The maximum cementitious content of designed mix concrete for water

retaining structures and watertight structures shall be 400 kg/m for concrete
containing OPC and shall be 450 kg/m for concrete containing either OPC
and PFA or PPFAC. The maximum cementitious content of designed mix
concrete other than for water retaining structures and water tight structures
shall be 550 kg/m.
(d)
The cementitious content of designed mix concrete may be varied during

routine production at the discretion of the Contractor by an amount not
exceeding 20 kg/m, provided that the total cementitious content is not less
than the specified minimum value and does not exceed the specified
maximum value.

4/53
January 2011
(e)
When PFA is incorporated in the concrete as a separate material, at least

75% of the specified minimum cementitious content shall be OPC.
(f)
The designed free-water/cementitious material ratio of designed mixes shall

not exceed:
(i)
0.40 for concrete of Grade 40 or above;
(ii)
0.45 for concrete of Grade 30; and
(iii)
0.60 for concrete below Grade 30.
(g)
When microsilica and corrosion inhibitor admixtures are incorporated in the

concrete, mixing water used in the designed mix shall be adjusted in
accordance with the manufacturers recommendations.
(h)
For prestressed concrete, the minimum cementitious content shall be 360

kg/m3 for 10 mm nominal maximum aggregate size and 300 kg/m3 for 40 mm
nominal maximum aggregate size.
Table 20.3 : Minimum Cementitious Content of Designed Mix concrete of

Grade 20 or Greater with 20mm Nominal Maximum Aggregate
Size
20.4.4
Grade strength (MPa)
20
25
30
35
40
45
50
Minimum cementitious
content (kg/m3)
290
290
310
330
350
375
400
Standard Mix Concrete

Standard mix concrete shall comply with the following requirements:
(a)
cement shall be OPC or PPFAC;
(b)
the total mass of dry aggregate to be used with 100 kg of OPC or with 110 kg
of PPFAC shall be as stated in Table 20.4;
(c)
the percentage by mass of fine aggregate to total aggregate shall be as stated

in Table 20.5; and
(d)
admixtures other than water-reducing admixtures shall not be used unless


5/53
January 2011
Table 20.4 : Mass of Total Aggregate for Standard Mix Concrete

Grade
Strength
(MPa)
Nominal maximum
aggregate size
(mm)
Slump value (mm)
10
20
25
30
Mass of total
aggregate (kg)
40
20
10
85 170
800
550
490
440
75 150
690
500
440
380
65 130
400
360
300
Table 20.5 : Percent by Mass of Fine Aggregate to Total Aggregate for

Standard Mix Concrete
Grade
Grading of fine
strength
aggregate
(MPa)
(BS 882: Table 5)
10
C, M or F
C
20, 25
or 30
20.4.5
Nominal
maximum
aggregate size
40
20
10
30 - 45
35 - 50
30 - 40
35 - 45
45 - 55
25 - 35
30 - 40
40 - 50
25 - 30
25 - 35
35 - 45
(mm)
Percentage by
mass
of fine aggregate
to total aggregate
(%)
No-fines Concrete
(a)
No-fines concrete shall comply with the following requirements:

(i)
cement shall be OPC or PPFAC;
(ii)
the nominal maximum aggregate size shall be 20 mm; not more than
15% by mass shall be retained on a 20 mm BS test sieve and not more
than 10% by mass shall pass a 10 mm BS test sieve;
(iii)
aggregate/cement ratio by mass shall be at least 10 and shall not

exceed 15; and
(iv)
the cement content shall be such that each particle of aggregate is

coated with cement paste but the compacted concrete has an open
texture which permits the flow of water through the hardened concrete.
(b)
If the Project Manager requires cubes to be made of the no-fines concrete,

these shall be prepared and cured in accordance with the instructions given in
BS 1881: Part 113 and shall achieve a strength of 10 MPa when crushed.
(c)
No-fines concrete shall be placed with the minimum of punning. No traffic

shall be allowed on the finished work and the surface shall be kept clean.
(d)
Before placing normal concrete over no-fines concrete a layer of polyethylene

sheet of 500 grade or 0.5 mm thickness shall be laid over it and it shall be well
lapped to ensure that no mortar from the overlying concrete penetrates to the
no-fines concrete.

6/53
January 2011
20.5
MATERIALS
20.5.1
Materials Permitted
(a)
20.5.2
The only materials permitted to be used to make concrete are:

(i)
cement;
(ii)
pulverised fuel ash;
(iii)
natural stone aggregates including crushed rock and natural sand;
(iv)
liquid admixtures reviewed without objection by the Project Manager ;

and
(v)
water.
(b)
Exceptionally special additives such as silica fume or ground granulated blast

furnace slag may be required to be incorporated in mixes, but if so required
this will be specified in the Specification.
(c)
All materials used in concrete shall be fully identified and shall be traceable to
their sources of extraction or manufacture.
(d)
Cement shall comply with the following:

(i)
Ordinary and rapid hardening Portland cement
: BS 12 : 1996
(ii)
Sulphate resisting Portland cement
: BS 4027
(iii)
Portland pulverised-fuel ash cement (PPFAC)
: BS 6588.
(e)
Portland cements having a tricalcium aluminate (C3A) content for the previous
6 months production, which when calculated according to the procedure given
in ASTM-C-150 exceeds either 11.5% for any individual test result or an
average value of 11.0% shall not be used.
(f)
The PFA content of PPFAC shall not exceed 25% by mass of the PPFAC.
PFA
PFA shall comply with BS 3892:Part 1 except that the criterion for maximum water
requirement shall not apply.
20.5.3
Aggregates
(a)
Aggregates shall be obtained from a source reviewed without objection by the

Project Manager.
(b)
Fine aggregate shall be clean, hard, durable crushed rock, or natural sand,
complying with BS 882, except that the note in Table 5 of BS 882 shall not
apply.
(c)
Coarse aggregate shall be clean, hard, durable crushed rock complying with
BS 882. The ten percent fines value shall be at least 100 kN. The water
absorption shall not exceed 0.8%. The flakiness index shall not exceed 35%.

7/53
January 2011
20.5.4
20.5.5
Water
(a)
Water for concrete and for curing concrete shall be clean, uncontaminated
and from a source reviewed without objection by the Project Manager. The
Contractor shall test water proposed to be used to produce concrete in
accordance with the requirements of Clause 20.8.3.
(b)
The use of recycled water for concrete is not permitted.
Admixtures
(a)
Admixtures will normally only be permitted if they are liquids and they shall be
measured by volume or weight. If the Project Manager has reviewed without
objection the use of a solid or paste admixture this shall be thoroughly
dispersed or dissolved in at least 10 times its weight of water so that it will be
distributed uniformly in the concrete before any concrete is placed. The water
used for dispersing the admixture shall be considered as part of the mixing
water in the concrete and shall be included in the calculation of the
water/cement ratio of the concrete.
(b)
Admixtures shall comply with the following:

(i)
Pigments for Portland cement and Portland

cement products
: BS 1014
Accelerating admixtures, retarding admixtures

and water-reducing admixtures
: BS 5075:Part 1
(iii)
Superplasticising admixtures
: BS 5075:Part 3
(iv)
Corrosion inhibitor admixtures
: BS 5075:Part 1
: 1982 or ASTMC
-494 Type C
(ii)
(c)
20.5.6
The chloride ion content of admixtures for concrete containing embedded

metal or for concrete made with SRPC shall not exceed 2% by mass of the
admixture or 0.03% by mass of the cementitious content, whichever is less.
Curing Compound
(a)
Curing compounds shall be a proprietary type reviewed without objection by

the Project Manager and shall have an efficiency index of at least 80%.
(b)
Curing compounds shall contain a fugitive dye. Curing compounds containing

organic solvents shall not be used. The curing compound shall become
stable and achieve the specified resistance to evaporation of water from the
concrete surface within 60 minutes after application. Curing compounds shall
not react chemically with the concrete to be cured and shall not crack, peel or
disintegrate within one week after application. Curing compounds shall
degrade completely within three weeks after application and the concrete
surface so treated shall not impair the bonding of applied finishes.
(c)
Curing compounds for use on concrete surfaces against which potable or

fresh water will be stored or conveyed shall be non-toxic and shall not impart
a taste to the water.

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January 2011
20.5.7
20.5.8
Materials for Joints in Water Retaining Structures and Water Tight Structures
(a)
Materials for joints in water retaining structures and water tight structures for
sewage shall be resistant to aerobic and anaerobic bacteriological attack and
to attack by petrol, diesel oil, dilute acids and alkalis.
(b)
Materials for joints in water retaining structures for potable and fresh water
shall be non-toxic and shall not impart taste and colour to the water.
Joint Filler
Joint filler shall be a proprietary type reviewed without objection by the Project
Manager and shall be a firm, compressible, single-thickness, non-rotting filler. Joint
filler for joints in water retaining structures and watertight structures shall be
non-absorbent.
20.5.9
Bitumen Emulsion
Bitumen emulsion for joints in water retaining structures and watertight structures
shall comply with BS 3416. Bitumen emulsion for surfaces against which potable or
fresh water will be stored or conveyed shall comply with BS 3416, Type II.
20.5.10 Joint Sealant

(a)
Joint sealant shall be a grade suited to the climatic conditions of Hong Kong
and shall perform effectively over a temperature range of 0C to 60C. The
colour of all sealants in exposed areas shall be reviewed without objection by
the Project Manager. Joint sealant for exposed joints in water retaining
structures shall be grey.
(b)
Joint sealant other than cold-applied bitumen rubber sealant shall be:
(i)
a gun grade for horizontal joints 15 mm wide or less and for vertical and
inclined joints; and
(ii)
a pouring grade for horizontal joints wider than 15 mm.
(c)
Polysulphide-based sealant shall be a cold-applied two-part sealant

complying with BS 4254. Polysulphide-based sealant for expansion joints in
water retaining structures shall have a transverse butt-joint movement range
of at least 20%.
(d)
Polyurethane-based sealant shall be a cold-applied two-part sealant

complying with the performance requirements of BS 4254.
(e)
Hot-applied bitumen rubber sealant shall comply with BS 2499, Type A1.
(f)
Cold-applied bitumen rubber sealant shall be a proprietary type reviewed

(g)
Joint sealant for joints in water retaining structures and watertight structures

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January 2011
(h)
Primers and caulking material for use with joint sealant shall be a proprietary
type recommended by the joint sealant manufacturer and reviewed without
(i)
Different types of joint sealant and primers which will be in contact, shall be
demonstrated as being compatible.
Table 20.6: Joint Sealant for Water Retaining Structures and Water Tight
Structures
Type of water retaining
structure
Sewage
Other than sewage
Type of joint
Type of joint sealant
All joints
Polyurethane-based
Expansion joints
Polysulphide-based
Horizontal joints other than

expansion joints
Hot-applied bitumen rubber
Vertical and inclined joints

other than expansion joints
Polysulphide-based or coldapplied bitumen rubber
20.5.11 Bond Breaker Tape

Bond breaker tape shall be a proprietary type recommended by the joint sealant
manufacturer and reviewed without objection by the Project Manager. The tape
shall be a polyethylene film with adhesive applied on one side and shall be the full
width of the groove.
20.5.12 Strip and Pad Bearings
(a)
Strip bearings shall be used where specified on the Employer's Drawings.

The preferred type of bearings shall consist of a polished stainless steel
sliding against a P.T.F.E. coated natural rubber strip blocked out either side
with expanded polystyrene spacer strips. Bearings shall be continuous over
the length of joint as indicated on the Employer's Drawings. Other proprietary
types of strip bearings may be submitted for review without objection by the
Project Manager.
(b)
Pad bearings shall be used where specified on the Employer's Drawings. The
preferred type of bearings shall consist of a stainless steel top plate
roughened on the upper surface and polished on the lower, sliding against a
P.T.F.E. coated natural rubber/reinforced rubber pad, blocked out all around
with expanded polystyrene spacer blocks. Bearings shall be placed at the
centres indicated on the Employer's Drawings. Other proprietary types of pad
bearings may be submitted for review without objection by the Project
Manager.
20.5.13 Waterstops
(a)
Waterstops, including intersections, reducers and junctions, shall be a

proprietary type reviewed without objection by the Project Manager, or as
shown on the Employer's Drawings and shall be natural or synthetic rubber or
extruded polyvinyl chloride with the properties stated in Table 20.7.

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January 2011
(b)
Unless otherwise stated on the Employer's Drawings, the size of waterstops

Wall or Slab Thickness (mm)
Waterstop Size (mm)
250
200 - 250
< 200
(c)
250
200
150
Hydrophilic waterstops shall be installed where shown on the Employer's

Drawings. They shall be made from a preformed elastomeric strip which can
integrate into existing waterstop networks and shall be free from rubber,
bentonite or other inclusions. The waterstop shall have an unrestrained
volumetric expansion of not less than 170% and must not deteriorate under
prolonged wet/dry cycling and must be able to withstand a hydrostatic head of
50 m. The waterstop shall be installed in accordance with the manufacturer's
instructions.
Table 20.7: Properties of Waterstops

Property
Rubber waterstops
PVC waterstops
Density
1100 kg/m ( 5%)
1300 kg/m ( 5%)
Hardness
60 - 70 IRHD
70 - 90 IRHD
Tensile strength
20 N/mm
13 N/mm
Elongation at break point
450%
285%
5% by mass after
0.15% by mass after
48 hours immersion
24 hours immersion
42 52
Water absorption
Softness number
20.6
SUBMISSIONS
20.6.1
Particulars of Materials for Concrete

(a)
The following particulars of the proposed cement, PFA and aggregates shall
be submitted to the Project Manager for review without objection:
(i)
a certificate applicable to the material to be supplied and not older than

6 months for each type of cement showing the manufacturer's name,
the date and place of manufacture and showing that the cement
complies with the requirements stated in the Contract and including
chemical composition;
fineness;
compressive strength at 3, 7 and 28 days;
initial and final setting times;
soundness; and
proportion by mass of PFA contained in PPFAC.

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January 2011
(ii)

6 months for PFA showing the source of the PFA and showing that the
PFA complies with the requirements stated in the Contract and including
(iii)

6 months for each nominal maximum aggregate size showing the
source of the aggregate and showing that the aggregate complies with
the requirements stated in the Contract and including results of tests for:
(b)
chemical composition;
fineness; and
moisture content.
grading;
silt content;
chloride content;
flakiness index of coarse aggregate;
ten percent fines value; and
water absorption.
The following particulars of the proposed admixtures shall be submitted to the

Project Manager for review without objection:
(i)
manufacturers' literature;
(ii)
description of physical state, colour and composition;
(iii)
recommended storage conditions and shelf life;
(iv)
method of adding to the concrete mix;
(v)
any known incompatibility with other admixtures or cement;
(vi)
recommended dosage;
(vii) effects of under-dosage and over-dosage; and

(viii) a certificate which is applicable to the material to be supplied and not
older than 6 months for each type of admixture showing the
that the admixture complies with the requirements stated in the Contract
and including results of tests for:
uniformity;
chloride content; and
details of toxicity.

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January 2011
(c)
20.6.2
The following particulars of the proposed curing compound shall be submitted

to the Project Manager for review without objection:
(i)
manufacturer's literature;
(ii)
description of physical state, colour and composition;
(iii)
recommended storage conditions and shelf life;
(iv)
method of application;
(v)
recommended rate of application; and
(vi)

manufacture and showing that the curing compound complies with the
requirements stated in the Contract and including results of tests for
efficiency index.
Particulars of Concrete Mix

(a)
The following particulars of each proposed designed concrete mix shall be

(i)
quantity of each constituent per batch and per cubic metre of

compacted concrete, with required tolerances on quantities of
aggregates to allow for minor variations in grading, silt content etc. The
maximum permitted variation in the quantity of fine aggregate shall be
20 kg of fine aggregate per 100 kg of cement;
(ii)
type and source of cement and PFA;
(iii)
type and quantity of admixture;
(iv)
the type and source of fine and coarse aggregates;
(v)
grading details in tabular and graphical form of coarse and fine

aggregates, including combined grading curves; and
(vi)
grading details, in tabular and graphical form, of the combined

aggregates, together with details of the proportions in which the fine and
coarse aggregates are to be combined;
(vii) workability in terms of designed slump value before and after the
addition of superplasticisers;
(viii) method of placing concrete;
(ix)
method of controlling the temperature of the concrete, if required;
(x)
test or trial mix data for designed mix concrete of the same Grade and
with similar constituents and properties, if available;
(xi)
test data for designed mix concrete of the same or other grade
produced in the plant or plants proposed to be used, if available; and
(xii) total chloride ion content of the mix.

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January 2011
20.6.3
Particulars of Ready-mixed Concrete Supplier

(a)
(b)
(c)
20.6.4
The name of the suppliers and the location of each plant, including a back-up
plant, from which the Contractor proposes to obtain ready-mixed concrete
shall be submitted to the Project Manager at least 14 days before trial mixes
are made or, if trial mixes are not required, at least 30 days before the readymixed concrete is programmed to be placed in the Permanent Works.
The plant producing the concrete shall be operated in accordance with the
Quality Scheme for the Production and Supply of Concrete (QSPSC) of the
Hong Kong Quality Assurance Agency (HKQAA).
Ready mix concrete shall be as defined in BS 5328.
Particulars of Batching and Mixing Plant

Particulars of the proposed batching and mixing plant to be used on Site, including
a layout plan and the output of the plant, shall be submitted to the Project Manager
for review without objection at least 28 days before the plant is delivered to Site.
20.6.5
Particulars of Precast Concrete Units

(a)
The method of manufacture of precast concrete units on or off Site shall be

reviewed without objection by the Project Manager before work commences.
No changes shall be made thereafter without prior review without objection by
(b)
The following particulars of the proposed precast concrete units shall be

(i)
Contractors Drawings showing the full details of the elements including

dimensions, fixings, lifting points, reinforcement and chases;
(ii)
method of manufacture which must include details of :
place of manufacture;
proposed formwork systems and materials;
method of placing and compacting concrete;
method of curing concrete;
proposed quality control procedures; and
details of lifting points and methods of handling;
(iii)
date of commencement of manufacture and casting of each type of

member;
(iv)
details of precasting yards;
(v)
procedure for testing precast units;
(vi)
not more than seven days after the transfer of stress, a certificate
showing the force and extension in the tendons after anchorage, the
strength and age of the test cubes cast as described in this section and
the minimum age in hours of the concrete at the time the stress was
applied to the member; and

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January 2011
(vii) a certificate showing the manufacturer's name, the date and place of
manufacture, the identification number of the precast concrete units and
including results of tests for:
(c)
20.6.6
compressive strength of concrete cubes at 28 days; and

routine tests, including loading tests, carried out at the precast yard;
The following particulars of the constructed precast concrete units shall be

submitted to the Project Manger for onward submission to the Buildings
Department:
(i)
the date and place of manufacture, the identification numbers of the

precast concrete units and including results of tests for compressive
strength of concrete cubes at 28 days tested by a HOKLAS accredited
testing laboratory;
(ii)
a detailed method statement including the design, drawings and

installation procedures for all the temporary support works for erection
of the precast concrete elements;
(iii)
the names and qualifications of the supervisory personnel supervising

the fabrication, erection and examination of the precast concrete units;
and
(iv)
a copy of the site log book recording the date and time of inspections
and details of Site activities.
Particulars of Construction Joints

Particulars of the proposed positions and details of construction joints in concrete
shall be submitted to the Project Manager for review without objection. This
submission shall include details of any material which is to remain permanently in
the Works as part of forming the joint.
20.6.7
Particulars of AAR in Concrete

(a)
(b)
The following particulars of the proposed concrete mix shall be submitted to

the Project Manager for review without objection:
(i)
HOKLAS endorsed test certificates not older than 6 months giving the
results of tests required in Section 20.8.4(c)(ii) to (vi); and
(ii)
calculation of the reactive alkali of the proposed mix.
New HOKLAS endorsed test certificates giving the results of tests required in
Section 20.8.4(c)(ii) to (vi) shall be submitted at quarterly intervals together
with any necessary further calculations to demonstrate that the mix continues
to comply with the limit on reactive alkali.

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January 2011
20.6.8
20.6.9
Trial Mix Concrete

(a)
Trial mixes are not required for designed mix concrete of Grade 20 and below,
for standard mix concrete or for prescribed mix concrete.
(b)
If test data for designed mix concrete of the proposed Grade and with similar
constituents and properties and produced in the plant or plants proposed to
be used are submitted in accordance with Section 20.6.2, and are reviewed
without objection by the Project Manager, no trials for that designed mix will
be required.
(c)
If test data for designed mix concrete of the proposed Grade and with similar
constituents and properties produced in plant other than that proposed to be
used are submitted in accordance with Section 20.6.2, and are reviewed
without objection by the Project Manager, the Project Manager may require
plant trials to be carried out in accordance with Section 20.6.9.
(d)
If test data for designed mix concrete produced in the plant or plants proposed
to be used, but of a Grade or with constituents and properties other than
those proposed, are submitted in accordance with Section 20.6.2, and are
reviewed without objection by the Project Manager, the Project Manager may
require laboratory mix trials to be carried out in accordance with Section
20.6.10.
(e)
If no test data for designed mix concrete are submitted or if test data
submitted in accordance with Section 20.6.2 does not in the opinion of the
Project Manager demonstrate the suitability of the proposed plant and mix
design, the Project Manager may require both plant trials and laboratory mix
trials in accordance with Sections 20.6.9 and 20.6.10 respectively.
(f)
Plant trials and laboratory mix trials shall be completed at least 35 days before
the concrete mix is programmed to be placed in the Permanent Works.
(g)
The Contractor shall notify the Project Manager before conducting plant trials
or laboratory mix trials.
Plant Trials
(a)
Plant trials shall be made using the plant or plants proposed and the mix
designs and constituents submitted to and reviewed without objection by the
Project Manager.
(b)
One batch of concrete of a proposed designed mix shall be made on each of

three days in each plant proposed to be used. The batch shall be at least
60% of the mixer's nominal capacity. If the concrete is batched in a central
plant and mixed in a truck mixer, three different truck mixers shall be used.
(c)
Three samples of concrete shall be provided from each batch at

approximately 1/6, 1/2 and 5/6 of the discharge from the mixer. Each sample
shall be of sufficient size to perform a slump test and make two 150 mm test
cubes. The method of sampling shall be as stated in CS1.

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January 2011
(d)
Each sample taken in accordance with Section 20.6.9(c) shall be tested to

determine its slump value in accordance with CS1.
(e)
Two 150 mm test cubes shall be made from each of the three samples taken
in accordance with Section 20.6.9(c) and stored, cured and tested to
determine the compressive strength at 28 days in accordance with CS1.
20.6.10 Laboratory Mix Trials

(a)
Laboratory mix trials shall be made in the Contractor's laboratory using the
mix designs and constituents submitted to and reviewed without objection by
(b)
Laboratory mix trials shall be carried out in accordance with Section 11 of

CS1. Three separate batches shall be made, each of sufficient size to
provide samples for two slump tests and to make six 150 mm test cubes.
(c)
Two slump tests in accordance with CS1 shall be performed on separate

specimens from each batch of laboratory trial mix concrete.
(d)
Six 150 mm test cubes shall be made from each batch of laboratory trial mix
concrete, stored, cured and tested for compressive strength at 28 days in
accordance with CS1.
20.6.11 Compliance Criteria : Plant trials

(a)
The results of tests on concrete taken from plant trials in accordance with
Section 20.6.9 shall comply with the following requirements :
(i)
the average of the three slump values shall be within 20mm or 25%,
whichever is the greater, of the designed slump value;
(ii)
the range of the three slump values for each batch of concrete shall not
exceed 20% of the average of the three slump values for that batch;
(iii)
the average compressive strength at 28 days of the 6 test cubes shall

exceed the Grade strength by at least 10 MPa and the compressive
strength of each individual test cube shall exceed the Grade strength by
at least 4 Mpa; and
(iv)
the range of the compressive strength of the six test cubes from each
batch of concrete shall not exceed 20% of the average compressive
strength of the six test cubes from that batch.
20.6.12 Compliance Criteria: Laboratory Mix Trials

(a)
When test data relating to the proposed plant or plants submitted in

accordance with Section 20.6.2 show that the plant standard deviation
exceeds 5 MPa, or in the absence of acceptable data, the results of tests on
laboratory trial mix concrete shall comply with the following requirements:
(i)
the average of the six slump values shall be within 20 mm or 25%,

whichever is the greater, of the design slump value; and

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January 2011
(ii)
(b)

at least 6 MPa.
When test data relating to the proposed plant or plants submitted in

accordance with Section 20.6.2 show that the plant standard deviation does
not exceed 5 MPa, the results of tests on laboratory mix trial concrete shall
comply with the following requirements :
(i)
the average of the six slump values shall be within 20 mm or 25%,

whichever is the greater, of the design slump value; and
(ii)

at least 2 MPa.
20.6.13 Trial Lengths and Trial Panels

Trial lengths required in accordance with Sections 10.5.2 to 10.5.5 and trial panels
required in accordance with Sections 18.5.2 and 18.5.3 shall be constructed for
each concrete mix as appropriate.
20.6.14 Non-compliance: Trial Mix Concrete
(a)
If the result of any test for workability or compressive strength of laboratory

mix trial and plant trial concrete does not comply with the specified
requirements for the property, particulars of proposed changes to the
materials, mix design or methods of production shall be submitted to the
Project Manager for review without objection. Further laboratory mix trials or
plant trials shall be made until the result of every test complies with the
specified requirements for workability and compressive strength of laboratory
mix trial and plant trial concrete.
(b)
If trial lengths or trial panels are constructed using the non-complying trial mix,
further trial lengths or trial panels shall be constructed.
20.6.15 Acceptable Concrete Mix

(a)
A concrete mix which complies with the specified requirements for laboratory
mix trials, plant trials and for trial lengths or trial panels is defined as an
"Acceptable Concrete Mix". The designed slump value used to produce an
"Acceptable Concrete Mix" shall become the "Acceptable Slump Value".
(b)
If laboratory mix trials or plant trials are not required, a concrete mix submitted
as stated in Section 20.6.12 and which complies with the specified
requirements for trial lengths or trial panels shall become an "Acceptable
Concrete Mix". The designed slump value of the concrete mix shall become
the "Acceptable Slump Value".

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January 2011
20.6.16 Records of Concrete

(a)
Each delivery of concrete to Site shall be accompanied by a certificate giving

full details of its origin and composition. The weights of materials in each
batch of concrete shall be recorded automatically by the batching equipment
and the printed records shall be available to the Project Manager for
inspection at all times. Manually prepared records of batch composition are
not acceptable. Delivery notes shall contain the following details:
(i)
serial number of delivery note;
(ii)
date and time of loading;
(iii)
name and location of batching and mixing plant;
(iv)
registration number of delivery vehicle;
(v)
name of purchaser;
(vi)
name and location of the Site;
(vii) designation of concrete mix and "Acceptable Slump Value";

(viii) type name and quantity of admixture;
(ix)
quantity of concrete;
(x)
quantity of water in litres per cubic metre of concrete and the time of
introduction of water to the concrete;
(xi)
moisture content of fine aggregate and amount of water subtracted from

the batch quantities to compensate for this;
(xii) type of cementitious material, weight in kilograms per cubic metre of

concrete and time of introduction to the concrete mix; and
(xiii) type of aggregate and weights of fine and coarse aggregates in
kilograms per cubic metre of concrete.
(b)
Records of concreting operations shall be kept by the Contractor on Site.

Records shall contain the following details:
(i)
date;
(ii)
designation of concrete mix and "Acceptable Slump Value";
(iii)
total quantity of each concrete mix produced that day;
(iv)
serial number of delivery note;
(v)
arrival time of delivery vehicle;
(vi)
time of completion of discharge;
(vii) position where concrete was placed;

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January 2011
(viii) results of slump tests;
(c)
(ix)
details of test cubes made; and
(x)
temperature of concrete.
The Contractor shall submit to the Project Manager for review without
objection a statement covering the method of placing concreting at any one
location. The statement shall cover all items of plant to be used and their
respective layout and shall include the extent of bays, sequence of concreting
and proposals for stop ends. With respect to concrete temperature, the
Contractor shall submit to the Project Manager for review without objection a
detailed method statement of his proposed temperature control and
monitoring strategy and the substantiation of this strategy. The information to
be submitted shall include, but shall not be limited to, the following:
(i)
concrete mix details including heat of hydration and specific heat

characteristics of the proposed constituents;
(ii)
formwork type and insulation;
(iii)
curing details related to temperature effects; and
(iv)
calculations of the forecast concrete temperature, temperature gradients

and resulting stresses. The calculation of temperature in concrete shall
be in accordance with the Construction Industry Research and
Information Association Report No. 91, "Early Age Thermal Crack
Control in Concrete"
20.6.17 Particulars of Materials for Joints

(a)
The following particulars of the proposed materials for joints shall be

(i)
manufacturer's literature and a certificate for joint filler showing the

that the joint filler complies with the requirements stated in the Contract
and including results of tests for;
disintegration and shrinkage;

recovery value and reduction in mass; and
extrusion;
(ii)
manufacturer's literature and a certificate for bitumen emulsion showing

the manufacturer's name, the date and place of manufacture and
showing that the bitumen emulsion complies with the Specification;
(iii)
manufacturer's literature for joint sealant, including details of the method

and time required for mixing the different components, and a certificate
and showing that the sealant complies with the Specification and
including results of tests as appropriate for:
rheological properties;
plastic deformation;
adhesion and tensile modulus;

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January 2011
(iv)
manufacturer's literature and a certificate for strip and pad bearings for
sliding joints showing the manufacturer's name, the date and place of
manufacture and showing that the strips comply with the Specification
(v)
vertical load;
coefficient of friction; and
a descriptions of the method of installation of bearings;
manufacturer's literature for waterstops, including details of

intersections, reducers and junctions, and a certificate showing the
that the waterstops comply with the requirements stated in the Contract
(vi)
application life;
adhesion in peel;
loss of mass after heat ageing;
staining;
transverse butt joint movement range;
extension;
flow;
penetration;
degradation; and
fire rating, where appropriate;
density;
hardness;
tensile strength;
elongation at break point;
water absorption;
softness number of PVC waterstops; and
hydrophilic properties, where appropriate; and
particulars of primers and caulking material for joint sealant and of bond
breaker tape.
20.6.18 Representative Samples of Materials

(a)
Representative samples of the following proposed materials shall be

submitted to the Project Manager at the same time as particulars of the
material are submitted:
(i)
joint filler and joint sealant;
(ii)
bond breaker tape;
(iii)
bearing strip for sliding joints; and
(iv)
waterstops, including intersections, reducers and junctions.

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January 2011
20.7
WORKMANSHIP
20.7.1
Storage of Cement and PFA
20.7.2
20.7.3
(a)
Cement in bags shall be stored in a dry, weatherproof store with a raised

floor. Each delivery shall be identified and kept separate and shall be used in
the order of delivery.
(b)
Bulk cement and PFA shall be stored in dry, weatherproof silos. Cement and
PFA of different types and from different sources shall be stored in separate
silos clearly marked to identify the different contents of each.
(c)
The loading, unloading, transfer, handling or storage of bulk cement or dry

PFA during or after the debagging process must be done in a totally enclosed
system or facility. Any vent or exhaust shall be fitted with fabric filter or
equivalent air pollution control system or equipment.
(d)
Consignments of cement and PFA shall be used in order of delivery. Any

cement stored for longer than one month shall be re-tested for moisture
content, soundness and setting time. Any PFA stored for longer than one
month shall be re-tested for moisture content.
Handling and Storage of Aggregates

(a)
Aggregates shall not be handled or stored in a manner which will result in

mixing of the different types and sizes or in segregation or contamination of
the aggregates.
(b)
Different types and sizes of aggregates shall be stored in separate hoppers or

in separate stockpiles. The stockpiles shall have well drained concrete floors
and shall have dividing walls of sufficient height to keep the different
aggregates separate.
Storage of Admixtures and Curing Compounds

Admixtures and curing compounds shall be stored in sealed containers marked to
identify the contents and protected from exposure to conditions which may affect
the material. The materials shall be stored in accordance with the manufacturers'
recommendations and shall not be used after the recommended shelf life has been
exceeded.
20.7.4
Handling and Storage of Precast Concrete Units

(a)
The identification number, date of casting and lifting points shall be marked on
precast concrete units in a manner reviewed without objection by the Project
Manager.
(b)
Precast concrete units shall be lifted and supported only at the designed lifting
points and shall not be subjected to rough handling, shock loading or
dropping.
(c)
Precast concrete units shall be stored off the ground on level supports and in
a manner which will not result in damage or deformation to the units or in
contamination of the units. Precast concrete units shall be protected from
damage and damaged units shall not be used in the Permanent Works.

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January 2011
20.7.5
20.7.6
(d)
At all stages of construction, precast concrete units and other associated

concrete shall be adequately protected to prevent damage to permanently
exposed concrete surfaces, particularly any decorative features.
(e)
Precast units shall not to be lifted until at least 24 hours after casting or until
concrete has attained a strength adequate to resist the resultant stresses
without inducing cracking or other damage to the concrete.
Batching Concrete
(a)
Concrete shall be produced at a plant certified, registered and operated in

accordance with the Quality Scheme for the Production and Supply of
Concrete (QSPSC) of the Hong Kong Quality Assurance Agency (HKQAA).
The requirements of the Specification shall prevail over those of the QSPSC.
(b)
Measuring and weighing equipment for batching concrete shall be maintained

in a clean, serviceable condition and their accuracy shall be maintained within
the tolerances given in BS 1305. The equipment shall be checked regularly at
intervals reviewed without objection by the Project Manager and at a minimum
in accordance with the requirements of Appendix A20.4, Part 1. The accuracy
of the measuring equipment shall be within 3% of the quantity of cementitious
materials, total aggregates or water being measured and within 5% of the
quantity of admixtures being measured.
(c)
The quantities of cement, PFA and fine and coarse aggregates shall be
measured by mass except that cement supplied in bags may be measured by
using a whole number of bags in each batch. The mass of aggregates shall
be adjusted to allow for the free moisture content of the aggregates.
(d)
Separate weighing equipment shall be used for cementitious material and

aggregates.
(e)
The quantity of water shall be adjusted for the free moisture content of the
aggregates and shall be measured by mass or volume.
(f)
Liquid admixtures shall be measured by mass or volume and powdered

admixtures shall be measured by mass.
Mixing Concrete
(a)
The quantities of concrete mixed and the speed of operation of a mixer shall
comply with the manufacturer's recommendations.
(b)
A mixer shall not be loaded in excess of its rated capacity and shall be
emptied before being re-charged. A mixer which has been out of use for
more than 30 minutes shall be cleaned before fresh concrete is mixed in it.
Mixers shall be cleaned whenever there is a change in the type of cement
being used.
(c)
Mixing times or the number and rate of revolutions of mixer drums shall be in
accordance with the recommendations of the manufacturer unless the
Contractor can demonstrate otherwise. Constituents shall be thoroughly
mixed and admixtures shall be uniformly distributed throughout the concrete.
(d)
Water shall be added to truck mixed concrete at the batching plant and shall
not be added in transit or be added at Site.

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20.7.7
20.7.8
(e)
Superplasticising admixtures used with concrete mixed off Site shall be added
at Site.
(f)
Water shall not be added to partially hardened concrete.
(g)
Partially hardened concrete shall not be remixed, with or without additional

cement, aggregate or water.
Transportation of Concrete
(a)
Concrete shall not be transported in a manner which will result in

contamination, segregation, loss of constituents or excessive evaporation.
(b)
Concrete batched off Site shall be transported to Site in purpose-made

agitators operating continuously.
(c)
Where an agitator is used for transporting concrete, the discharge shall be

completed within a period reviewed without objection the Project Manager.
The time of contact between cement and water shall be deemed to be the
loading time recorded on the delivery ticket.
(d)
Where concrete is transported in non-agitating equipment, discharge shall be

completed within a period reviewed without objection the Project Manager.
The time at which mixing was completed shall be deemed to be the loading
time recorded on the delivery ticket.
(e)
Transportation equipment shall be checked regularly at intervals reviewed

without objection by the Project Manager in accordance with the requirements
of Appendix A20.4, Part 2.
Commencement of Concreting
Concrete shall not be placed in the Permanent Works until the concrete mix has
20.7.9
Changes in Materials and Methods of Construction

The materials, mix design, methods of production or methods of construction used
to produce an "Acceptable Concrete Mix" shall not be changed except that the
variations of cement content as stated in Section 20.4.3(d), and variations in
aggregate quantities within the permitted tolerances, will be allowed.
20.7.10 Concrete Placing and Temperature

(a)
The Contractor shall notify the Project Manager before concrete is placed in
any part of the Permanent Works, allowing sufficient time for the Project
Manager to inspect the works which are to be concreted.
(b)
Concrete shall be compacted in its final position within 1 hour of discharge

from the mixer unless carried in purpose made agitators, operating
continuously, when the time shall be within 2 hours of the introduction of
cement to the mix and within 30 minutes of discharge from the agitator.
(c)
Concrete which does not satisfy the compliance criteria for workability as
stated in Section 20.8.9 shall not be placed in the Permanent Works.

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January 2011
(d)
Where it is necessary to deposit concrete under water, details of the methods,

equipment, materials and proportions of the mixes to be used shall be
submitted to the Project Manager for review without objection before the work
is commenced. Where the concrete is placed by a tremie, its size and method
of operation shall be in accordance with BS 8004. During and after concreting
under water, pumping or dewatering operations in the immediate vicinity shall
be suspended for a period which has been reviewed without objection by the
Project Manager.
(e)
All formwork and reinforcement contained within it shall be clean and free
from standing water immediately before the placing of the concrete.
(f)
Concrete shall be placed as close as practicable to its final position and shall
not be moved into place by vibration. Trunking or chutes shall be used to
place concrete which would otherwise fall more than 2.0 m. When trunking or
chutes are used they shall be kept clean and used in such a way as to avoid
segregation.
(g)
Concrete shall be placed in such a manner that the formwork, reinforcement

or built-in components are not displaced.
(h)
Concrete unless placed by tremie, shall be placed in horizontal layers to a

compacted depth of not more than 450 mm if internal vibrators are used and
to a compacted depth of not more than 150 mm in other cases.
(i)
Concrete shall be placed continuously within the element to be concreted.

Fresh concrete shall not be placed against concrete which has been in
position for more than 30 minutes. Otherwise a construction joint shall be
formed as stated in Section 20.7.14.
(j)
Concrete shall not be placed in ground or water which has a temperature

below 5C.
(k)
Where the ambient temperature is greater than 32C full hot weather
concreting techniques as described in ACI document ACI 305R-89, Clauses
3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 4.1, 4.2 and 4.3 shall be implemented.
(l)
No concrete shall be placed in free-flowing water. Cofferdams or forms shall

be sufficiently tight to reduce the flow or current of water through the space
where the concrete is to be deposited to a velocity or flow rate, reviewed
without objection by the Project Manager. Cofferdams or forms in still water
shall be sufficiently tight to prevent loss of mortar through the walls.
(m)
Before concrete is placed on a rock foundation the rock surface shall be clean
and free from soft rock and loose rock, dust or other debris. The final
cleaning shall be done with air and/or water jets and excavation with hand
held tools.
(n)
After the rock surface has been prepared and reviewed without objection by
the Project Manager and immediately before placing blinding or other
concrete, the surface of the rock shall be covered with a layer of grout 6 mm
thick. The grout shall have the consistency of a stiff paste and it shall be well
brushed over the rock and into all crevices.

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(o)
The temperature of concrete at the time of placing shall be measured and

controlled. The Contractor shall take measures to ensure that after placing,
the maximum temperature attained in the concrete and the temperature
gradient does not exceed specified levels.
(p)
The temperature of concrete at the time of placing in the forms shall not be
more than 32C. The Contractor shall submit details of the proposed
measures to ensure that this temperature will not be exceeded.
(q)
The temperature shall be measured by placing a calibrated probe-type

thermometer into the concrete at the time of discharge from the vehicle
transporting it or not later than 15 minutes thereafter.
(r)
The Contractor shall employ effective means such as pre-cooling the

aggregates and mixing water, as necessary, to maintain the temperature of
the concrete below 32C prior to placing.
(s)
After concrete has been placed its temperature shall not be permitted to rise
above 70C.
(t)
The maximum temperature gradient within any structure due to heat of

hydration taken at any two points one metre apart shall not exceed 15C.
Irrespective of the thickness of a section the maximum temperature
differential between the core and the surface shall not exceed 20C overall.
(u)
Prior to laying slabs on ground a damp proof membrane shall be laid. The
damp proof membrane shall be a polythene sheet at least 0.3mm thick. Each
sheet of damp proof membrane shall be lapped at least 300mm at the edges
and sealed and taped to adjacent sheets. Sealing shall be achieved with
double sided mastic tape or similar as recommended by the manufacturer. All
punctures and tears shall be repaired prior to placing concrete.
(v)
Damp proof membranes shall be lapped and sealed to vertical faces of walls
and slab edges by a minimum of 300mm or as shown on the Employers
Drawings.
20.7.11 Placing Concrete by Pumping

(a)
Concrete pumps shall be operated and maintained in accordance with the

The pumps and pipelines shall be
maintained in a clean condition. Internal surfaces of pipelines shall not be
aluminum. Joints in pipelines shall not permit grout loss.
(b)
Concrete pumps shall be positioned such that pipelines are as short and
straight as practicable and require as little repositioning as practicable. Bends
in pipelines shall be arranged in such a manner that the concrete, formwork,
reinforcement or built-in components are not disturbed.
(c)
Pipelines shall be lubricated by passing cement grout or concrete through the

pipeline before the Permanent Works concrete is pumped. This initial
lubricating grout or concrete shall not be placed in the Permanent Works.

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20.7.12 Placing Concrete by Tremie

(a)
Tremies used to place concrete shall be securely supported in position and

the joints shall be watertight. A temporary seal of a type reviewed without
objection by the Project Manager shall be used to keep the water and the
concrete separate at the start of concreting.
(b)
After the concrete is flowing, the tremie shall be raised in a manner reviewed
without objection by the Project Manager; the lower end of the tremie shall be
kept immersed in the concrete to a depth of at least 1 m. Water, mud and
other deleterious material shall be prevented from entering the tremie after
concreting has started.
(c)
If the tremie becomes blocked or is removed from the concrete, concreting

shall be stopped immediately. Concreting shall not recommence for at least
24 hours; contaminated concrete shall be removed before concreting
recommences.
(d)
Concrete placed by tremie shall be placed above the specified level by an

amount to allow for the removal of concrete, including laitance and excess
cement slurry. Contaminated concrete shall be removed.
20.7.13 Compacting Concrete

(a)
Concrete shall be compacted to form a dense homogeneous mass.
(b)
Concrete shall be compacted by means of internal vibrators of suitable

diameter. A sufficient number of vibrators shall be maintained in serviceable
condition on Site to ensure that spare equipment is available in the event of
breakdown.
(c)
Vibrators shall be used in such a manner that vibration is applied continuously

and systematically during placing of the concrete until the expulsion of air has
practically ceased. Vibrators shall not be used in a manner which will result in
segregation. Internal vibrators shall be inserted to the full depth of the
concrete placed and shall be withdrawn slowly.
(d)
Vibration shall not be applied by way of the reinforcement, and contact

between internal vibrators and formwork, reinforcement or built-in components
shall be avoided as far as possible. Concrete shall be vibrated in such a
manner that the formwork, reinforcement or built-in components shall not be
displaced.
(e)
Concrete which has been in position for more than 30 minutes shall not be
vibrated.
(f)
No-fines concrete shall be compacted using a minimum amount of punning.

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January 2011
(g)
Vibrating equipment shall comply with BS 2769:Part 2 and the following:

(i)
internal vibrators operating at a minimum of 10,000 cycles per minute;
(ii)
external vibrators operating at a minimum of 3,000 cycles per minute;
(iii)
vibrating tables operating at a minimum of 5,000 oscillations per minute

may be used for precast elements subject to review without objection by
the Project Manager; and
(iv)
external clamp-on type, vibrators shall not be used.
20.7.14 Construction Joints

(a)
The position and details of construction joints shall be arranged in such a

manner that the possibility of cracking due to shrinkage is minimized. The
Contractor shall submit a detailed method statement of its proposed pour
strategy and substantiation of this strategy to the Project Manager for review
without objection.
(b)
Construction joints shall be normal to the axis or plane of the element being
constructed.
(c)
Waterstops shall be provided at construction joints in water retaining

structures, tunnels and at any other locations as shown on the Employer's
Drawings.
Laitance and loose material shall be removed from the surface of construction
joints and the aggregate shall be exposed by a method reviewed without
objection by the Project Manager. The work shall be carried out as soon as
practicable after the concrete has hardened sufficiently for the cement matrix
to be removed without disturbing the coarse aggregate. The surface of the
construction joint shall be cleaned after the matrix has been removed.
(d)
(e)
The surface of the construction joint shall be clean and dry before fresh
concrete is placed against it.
20.7.15 Curing Concrete

(a)
Concrete shall be protected against harmful effects, including those due to

weather, running water and drying out by one of the following methods:
(i)
Method 1 : A liquid curing compound shall be applied to the concrete

surface by a low-pressure spray at the rate recommended
by the manufacturer until a continuous visible covering is
achieved;
(ii)
Method 2 : The concrete surface shall be covered with hessian,

sacking, canvas or with a layer of fine aggregate at least
25 mm thick; the hessian, sacking, canvas or fine aggregate
shall be kept constantly wet;
(iii)
Method 3 : The concrete surface shall be covered with polyethylene

sheeting; concrete surfaces which have become dry shall be
thoroughly wetted before the sheeting is placed; or

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January 2011
(iv)
Method 4 : Unformed concrete surfaces shall be covered with

polyethylene sheeting until the concrete has hardened
sufficiently for water curing to be carried out. Water curing
shall be carried out by spraying the concrete surface
continuously with cool water or by ponding immediately after
the sheeting is removed. If in the opinion of the Project
Manager water curing is impracticable, Method 2 shall be
used instead of water curing.
(b)
Method 1 shall not be used on concrete surfaces against which concrete will
be placed or which will have a Class T1 finish or which will be painted or tiled.
(c)
Methods 1, 2, 3 or 4 shall be used on unformed concrete surfaces

immediately after the concrete has been compacted and finished.
Methods 1, 2 or 3 shall be used on formed concrete surfaces immediately
after the formwork has been removed.
Polyethylene sheeting shall be impermeable and shall have a nominal
thickness of 0.125 mm.
(d)
(e)
Hessian, sacking, canvas and polyethylene sheeting shall be lapped and

securely held in position in such a manner that the concrete surface will not
be damaged.
(f)
Cold water shall not be applied to concrete surfaces or formwork.
(g)
The different methods of protection shall be maintained for the minimum

periods stated in Table 20.8 after the concrete has been placed. The
minimum periods may, subject to review without objection by the Project
Manager, be reduced by the number of days during which formwork is left in
position.
(h)
When the ambient temperature exceeds 32C full hot weather curing
techniques as described in ACI document ACI 305R-89, shall be
implemented. Absorptive wood forms remaining in place shall not be
considered a satisfactory means of curing in hot dry weather. Such forms
shall be covered and kept moist.
Table 20.8:
Minimum Periods of Protection for Concrete

Minimum period of protection (days)
Type of Structure
Water retaining
structures, tunnels,
and water
tight structures
Others

Method of
protection
Concrete not
containing PFA
or PPFAC
Concrete
containing
PFA or PPFAC
2, 3 or 4
1
2, 3 or 4
7
4
7
5
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20.7.16 Manufacture of Precast Concrete Units

(a)
For all prestressed pretensioned members the length, cross section

dimensions and straightness of precast concrete shall be measured at 28 2
days after casting;
(b)
Unless otherwise stated in the Contract the allowable dimensional variations

for precast concrete units shall not exceed those given in Table 20.9.
Table 20.9 Allowable Dimensional Variations

Length
Up to 3 m
3 to 4.5 m
4.5 to 6 m
Additional for every subsequent 6 m
Cross Section
(each direction)
Up to 500 mm
500 to 750 mm
Additional for every
subsequent 250 m
Straightness or bow
(deviation from intended line)
Up to 3 m
3 to 6 m
6 to 12 m
Additional for every
subsequent 6 m
Variation
6 mm
9 mm
12 mm
6 mm
Variation
6 mm
9 mm
3 mm
Deviation
6 mm
9 mm
12 mm
6 mm
(c)
Where the Project Manager requires tests to be carried out on members

manufactured off-Site, no members to which the tests relate shall be
dispatched to Site until the tests have been completed and the results
(d)
All members shall be indelibly marked to show the description of the member
as shown on the Employer's Drawings, the production line on which they were
manufactured, the date on which the concrete was cast and, if they are of
symmetrical section, the face that will be uppermost when the member is in its
correct position in the Permanent Works. The markings shall be so located
that they are not exposed to view when the member is in its permanent
position.
(e)
Unless otherwise specified the vibrated top surface of precast concrete

members which will subsequently receive in-situ concrete shall be further
prepared by the following methods:
(i)
when the concrete is self-supporting but still sufficiently green the

concrete surface shall be sprayed with a fine spray of water or brushed
with a stiff brush just sufficiently to remove the outer mortar skin and
expose the larger aggregate without disturbing it; or
(ii)
alternatively where this preparation proves impracticable the hardened

surface skin and laitance shall be removed by sand blasting or a needle
gun.

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January 2011
(f)
Hardened surfaces shall not be hacked.
(g)
Retarding agents shall not be used.
(h)
The joint surface shall be clean and damp but free of standing water
immediately before any fresh concrete is placed against it.
20.7.17 Installation of Precast Concrete Units

(a)
Contact surfaces between in-situ concrete and precast concrete units shall be
prepared as stated in the Contract. Dimensional tolerances shall be checked
before the precast concrete units are lifted into position.
(b)
Temporary supports and connections shall be provided as soon as practicable

during installation of precast concrete units.
(c)
Final structural connections shall be completed as soon as practicable after

the precast concrete units have been installed.
(d)
Levelling devices which have no load bearing function in the finished structure
shall be slackened, released or removed after the precast concrete units have
been installed.
20.7.18 Loading of Concrete

(a)
Loads which will induce a compressive stress in the concrete exceeding

one-third of the compressive strength of the concrete at the time of loading or
exceeding one-third of the grade strength, whichever is less, shall not be
applied to concrete; allowance shall be made for the weight of the concrete in
determining the loading. The strength of the concrete and the stresses
produced by the loads shall be assessed by a method reviewed without
(b)
Loads from materials not forming part of the Permanent Works or from
Contractor's Equipment or other vehicles, shall not be applied to no-fines
concrete.
20.7.19 Storage of Materials for Joints

(a)
Bitumen emulsion, joint sealant and primer for joint sealant shall be stored in
sealed containers marked to identify the contents and protected from
exposure to conditions which may affect the material. The materials shall be
stored in accordance with the manufacturers' recommendations and shall not
be used after the recommended shelf life has been exceeded.
(b)
Joint filler, bond breaker tape and waterstops shall be stored in accordance
with the manufacturers' recommendations in a dry weatherproof store with a
raised floor. Absorbent joint filler shall be stored in sealed plastic bags and
shall not be exposed to moisture or air.

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January 2011
(c)
Bearing strip for sliding joints supplied in rolls of 5 m length or less shall be
unrolled immediately after delivery and shall be stored flat at full length on an
even surface. Bearing strip supplied in rolls of more than 5 m length may be
left in the original packing. Bearing strip shall be stored in accordance with
the manufacturer's recommendations and shall be protected from mechanical
damage and creasing; the two layers of strip shall be kept free from
deleterious material.
20.7.20 Forming Joints

(a)
Materials for joints shall be mixed and used in accordance with the
manufacturers' recommendations.
(b)
Joint filler shall be cut to size before fixing and shall be securely fixed in
position to the existing concrete surface before concreting. There shall be no
gaps between the joint filler and formation.
(c)
Waterstops shall be securely fixed in position to formwork in such a manner

that compaction of the concrete will not be affected. In-situ joints in
waterstops shall be made using methods and equipment recommended by
the manufacturer. Exposed waterstops shall be protected from exposure to
conditions which may affect the waterstop and shall be kept free from rust,
hydrocarbons and other deleterious material.
(d)
Joints shall be formed in straight lines perpendicular to the surface of the

concrete unless otherwise stated in Contract.
(e)
Saw-cut joints shall be formed where shown on the Employer's Drawings, in

slab-on-ground areas. Joints shall be formed by use of a rotary-concrete saw
to the depths shown on the Employer's Drawings.
20.7.21 Forming Grooves

(a)
Grooves for joint sealant shall be straight and shall be perpendicular to the
surface of the concrete. The bottom of the groove shall be flat and shall be
parallel to the surface of the concrete.
(b)
Grooves shall be formed by using timber or other formers reviewed without

objection by the Project Manager and shall not be formed by cutting back or
raking out the joint filler. The grooves shall be located over the joint filler such
that the upper surface of the joint filler is entirely contained in the groove.
20.7.22 Protection of Grooves

Before permanent sealing, grooves for joint sealant shall be protected from
contamination by a temporary sealing strip or cover.
20.7.23 Sealing Joints
(a)
The permanent sealing of joints shall be carried out at least 7 days after
concreting.
(b)
Immediately before permanent sealing, timber formers, temporary seals, dirt

and loose material shall be removed from the groove and the sides of the
groove shall be cleaned and roughened by water jetting or sand blasting.

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January 2011
(c)
Caulking material shall be firmly packed in the bottom of the groove if the joint
sealant is not required to extend to the bottom of the groove.
(d)
Bond breaker tape shall be fixed continuously and evenly along the bottom of
the groove for the full width and length of the groove.
(e)
Concrete surfaces within 75 mm of the edges of the joint shall be masked with
tape before the primer is applied and until the sealing of the joint is complete.
(f)
Primer for the joint sealant shall be applied to the sides of the groove in
(g)
Joint sealant shall be applied between the minimum and maximum drying
times of the primer recommended by the manufacturer. The components of
the sealant shall be thoroughly mixed in accordance with the manufacturer's
recommendations using a power operated paddle mixer for sufficient time to
produce a homogeneous mass without entrapped air. The sealant shall be
dispensed into the groove as soon as practicable after mixing and within the
time recommended by the manufacturer.
(h)
The groove shall be clean and dry at the time of applying the primer and joint
sealant.
(i)
Excess joint sealant shall be removed by using a purpose made finishing tool
such that the finished surface of the sealant is between 4 mm and 6 mm
below the face of the concrete.
20.7.24 Strip and Pad Bearing Installation

(a)
The concrete surface shall be prepared with a mortar pad as specified on the
Employer's Drawings. The mortar pad should be a minimum of 10 mm thick.
The top surface of the mortar pad must not deviate by more than 3 mm in 1 m
for strip bearings and no more than 2 mm across the mortar seating for pad
bearings. The thickness of the mortar pad shall be such as to allow the
bearing to be seated within the nominal 50 mm distance between concrete
bearing faces, without intrusion into the upper concrete element concrete
cover. The maximum thickness of mortar pad shall be 30 mm.
(b)
The bearing shall be placed in position on the mortar pad and fixed in position
with epoxy adhesive of a type recommended by the bearing manufacturer and
(c)
The areas around the bearing must be blocked out with a void former to
ensure that concrete, when poured in the upper element cannot contact the
lower concrete element.
20.7.25 Tolerances: Joints

(a)
The line of straight joints shall be within 10 mm of the true line.
(b)
The line of curved joints shall be within 10 mm of the true curved line.
(c)
Joints shall be continuous across intersections of joints to within 5 mm of the

joint opposite.
(d)
The depth of grooves for joint sealant shall be within 3 mm of the specified
depth.

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January 2011
20.7.26 Drilled in bolts

The Contractor shall survey by cover meter, chipping of the concrete cover or trial
drilling to the depth of the anchor bolt or bar anchorage to accurately identify the
positions of the reinforcement in the vicinity of the required drill holes. Where holes
clash with existing reinforcement, the Contractor shall submit this survey to the
Project Manager for his review without objection four weeks prior to the
commencement of fabrication of the base plates or other follow on work. The
Contractor shall repair all redundant drill holes and chipped concrete with a nonshrink grout of equivalent strength to the concrete being investigated.
20.8
INSPECTION, TESTING & COMMISSIONING
20.8.1
Batch: Cement, PFA, Aaggregate, Admixture, Curing Compound

A batch of cement, PFA, aggregate, admixture or curing compound is any quantity
of cement, PFA, aggregate, admixture or curing compound of the same type,
manufactured or produced at the same time in the same place, covered by the
same certificates and delivered to Site, or stored at the ready-mixed concrete plant,
at any one time.
20.8.2
20.8.3
20.8.4
Samples: Cement, PFA, Aggregate, Admixture, Curing Compound, Water

(a)
One sample of each type of cement, PFA, aggregate, admixture, curing

compound and water shall be provided at the same time as particulars of the
material are submitted to the Project Manager for review without objection.
(b)
The size of each sample and the method of sampling shall be as stated in
Table 20.10.
Testing: Cement, PFA, Aggregate, Admixture, Curing Compound, Water

(a)
Each sample of cement, PFA, aggregate, admixture, water and curing

compound shall be tested to determine the properties stated in Table 20.11.
(b)
The method of testing shall be as stated in Table 20.11.
(c)
The maximum total sulphate and chloride content of concrete shall be

determined on the basis of the results of tests for chloride content of each
constituent.
Control of Alkali-aggregate Reaction in Concrete

(a)
Measures to control the occurrence of alkali-aggregate reaction (AAR) in

concrete shall be in accordance with Practice Note for Authorized Persons
and Registered Structural Engineers No. 180 and submitted for review without
objection by the Project Manager. Such control shall be achieved by limiting
the reactive alkali content of the concrete as described in Clauses (b) - (d)
unless in the opinion of the Project Manager the concrete element will not be
subjected to moisture ingress throughout its design life.
(b)
The reactive alkali content of concrete expressed as the equivalent sodium

oxide per cubic metre of concrete shall not exceed 3.0 kg.

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(c)
The equivalent sodium oxide (Na2O) content of concrete shall be calculated

from the following expression:
Equivalent Na2O = A + B + C
(d)
(i)
where A is the sum of the acid-soluble alkalis (expressed as equivalent

Na2O) of cement, admixtures and water; B is equal to 1/6 of the total
alkalis of PFA (expressed as equivalent Na2O); and C is equal to 0.76
times the chloride ion (Cl) of the aggregate;
(ii)
the acid-soluble alkali content of the cement shall be determined in

accordance with BS 4550:Part 2:1970 (excluding amendment AMD
7285, July 1992) and shall be taken as the average of the latest 25 daily
determinations of equivalent sodium oxide plus twice the standard
deviation of the results;
(iii)
the acid-soluble alkali content of admixtures shall be determined in

accordance with BS 1881:Part 124:1988;
(iv)
the acid-soluble alkali content of water shall be determined in

accordance with APHA (17ed. 1989) Sections 3500-K and 3500Na;
(v)
the total alkali content of the pulverised fuel-ash shall be determined in

accordance with BS 4550:Part 2:1970 (excluding amendment AMD
7285, July 1992) and shall be taken as the average of the latest 25 daily
determinations of equivalent sodium oxide plus twice the standard
deviation of the results; and
(vi)
the equivalent sodium oxide content of the coarse and fine aggregates
shall be calculated from the quantity of chloride ion present which shall
be measured in accordance with BS 812:Part 4:1976.
The following particulars of the proposed concrete mix shall be submitted for
review without objection by the Project Manger:
(i)
HOKLAS endorsed test certificates not older than 6 months giving the
results of tests required in Clauses 20.8.4 (c) (ii)-(vi), with new HOKLAS
test certificates submitted at quarterly intervals together with any
necessary further calculations to demonstrate that the mix continues to
comply with the limit on reactive alkali; and
(ii)
calculations of the reactive alkali of the proposed mix.
Table 20.10:
Size of Samples and Method of Sampling Cement, PFA,

Aggregate, Admixture, Curing Compound and Water
Material
Cement
PFA
PPFAC
Coarse aggregate
Fine aggregate
Water
Admixture (powdered)
Admixture (liquid)
Curing compound
35/53
Size of sample
Method of
20 kg
20 kg
20 kg
25 kg
10 kg
10 L
1 kg
1L
5L
BS 4550:Part 1
BS 4550:Part 1
BS 4550
BS 812:Part 102
BS 812:Part 102
BS 3148
BS 5075:Part 1
BS 5075:Part 1
BS 5075:Part 1
January 2011
Table 20.11 :
Methods of Testing Cement, PFA, Aggregate, Admixture,

Curing Compound and Water
Material
OPC, RHPC, SRPC,
PPFAC
PPFAC
PFA
Coarse aggregate,
fine aggregate
Coarse aggregate
Admixture
Curing compound
Water
Property
Chemical composition
Fineness
Compressive strength at 3, 7
and 28 days
Initial and final setting times
Soundness
Proportion by mass of PFA
Chemical composition
Fineness
Moisture content
Grading
Silt content
Chloride content
Flakiness index
Ten percent fines
Water absorption
Chloride content
Efficiency index
Initial setting times of cement
compressive strength of test
cubes
Organic content
Inorganic impurities content
Chloride content
Sulphide content
Alkaline carbonate and
bicarbonate content
pH value
20.8.5
Method of testing
BS 4550:Part 2
BS 4550:Part 3
BS 6588
BS 3892:Part 1
BS 3892:Part 1
BS 812:Part 103
BS 812:Part 1
BS 812:Part 117
BS 812:Part 105.1
PS 812:Part 111
BS 812:Part 2
BS 5075 : Part 1
Appendix 20A.1
BS 3148
By inspection
APHA 209A
ASTM D512-81,
Method B
ASTM D516-80,
Method A
AOAC 1984, Text
33.076
ASTM D1293-78
Batch: Concrete
A batch of concrete is any quantity of concrete produced in one cycle of operations
of a batch mixer, or conveyed ready-mixed in a delivery vehicle, or discharged
during one minute from a continuous mixer.
20.8.6
Reduction of Resting Frequency

The number of tests for workability or compressive strength of standard mix
concrete may be reduced if after review without objection by the Project Manager it
is confirmed that the standard of quality control is satisfactory.

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20.8.7
20.8.8
20.8.9
Samples: Workability of Concrete

(a)
One sample of concrete shall be provided from each batch of concrete to

determine the workability of the concrete.
(b)
with CS1 except that if a superplasticising admixture is included in the
concrete mix to produce flowing concrete, the sample shall be taken before
the superplasticiser is added.
Testing: Workability of Concrete

(a)
Each sample of concrete taken as stated in Section 20.8.7 shall be divided

into two specimens; each specimen shall be tested to determine the
workability of the concrete. The method of testing shall be the slump test in
accordance with CS1.
(b)
The average of the two slump values shall be calculated and referred to as
the average slump value.
Compliance Criteria: Workability of Concrete

(a)
standard mix concrete shall be within the appropriate range stated in
Table 20.1.
(b)
designed mix concrete shall be within 25 mm or 33% of the "Acceptable
Slump Value", whichever is the greater.
20.8.10 Non-compliance: Workability of Concrete

A batch of concrete shall be considered as not complying with the specified
requirements for workability if the result of any test for workability, carried out on a
sample taken from the batch, does not comply with the specified requirements for
workability.
20.8.11 Samples: Compressive Strength of Concrete
(a)
For each concrete mix, one sample of concrete shall be provided from each
amount of concrete as stated in Table 20.12 or from the amount of concrete
produced each day, whichever is less. The sample shall be selected at
random as follows:
(i)
at the point of discharge from the mixer; or
(ii)
in the case of ready-mixed concrete, at the point of discharge from the

delivery vehicle; or
(iii)
elsewhere as directed by the Project Manager; and
(iv)
in no case to be from the first 0.3 m3 of concrete discharged from the

truck.

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(b)
If the Contractor requests, or if the Project Manager directs, that the concrete
be tested for compressive strength at ages other than 28 days, additional
samples shall be provided. The number of additional samples shall be as
stated in Section 20.8.11(a).
(c)
with CS1. If a superplasticising admixture is included in the concrete mix, the
samples shall be taken after the superplasticiser is added and after the
concrete is remixed.
Table 20.12: Rate Sampling of Concrete
Type of structure
Amount of concrete
Masts
Cantilevers 3 m or more in length
Columns
Shear walls
Prestressed elements
Other critical elements
Solid rafts
Pile caps
Mass concrete
Retaining walls
Other types
10 m3 or 10 batches, whichever
is less
100 m3 or 100 batches,

whichever is less
25 m3 or 25 batches, whichever
is less
20.8.12 Testing: Compressive Strength of Concrete

(a)
Two 150 mm test cubes shall be made from each sample of concrete taken
as stated in Section 20.8.11. Each pair of test cubes shall be tested to
determine the compressive strength at 28 days.
(b)
The method of making test cubes shall be in accordance with CS1.
(c)
The method of storing test cubes shall be in accordance with CS1. Test
cubes which are cured on Site shall be delivered to the HOKLAS accredited
testing laboratory at least 48 hours before the tests are due to be carried out.
(d)
The method of testing shall be in accordance with CS1.
(e)
For the purpose of assessing compliance of designed mix concrete as stated

in Sections 20.8.14 and 20.8.15, the average of the two compressive
strengths of the pair of test cubes shall be calculated and referred to as the
test result.
20.8.13 Non-compliance : Compressive Strength of Standard Mix Concrete

If the result of any test for compressive strength at 28 days of standard mix
concrete is less than the grade strength, the Project Manager may direct that tests
as stated in Sections 20.8.16 to 20.8.19 be carried out on concrete cores or on
samples taken from the hardened concrete.

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20.8.14 Compliance Criteria : Compressive Strength of Designed Mix Concrete

The results of tests for compressive strength at 28 days of designed mix concrete
shall comply with Clause 59 of the Building (Construction) Regulations of Hong
Kong.
20.8.15 Non-compliance : Compressive Strength of Designed Mix Concrete
If designed mix concrete is considered as not complying with the specified
requirements for compressive strength as stipulated in Clause 59 of the Building
(Construction) Regulations of Hong Kong, the Project Manager may direct that tests
as stated in Sections 20.8.16 to 20.8.19 are carried out on concrete cores or on
samples taken from the hardened concrete.
20.8.16 Samples: Hardened Concrete and Concrete Cores
(a)
The number of samples, including cores, of hardened concrete to be provided

for testing shall be as stated in the Contract or, if testing is to be carried out as
a result of the concrete not complying with the Specification, shall be as
directed by the Project Manager and to the satisfaction of the Buildings
Department. In the event testing is directed as a result of concrete not
complying with the Specification, all the concrete being investigated shall be
divided as directed by the Project Manager into separate test locations. The
number of samples taken from each location shall be as directed by the
Project Manager and the quality of concrete at each location shall be
assessed separately. The positions from which the samples are taken shall
be as directed by the Project Manager.
(b)
The size of samples and the method of sampling shall be in accordance with
CS1.
Cores shall be set out to avoid cutting steel reinforcement. .
(c)
(d)
After coring, all coring locations shall be made good with non-shrink
cementitious grout with the same minimum compressive strength as at the
core location.
20.8.17 Testing: Concrete Cores

(a)
Each concrete core shall be inspected for evidence of segregation of the

constituents and for the presence of voids. Specimens selected from each
core shall be tested to determine the compressive strength.
(b)
The method of preparing and inspecting concrete cores and of testing the
cores to determine the compressive strength shall be in accordance with CS1.
Concrete cores shall not be tested for compressive strength until the concrete
has reached an age of 28 days.
20.8.18 Compliance Criteria: Concrete Cores

(a)
Concrete cores shall not show evidence of segregation. The extent of voids
in the core shall not be more than 'few' in accordance with Table 4 of CS1 and
there shall be no honeycombing.

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(b)
The results of tests for compressive strength of concrete cores shall be

interpreted in accordance with BS 6089. Adjustments to the measured
strength in respect of the age of the core when tested shall not be made. The
estimated equivalent cube strength of each core specimen shall be calculated
in accordance with CS1. Subject to the approval of the Buildings Department,
for any set of cores representing a test location, the average estimated
equivalent cube strength shall be at least 85% of the specified grade strength,
and each individual estimated equivalent cube strength shall be at least 75%
of the specified grade strength.
20.8.19 Analysis of Hardened Concrete

(a)
Each sample of hardened concrete shall be tested to determine the properties

or the composition of the concrete as stated in the Contract or, if testing is to
be carried out as a result of the concrete not complying with the specified
requirements, shall be tested as directed by the Project Manager.
(b)
Tests on hardened concrete shall be carried out within 14 days of the Project
Manager's request for the test.
(c)
The method of testing shall be in accordance with CS1.
(d)
When directed by the Project Manager, in-situ rebound hammer tests to

determine the strength of hardened concrete shall be undertaken in
accordance with BS EN 12504-2:2001.
20.8.20 Batch: Precast Units

A batch of precast units is any quantity of precast units, including prestressed units,
of the same type and size, of the same concrete mix, manufactured in the same
place, covered by the same certificates and delivered to Site at any one time.
20.8.21 Samples: Precast Units
The number of precast units to be provided for testing from each batch shall be as
20.8.22 Testing: Precast Units
(a)
Load tests shall be carried out to determine the deflection and recovery of
each precast unit, including prestressed units, provided for testing and to
determine the resistance to cracking of each prestressed unit provided for
testing.
(b)
Load tests shall be carried out in accordance with a procedure submitted to

and reviewed without objection by the Project Manager. The age at which the
units are to be tested, the test load, the points at which the loads are to be
applied and the points at which the unit is to be supported shall be as stated
in the Contract or as proposed by the Contractor and reviewed without
(c)
The method of testing shall be as stated in Appendix A20.2.
(d)
Post-tensioned units shall not be tested until at least 7 days after the ducts
have been grouted.

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20.8.23 Compliance Criteria: Precast Units

The results of load tests on precast units shall comply with the requirements stated
in the Contract.
20.8.24 Batch: Joint Filler, Joint Sealant, Waterstops
A batch of joint filler, joint sealant or waterstop is any quantity of joint filler, joint
sealant or waterstop of the same type, manufactured by the same manufacturer,
covered by the same certificates and delivered to Site at any one time.
20.8.25 Samples: joint filler, joint sealant, waterstops
(a)
One sample of each type of joint filler, joint sealant or waterstop shall be
provided at the same time as particulars of the material are submitted to the
Project Manager for review without objection. One sample of each type of
material shall be provided from each batch of the material delivered to Site.
One sample of mixed joint sealant shall be provided on each day that joints
are sealed.
(b)
The size of each sample of joint filler shall be sufficient to permit all tests
stated in Appendix A20.3 to be carried out.
(c)
Samples of unmixed joint sealant and primers for joint sealant shall be taken
from sealed containers delivered to Site. Samples of mixed joint sealant shall
be taken immediately before the sealant is applied to the joint. The method of
sampling shall be as stated in BS 2499, Appendix A. The size of each sample
(d)
(i)
unmixed joint sealant : 1 kg;
(ii)
mixed joint sealant
(iii)
primer for joint sealant : 1 L.
: 1.5 kg; and
The size of each sample of waterstop shall be 1 m.
20.8.26 Testing: Joint Filler, Joint Sealant, Waterstops

(a)
Samples of joint filler shall be tested to determine the disintegration and

shrinkage, the recovery value and reduction in mass and the extrusion. The
method of testing shall be in accordance with Appendix A20.3.
(b)
Samples of joint sealant shall be tested to determine the properties stated in

Table 20.13. The method of testing shall be as stated in Table 20.13.
(c)
Samples of waterstop shall be tested to determine the properties stated in

Table 20.14. The method of testing shall be as stated in Table 20.14.

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Table 20.13: Testing Joint Sealant

Type of joint sealant
Properties to be tested
Polysulphide-based sealant
Rheological properties
Polyurethane-based sealant
Plastic deformation
Method of testing
BS 4254
Adhesion and tensile

modulus
Application life
Adhesion in peel
Loss of mass after heat
ageing
Staining
Hot-applied bitumen rubber
sealant
Extension
BS 2499
Flow
Penetration
Degradation
Table 20.14 : Testing Waterstops

Method of testing
Property
Rubber waterstops
Density
BS 903:Part A1
Hardness
BS 903:Part A26
Tensile strength
Elongation at
break point
BS 903:Part A2
and
BS 903:Part A5
BS 903:Part A2
and
BS 903:Part A5
PVC waterstops
BS 2782:Part 6,
Methods 620A to 620D
BS 2782:Part 3,
Method 365D
BS 2782:Part 3,
Methods 320A to 320F
BS 2782:Part 3,
Methods 320A to 320F
Water absorption
BS 903:Part A18
BS 2782:Part 4,
Methods 430A to 430D
Softness number
BS 2782:Part 3,
Method 365A
20.8.27 Compliance Criteria: Joint Filler

(a)
The results of tests on joint filler shall comply with the following requirements:
(i)
none of the three specimens in the weathering test shall show any sign
of disintegration or shrinkage;
(ii)
each of the four specimens in the compression and recovery test shall
have a recovery value of at least 70%, and the reduction in mass of
each of the two new specimens shall not exceed 1%; and
(iii)
the extrusion of the free edge of the specimen shall not exceed 6 mm as
determined by the extrusion test.

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APPENDIX A20.1
DETERMINATION OF THE EFFICIENCY INDEX
OF CURING COMPOUNDS
A20.1.1 Scope
This method covers the determination of the efficiency index of membrane forming
curing compounds for concrete.
A20.1.2 Materials
(a)
The following materials are required:

(i)
Ordinary Portland cement complying with BS 12, specially selected for

testing admixtures and identified as 'CAA/BS 5075:Part 1 Reference
Portland Cement'; the cement shall be stored in an airtight container;
(ii)
oven-dry natural sand with a rounded particle shape complying with

BS 882 and with the grading stated in Table A20.1.1; and
(iii)
petroleum jelly, mineral oil or a proprietary release agent.

Table A20.1.1 : Grading of Sand
BS test sieve
1.18 mm
100
600 m
90 - 100
300 m
12 - 40
150 m
0-6
A20.1.3 Apparatus
(a)

(i)
moulds constructed of corrosion resistant metal. The moulds shall be

watertight, tapered and constructed so as to prevent distortion and shall
have the following dimensions:
(ii)
internal size (top):
150 mm (0 mm to +5 mm) x 300 mm (0 mm

to +5 mm);
internal size (bottom): 145 mm (0 mm to +5 mm) x 295 mm (0 mm
to +5 mm);
internal depth:
50 mm 2 mm;
side and end slope:
5% 1%; and
top flange width:
at least 12 mm;
a balance readable and accurate to 0.1 g;

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(iii)
a cabinet complying with BS 2648 capable of storing specimens at a

temperature of 38C 1C and at a relative humidity of 35% 5%. The
cabinet shall have three perforated or mesh shelves each capable of
supporting two specimens during the test so as to ensure a clear space
of at least 40 mm on all sides of individual specimens. The cabinet shall
be equipped to circulate air over the specimens at an approximate rate
of 0.5 m/s;
(iv)
spray equipment, such as the Wagner model W320 electric spray gun,
designed to permit the curing compound to be aspirated and applied
evenly to the specimen;
(v)
an electrically driven mixer complying with Clause 8.3 of BS 4551 and

having a nominal capacity of 12 kg;
(vi)
a vibrating table or a vibrating hammer with a 40 mm square foot or a

compacting bar made of non-absorbent material, approximately 200 mm
long and with a 40 mm square foot;
(vii) a metal screed, 148 mm long, of L-shaped section 50 mm x 25 mm with

the shorter side having a sharpened leading edge. The screed shall be
supported across the top of the mould by a 200 mm long rigid member
which can slide on the flanges of the mould while holding the screed
horizontal. The height of the screed shall be adjustable to give a
uniformly flat surface finish to the mortar 7 mm 1 mm below the top of
the mould;
(viii) a metal tray with sides at least 3 mm high and an area equal to the
surface area of the specimen;
(ix)
a hydrometer complying with BS 718;
(x)
a float, 250 mm x 140 mm 5 mm; and
(xi)
a medium soft 50 mm paint brush.
A20.1.4 Procedure: Preparation of Specimens

(a)
The procedure for preparation of the specimens shall be as follows:

(i)
three pairs of specimens shall be prepared, each pair comprising one

test specimen and one control specimen;
(ii)
mixing shall be carried out in a room having a temperature of 27C 3

C. The materials shall be brought to room temperature before mixing.
A mortar mix shall be prepared comprising one part by mass of cement,
three parts by mass of sand and 0.44 parts by mass of water;
(iii)
the sand and cement shall be placed in the mixer and mixed for
1 minute. The water shall be added and mixing continued for a further 4
minutes;
(iv)
the two moulds shall be cleaned, lightly coated with the petroleum jelly,
mineral oil or release agent and weighed to the nearest 0.1 g (m1);

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(v)
the specimens shall be prepared 20 minutes after completion of mixing

and shall be cast in pairs;
(vi)
a layer of mortar approximately 25 mm deep shall be placed in each

mould and tamped 50 times with the compacting bar. A second layer of
mortar, sufficient to overfill the moulds slightly, shall be placed in each
mould and tamped 50 times with the compacting bar. Indentations
formed by tamping shall be filled and the surface shall be levelled by
vigorous compaction by manual methods. Alternatively, each layer shall
be compacted by using the vibrating table or vibrating hammer and
levelled using the float;
(vii) a uniform surface, free from undulations and surface defects, shall be
produced using the minimum number of passes of the metal screed
working along the length of the mould in both directions. The finished
surface shall be 7 mm 1 mm below the top of the mould;
(viii) the surface shall be brushed lightly with the paint brush to give an even
texture; and
(ix)
The moulds and specimens shall each be weighed to the nearest

0.1 g (m2) immediately before the curing compound is applied.
A20.1.5 Procedure: Determination of Efficiency Index

(a)
The procedure for determination of the efficiency index shall be as follows:

(i)
a sample of the curing compound shall be taken by the method for

sampling admixtures in accordance with BS 5075:Part 1, Appendix A;
(ii)
the sample shall be agitated thoroughly and the relative density

determined at room temperature with the hydrometer. The mass
required to give the coverage rate stated in Section A20.1.5(c) shall be
calculated from the relative density. The mass of the curing compound
applied shall be within 0.5 g of that required to give the specified
coverage rate;
(iii)
the curing compound shall be applied at the coverage rate

recommended by the manufacturer, or at a rate of 0.2 L/m 0.01 L/m
if no rate is recommended;
(iv)
the curing compound shall be applied to the test specimen one hour
after the specimen has been prepared, using the spray equipment or in
accordance with the manufacturer's recommendations. The curing
compound shall be shaken well before and during application. The
spray gun shall be held so that the nozzle is as near vertical as possible
and at a height which will result in uniform application and minimum
overspray. The specimen shall be coated uniformly by applying several
layers over the whole surface until the specified coverage is reached,
checked by repeated weighing. Over spray shall be wiped from the
exposed faces and edges of the mould. The whole application
procedure shall be completed in not more than 2 minutes;

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(v)
the test specimen and the control specimen shall each be weighed to
the nearest gram (m3) and placed immediately on the lowest shelf of
the cabinet. After the second pair of specimens has been prepared and
weighed, the first pair shall be moved up one shelf and the second pair
placed on the lowest shelf. After the third pair of specimens has been
prepared and weighed, the first two pairs shall be moved up one shelf
and the third pair placed on the lowest shelf;
(vi)
the total time for making the specimens, coating the test specimen and
placing the pair in the cabinet shall not exceed 2 hours;
(vii) the specimens shall be kept in the cabinet for 72 hours 15 minutes
after application of the curing compound. Each specimen shall be
weighed to the nearest 0.1 g at 24 hours 15 minutes and 48 hours
15 minutes. Each specimen shall be weighed to the nearest 0.1 g (m4
and m5) at 72 hours 15 minutes; and
(viii) the metal tray shall be weighed to the nearest 0.1 g (m6) and coated
with the same quantity 0.5 g of curing compound used on the test
specimen. The coated tray shall be weighed to the nearest 0.1 g (m7)
and placed in the cabinet for 72 hours 15 minutes after application of
the curing compound. The tray shall be removed from the cabinet and
weighed to the nearest 0.1 g (m8).
A20.1.6 Calculation
(a)
The proportion of solvent lost (V) by the curing compound during the test
period shall be calculated from the equation:
V=
(m7 - m8)
________
(m - m )
7
6
where:
m6 is the mass of the tray measure in grams;

m7 is the mass of the tray after coating measured in grams; and
m8 is the mass of the tray after 72 hours in the cabinet measured in grams.

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(b)
The loss of water from the test specimen (Wt) and the loss of water from the
control specimen (Wc) shall be calculated for each pair of specimens from the
following equations:
(m3 - m4) - V(m3 - m2)
___________________ x 100%
(m2 - m1)
Wt =
(m2 - m5)
Wc = _______ x 100%
(m2 - m1)
where:
- m1 is the mass of the mould measured in grams;
- m2 is the mass of the mould and test or control specimen as appropriate
measured in grams;
- m3 is the mass of the mould and test specimen after coating measured in
grams;
- m4 is the mass of the mould and test specimen after 72 hours in the cabinet
measured in grams; and
- m5 is the mass of the mould and control specimen after 72 hours in the
cabinet measured in grams.
(c)
The efficiency index (Et) of the curing compound shall be calculated for each
test specimen from the equation:
Et =
(Wc - Wt)
________ x 100%
Wc
The efficiency index (E) of the curing compound shall be calculated as the
average of Et for the three test specimens.
(a)

(i)
details of the sample of curing compound including identification,

source, size, date received and age at test;
(ii)
method of compacting the mortar;
(iii)
method of applying the curing compound and the type of spray gun
used;
(iv)
rate of application of the curing compound to the nearest 0.01 L/m;
(v)
duration of the test; and
(vi)
efficiency index of the curing compound to the nearest 0.1%.

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APPENDIX A20.2
DETERMINATION OF THE DEFLECTION, RECOVERY
AND RESISTANCE TO CRACKING OF PRECAST UNITS
A20.2.1 Scope
This method covers the determination of the deflection and recovery of precast
units, including prestressed units, and the resistance to cracking of prestressed
units by means of a load test.
A20.2.2 Equipment
(a)

(i)
rigid supports;
(ii)
test loads;
(iii)
equipment for measuring the loads applied, readable and accurate to

2% of the specified test load; and
(iv)
equipment for measuring the deflection and recovery, readable and

accurate to 0.5 mm.
A20.2.3 Procedure
(a)

(i)
precast unit shall be supported at the specified points of support;
(ii)
upward deflection at mid-span due to the prestressing force in a

prestressed unit and the deflection at mid-span due to the self-weight of
a non-prestressed unit shall be measured;
(iii)
specified test load shall be applied at the specified loading points in not
less than ten approximately equal increments;
(iv)
specified test load shall be maintained for 5 minutes and removed in not
less than five approximately equal decrements;
(v)
deflection at mid-span shall be measured for each load increment and

each load decrement and 5 minutes after the loads have been removed;
(vi)
steps (iii) to (v) shall be repeated; and
(vii) load-deflection graphs shall be plotted.

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(a)

(i)
details of the precast unit, including place of manufacture;
(ii)
the age of the concrete in the precast unit at the time of the test;
(iii)
loads applied to the nearest 2% of the specified test load;
(iv)
deflections measured to the nearest 0.5 mm;
(v)
load-deflection graphs; and
(vi)
details of any cracks.

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APPENDIX A20.3
DETERMINATION OF THE DISINTEGRATION AND
SHRINKAGE, THE RECOVERY VALUE AND
REDUCTION IN MASS, AND THE EXTRUSION OF JOINT FILLER
A20.3.1 Scope
This method covers the determination of the disintegration and shrinkage of joint
filler, by weathering test, the recovery value and reduction in mass of joint filler by
the compression and recovery test, and the extrusion of joint filler by the extrusion
test.
A20.3.2 Apparatus
(a)

(i)
equipment for measuring the size of the joint filler, readable and
accurate to 0.5mm;
(ii)
ventilated drying oven;
(iii)
water bath;
(iv)
watertight weathering test pan with a ribbed bottom and a fitted slotted
lid designed to hold 3 specimens of joint filler vertically on edge;
(v)
refrigerator;
(vi)
equipment for measuring the thickness of the joint filler readable and
accurate to 25 m;
(vii)
balance readable and accurate to 0.01 g;
(viii) compression test machine complying with BS 1610 : 1985 with

auxiliary platens 100 mm x 100 mm and a minimum thickness of 13
mm; and
(ix)
extrusion mould open on one side only and rigidly fixed to a base
plate. The mould shall be 100 mm x 100 mm (+ 0.5 mm, - 0 mm)
internally and shall be of sufficient depth to test the specimen. The
mould shall be provided with a close fitting pressure plate which shall
fit without binding and with a horizontal measuring dial gauge or
device readable and accurate to 25 m.
A20.3.3 Procedure : Weathering Test

(a)
The procedure for determination of the disintegration and shrinkage by the

weathering test shall be as follows:
(i)
3 specimens from the sample shall be prepared, each 115 mm x 115

mm ( 2.5 mm);

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(ii)
specimens shall be placed in the oven and maintained at a

temperature of 55C, 5C for 7 days. The specimens shall be
removed from the oven and immediately immersed in water at room
temperature for 24 hours;
(iii)
specimens shall be placed in the test pan and the pan shall be filled
with water to half the depth of the specimens;
(iv)
specimens shall be subjected to 5 cycles of freezing and thawing as

follows:
-
test pan and specimens shall be placed in a refrigerator and the

water frozen to minus 7C or below for a period of at least 4 hours
after initial freezing; and
test pan shall be removed from the refrigerator and placed in the
bath without disturbing the specimens for a period of one hour
after thawing of the water in the test pan is complete. The water
in the bath shall be maintained at a temperature of between 18C
and 38C;
(v)
after the fifth cycle, the specimens shall be removed from the test pan
and air dried at room temperature for 48 hours; and
(vi)
specimens shall be inspected for evidence of disintegration or

shrinkage.
A20.3.4 Procedure: Compression and Recovery Test

(a)
The procedure for determination of the recovery value and reduction in mass
by the compression and recovery test shall be as follows:
(i)
four specimens from the sample

100 mm x 100 mm ( 2.5 mm);
(ii)
thickness (t1) of the four specimens shall be measured to the nearest

0.1 mm, and two specimens shall be weighed to within 0.1% of their
mass (m1);
(iii)
each specimen shall be subjected to three applications of load in the

compression test machine at 24 hour intervals.
During each
application of load the specimen shall be compressed to 50% of its
original thickness at a rate of strain of 1.3 mm per minute. The load
required to achieve the compression shall be at least 0.07 N/mm and
shall not exceed 10 N/mm. The load shall be released immediately
the specified amount of compression is reached;
(iv)
after the third application of load, a recovery period of 30 minutes shall

be allowed and the thickness (t2) of each specimen shall be measured
to the nearest 0.1 mm; and
(v)
two previously weighed specimens shall be re-weighed to within 0.1%

of their mass (m2).

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shall
be
prepared,
each
January 2011
A20.3.5 Procedure: Extrusion Test

(a)
The procedure for determination of the extrusion by the extrusion test shall be
as follows:
(i)
one 100 mm x 100 mm ( 0.5 mm) specimen shall be prepared;
(ii)
thickness of the specimen shall be measured to the nearest 0.1 mm;

and
(iii)
specimen shall be placed in the extrusion mould and subjected to one

application of load as stated in Section A20.3.4(c). The extrusion at
the open side of the mould shall be measured to the nearest 0.1 mm
with the gauge or device when the specimen is compressed to 50% of
the original thickness and before the load is released.
A20.3.6 Calculation
(a)
The recovery value (R) of each specimen shall be calculated from the
equation:
R = t 2/t1 x 100 %
where:
- t1 is the original thickness of the specimen (mm)
- t2 is the thickness of the specimen after the third application of load (mm)
(b)
The reduction in mass (M) of each specimen shall be calculated from the
equation:
M = (m1 - m2)/m1 x 100 %
where:
- m1 is the original mass of the specimen (g)
- m2 is the mass of the specimen after the third application of load (g)

(a)

(i)
type and source of filler;
(ii)
any evidence of disintegration or shrinkage as a result of the

weathering test;
(iii)
recovery values to the nearest 0.5%;
(iv)
reductions in mass to the nearest 0.1%; and
(v)
extrusion to the nearest 0.1 mm.

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January 2011
APPENDIX A20.4
ROUTINE CHECKS FOR PLANT AND EQUIPMENT
PART 1 BATCHING AND MIXING EQUIPMENT

A20.4.1 Daily Routine
Adjust tare weights and clean weighing dials.
Ensure weighing hoppers empty properly.
Wash-out central mixer drum or pan.
A20.4.2 Weekly Routine
Maintain all hoppers and doors in clean and efficient working order.
Remove any cement or concrete build-up in mixer.
Shake out cement silo filler sock and maintain in efficient working order.
Clean knife edges on weighing equipment.
Check calibration of moisture meter.
A20.4.3 Monthly Routine
Check calibration of all weigh scales.
Check calibration of water meter.
Check calibration of admixture dispenser.
A20.4.4 Quarterly Routine
Inspection and testing of all weigh scales over their complete range.
PART 2 TRANSPORTING EQUIPMENT - MIXER AND AGITATOR UNITS

A20.4.5 Daily Routine
Wash out truck mixer drum.
A20.4.6 Monthly Routine
Check operation of revolution counters.
Check calibration of mixer truck water meter.

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January 2011
SECTION 21 PRESTRESSING
21.1
GENERAL
21.1.1
Materials for Grout

Materials for grout for prestressing systems shall comply with Section 20 except as
stated in this Section.
21.2
21.2.1
Duct
Duct is a void formed in the concrete to accommodate a prestressing tendon.
21.2.2
Prestressing Components
Prestressing components are the components used in a prestressing system,
including anchorages, grips, tendon deflectors, couplers, wedges, swages, nuts and
other devices used to grip the prestressing tendon.
21.2.3
Prestressing Tendon
(a)
21.2.4
Prestressing tendon is:

(i)
an individual steel wire, wire strand or alloy steel bar in a duct, or
(ii)
an individual steel wire, wire strand or alloy steel bar not in a duct, or
(iii)
a group of steel wires or wire strands in a duct used in a prestressing

system.
Sheath
Sheath is a tube or lining which is used to form a duct and which is left in place.
21.3
MATERIALS
21.3.1
Prestressing Tendons
(a)
Prestressing tendons shall comply with the following:

High tensile steel wire and strand
for the prestressing of concrete
: BS 5896
Hot rolled and processed high tensile alloy steel bars

for the prestressing of concrete
: BS 4486.
(b)
Steel wire and wire strand shall be in coils of sufficiently large diameter to
allow the steel wire and wire strand to pay off straight, without any permanent
set or bends.
(c)
Alloy steel bars shall be straight.

Section 21 - Prestressing
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January 2011
21.3.2
21.3.3
21.3.4
Prestressing Components
(a)
Prestressing components shall be a proprietary type reviewed without

(b)
Prestressing anchorages shall comply with BS 4447 and shall allow a

minimum of 25 mm cover to cropped ends of prestressing tendons.
Sheaths
(a)
Sheaths shall be a proprietary type reviewed without objection by the Project

Manager and shall be steel or other material reviewed without objection by the
Project Manager. Sheaths shall be rigid and strong enough to retain their
shape during fixing and concreting and to withstand forces from the
prestressing tendons without damage.
(b)
The design of ducts shall allow for grout to be injected from either end. There
shall be no sudden changes in the diameter of the duct.
Grout Vents and Taps

Taps for grout vents in ducts shall be a proprietary type reviewed without objection
by the Project Manager and shall allow closure of the vents without loss of pressure
in the duct. Vents to be used as grout entry points shall be threaded or fitted with
screw connectors or other similar devices for connection to grout pumps.
21.3.5
21.3.6
Grout for Prestressing Systems

(a)
Grout for prestressing systems shall consist of ordinary Portland cement and
water. Sand, PFA and admixtures shall not be used unless otherwise
specified in the Contract, or reviewed without objection by the Project
Manager.
(b)
Grout shall have a minimum crushing strength of 25 MPa at 7 days.
(c)
The amount of bleeding of grout shall not exceed 2% in the first 3 hours and
shall not exceed 4% in total; the water shall be reabsorbed by the grout during
the 24 hours after mixing.
(d)
Free expansion of grout shall not exceed 10% at the ambient temperature.
(e)
The maximum total chloride content of grout, expressed as a percentage

the grout, shall not exceed 0.1%.
(f)
Admixtures for grout shall not contain chlorides.
(g)
Grout shall have a water cement ratio as low as possible consistent with the
necessary workability and under no circumstances shall the water cement
ratio exceed 0.45.
Handling of Prestressing Tendons

Prestressing tendons shall not be subjected to rough handling, shock loading or
dropping from a height.

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January 2011
21.3.7
Handling of Prestressing Components

Prestressing components shall be handled in accordance with the manufacturers'
recommendations.
21.3.8
21.3.9
Storage of Materials for Prestressing Systems

(a)
Each prestressing tendon shall be tagged with a number to identify the coil or
bundle number of the prestressing tendon used.
(b)
Prestressing tendons and sheaths shall be stored off the ground on level
supports and in a manner which will not result in damage or deformation to
the materials or in contamination of the materials.
(c)
Different types and sizes of prestressing tendons, prestressing components

and sheaths shall be stored separately.
(d)
Prestressing tendons, prestressing components and sheaths shall not be

stored on or adjacent to concrete surfaces which form part of the Permanent
Works.
(e)
Prestressing tendons, prestressing components and sheaths shall be

protected from exposure to conditions which may affect the material.
Surface Condition of Materials for Prestressing Systems

(a)
Prestressing tendons, prestressing components and sheaths shall be clean at

the time of installation and shall be free from loose mill scale, loose rust,
pitting, grease or any substance which in the opinion of the Project Manager
is likely to reduce the bond or affect the prestressing tendons, prestressing
components, sheaths, concrete or grout chemically. The prestressing
tendons, prestressing components and sheaths shall be maintained in this
condition until concrete or grout is placed around them.
(b)
If the surface condition of the prestressing tendons, prestressing components

or sheaths deteriorates such that it does not comply with the requirements
stated in Clause 21.3.9(a), the prestressing tendons, prestressing
components or sheaths shall be cleaned or dealt with by other methods
21.4
SUBMISSIONS
21.4.1
Particulars of Prestressing Systems

(a)
The following particulars of the proposed prestressing systems shall be

submitted to the Project Manager for review:
(i)
details of the prestressing system, including prestressing tendons,

prestressing components, sheaths and tensioning apparatus;
(ii)
sequence of prestressing and ends of prestressing tendons from which

prestress will be applied ;

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January 2011
(iii)
calculated values of:

each type of loss of prestress;
prestressing tendon forces; and
extensions of prestressing tendons and details of the method of
measuring the extensions;
(iv)
a certificate showing that the tensioning apparatus has been tested and
calibrated by an agent reviewed without objection by the Project
Manager within a period of two years before the apparatus is to be
used;
(v)
any alterations to the reinforcement or additional reinforcement required

to allow for primary bursting effects;
(vi)
details of corrosion protection required for the prestressing system; and
(vii) details of the format of tensioning schedules and of reports of tensioning

operations, grouting operations and testing of duct friction.
(b)
21.4.2
Calculations for loss of prestress due to creep shall be based on the

information stated in the Contract.
Particulars of Prestressing Tendons

(a)
The following particulars of the proposed prestressing tendons shall be

(i)
21.4.3
a certificate from the manufacturer showing the manufacturer's name,

the date and place of manufacture and showing that the prestressing
tendons comply with the requirements stated in the Contract and
including details of:
cast analysis;
diameter, cross-sectional area and unit mass;
results of tests for mechanical properties, including the characteristic
breaking load, characteristic 0.1% proof load, elongation at
maximum load, relaxation and modulus of elasticity; and
results of tests for ductility of prestressing wires.
Particulars of Grout Mix and Grouting Procedure

(a)
The following particulars of the proposed grout mix and grouting procedure for
prestressing systems shall be submitted to the Project Manager for review
without objection:
(i)
water:cement ratio by mass;
(ii)
details of mixing and grouting equipment;
(iii)
method of quality control during grout injection; and
(iv)
details of grouting trials.

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January 2011
21.4.4

(a)
Representative samples of the following items shall be submitted to the

Project Manager at the same time as particulars of the prestressing systems
are submitted:
(i)
prestressing tendons;
(ii)
prestressing components;
(iii)
sheaths; and
(iv)
grout vents and taps.
21.5
WORKMANSHIP
21.5.1
Installation of Prestressing Systems
21.5.2
21.5.3
(a)
Prestressing operations shall be carried out with due regard to the energy
stored in a stressed tendon.
(b)
Prestressing tendons, prestressing components and sheaths shall be

accurately located and maintained in the correct position during all operations;
supports shall be placed at a maximum spacing of 600 mm.
Installation of Prestressing Tendons

(a)
Prestressing tendons from each batch shall not be installed until testing of the
batch has been completed.
(b)
Steel wires, wire strands and alloy steel bars which will be tensioned in one
operation shall be taken from the same batch.
(c)
Individual steel wires and wire strands in the same duct shall not be twisted
together. Strands which have become unravelled shall not be used.
(d)
Alloy steel bars which have become bent shall not be straightened. Small
adjustments for straightness may be made provided the straightening is
carried out at the ambient temperature by non-mechanical methods and
provided that no force is applied on the threaded portion. Bars which have
become bent in the threaded portion shall not be used.
(e)
After manufacture, prestressing tendons shall not be welded and heat

treatment, work-hardening, galvanizing and other metallic coatings shall not
be applied. Prestressing tendons which have been damaged mechanically or
by work-hardening or heating shall not be used.
Cutting Prestressing Tendons

Prestressing tendons shall be cut using either a high speed abrasive cutting wheel
or a friction saw. Flame cutting shall not be used.

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January 2011
21.5.4
Joints in Prestressing Tendons

Joints in prestressing tendons shall be made using proprietary couplers fixed in
21.5.5
Use of Prestressing Components

Prestressing components shall be used in accordance with the manufacturers'
recommendations.
21.5.6
Installation of Sheaths
At the time of tensioning, sheaths shall be free from dents or other irregularities
which may affect tensioning.
21.5.7
21.5.8
Joints in Sheaths
(a)
Joints in sheaths shall be securely taped to prevent penetration of the duct by

concrete or grout. Joints in adjacent sheaths shall be staggered by at least
300 mm.
(b)
Where sheaths are used, the number of joints shall be kept to a practicable
minimum and sleeve connectors shall be used for jointing.
Installation of Grout Vents and Taps

(a)
(b)
21.5.9
Grout vents and taps shall be provided at the following positions:

(i)
all crests of the prestressing tendon profile;
(ii)
all low points of the prestressing tendon profile;
(iii)
all anchorages; and
(iv)
intervals not exceeding 15 m.
Vents shall not be placed at positions where they will be blocked by the
prestressing tendons after tensioning.
Tensioning of Prestressing Tendons

(a)
Apparatus for tensioning prestressing tendons shall impose a controlled total

force gradually and shall not induce excessive secondary stresses in the
prestressing tendons, prestressing components, structure or element to which
prestress is being applied.
(b)
Prestressing tendons shall be securely attached to jacks and tensioning

apparatus.
(c)
Steel wires or wire strands which are tensioned simultaneously shall be

approximately the same length between anchorage points.
(d)
The force in the prestressing tendons during tensioning shall be measured by

direct reading load cells or obtained indirectly from pressure gauges fitted in
the hydraulic system. Load measuring devices shall be accurate to within 2%.

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January 2011
(e)
The extension of prestressing tendons and any movement of prestressing

tendons in the gripping devices shall be measured during tensioning. The
elongation of prestressing tendons shall be measured to an accuracy of 2% or
2 mm, whichever is the more accurate.
(f)
Tensioning apparatus and load measuring devices shall be calibrated before

tensioning starts and at regular intervals reviewed without objection by the
Project Manager.
(g)
The force in the prestressing tendons shall not be transferred to the concrete
until the concrete has reached the specified transfer strength.
21.5.10 Pretensioning
(a)
The stress in prestressing tendons shall be fully maintained during the period
between pretensioning and transfer of stress. Transfer of stress shall take
place gradually to minimise shock or damage to the transmission length and
shall be carried out in conjunction with the release of any hold-down and holdup forces in tendon deflectors.
(b)
In the long-line method of pretensioning, locator plates shall be distributed

throughout the length of the bed to ensure that the steel wires or wire strands
are maintained in the correct positions during concreting. Units which are
made in line shall be free to slide in the direction of their length to permit
transfer of the prestressing force to the concrete along the whole line.
(c)
Moulds used in the individual mould system of pretensioning shall be

sufficiently rigid to provide the reaction to the prestressing force without
distortion.
(d)
Tendon deflectors in contact with pretensioned prestressing tendons of single

steel wire or wire strand shall have a radius of at least five times the
prestressing tendon diameter for steel wire and at least ten times the
prestressing tendon diameter for wire strand. The total angle of deflection
shall not exceed 15. If a system is used such that friction develops between
prestressing tendons and tendon deflectors, the friction force shall be
determined by a test procedure reviewed without objection by the Project
Manager and any necessary allowance shall be made.
21.5.11 Post-tensioning
(a)
A tensioning schedule shall be submitted to the Project Manager for review

without objection at least 7 days before each post-tensioning operation starts.
The schedule shall include the proposed sequence of tensioning the
prestressing tendons, the required prestressing loads and the calculated
extensions of the prestressing tendons.
(b)
Spacers used with post-tensioned steel wire or wire strand which are not
tensioned simultaneously shall be sufficiently rigid to ensure that they will not
be displaced during successive tensioning operations.
(c)
If both ends of the prestressing tendon are free to move, a demonstration

shall be carried out before post-tensioning starts to show that all prestressing
tendons are free to move in the ducts.

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January 2011
(d)
Post-tensioning shall be carried out in such a manner that the stress in the
prestressing tendons increases at a gradual and steady rate. The sequence
of tensioning prestressing tendons and the ends of prestressing tendons from
which prestress will be applied, shall be reviewed without objection by the
Project Manager.
(e)
For each element of a structure being stressed, post-tensioning of the

prestressing tendons shall be carried out until the required prestress to that
element has been reached. Tensioning of each prestressing tendon shall be
carried out continuously until the required tendon loads or extensions have
been reached. If tensioning is stopped for more than 2 days, particulars of
any proposals for remedial or other work shall be submitted to the Project
Manager for review without objection and tensioning shall not recommence
until the remedial or other work has been carried out and reviewed without
(f)
Measurement of extensions shall not commence until any slack in the

prestressing tendon has been taken up. If the design permits, the draw-in of
prestressing tendons at the non-jacking end shall also be measured. The
tensioning shall be applied in increments of load and the extensions shall be
measured at each increment. The average measured extension of the
prestressing tendons shall be within 5% of the calculated extension and the
measured extension of individual prestressing tendons shall be within 10% of
the calculated extension.
(g)
If the tendon deflector in contact with a post-tensioned prestressing tendon

has a radius of less than 50 times the diameter of the prestressing tendon or if
the total angle of deflection exceeds 15, the loss of strength of the
prestressing tendon shall be determined by a test procedure reviewed without
objection by the Project Manager and any necessary allowance shall be
made.
(h)
If the pull-in of the tendons at completion of anchoring is greater than that

agreed by the Project Manager, tensioning shall be carried out afresh.
(i)
The Project Manager may direct that the force in any strand or wire be tested
by re-jacking. The strand or wire shall than be re-anchored at the proper
tension.
(j)
When the prestressing has been applied, the tendons shall be anchored. The
jack pressure shall then be released in such a way as to avoid shock to the
anchorage, tendons, or concrete.
(k)
Post-tensioned prestressing tendons shall be cut at a distance from the

anchorage of at least one diameter or 10 mm, whichever is greater. The
tendons shall not be cut until at least 1 day after stressing, if the tendon is to
be cut before grouting, or alternatively, at least 3 days after grouting.
21.5.12 Protection of External Prestressing Tendons and Anchorages

External prestressing tendons and anchorages shall be protected in their
permanent positions from mechanical damage or corrosion until the permanent
protection is applied.

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January 2011
21.5.13 Records of Tensioning Operations

Records of tensioning operations shall be kept by the Contractor on Site and a
report shall be submitted to the Project Manager for review without objection within
24 hours of each tensioning operation. Tendons shall not be cut prior to the Project
Manager's review without objection of the records of each tensioning operation.
The report shall contain the following details:
(a)
location of tensioning operations;
(b)
coil, heat and bundle numbers of strand used;
(c)
date and time of starting and completing tensioning operations;
(d)
weather conditions;
(e)
technical personnel supervising or carrying out tensioning operations;
(f)
prestressing tendon reference numbers;
(g)
tensioning apparatus identification;
(h)
measured extensions;
(i)
pressure gauge or load cell readings;
(j)
amount of draw-in; and
(k)
concrete temperature.
21.5.14 Grouting Equipment

(a)
Grout for prestressing systems shall be mixed by a machine capable of

producing a homogeneous colloidal grout and of keeping the grout in slow
continuous agitation after mixing and until the grouting operation starts.
(b)
Grouting equipment shall be capable of continuous operation at a constant

pressure and shall include a system of recirculating the grout when grouting is
not in progress.
(c)
Grout pumps shall be fitted with a safety valve to prevent the build-up of
excessive pressure. The connection of the pump to the duct shall be by a
screw connector or other positive method. Baffles to the pump shall be fitted
with 1.18 mm sieve strainers; suction circuits shall be airtight.
(d)
Grouting equipment shall be thoroughly washed through with clean water after
every series of grouting operations and at the end of use each day.
21.5.15 Grouting Effectiveness

Grouting of prestressing tendons shall be effective such that the duct is completely
filled and the prestressing tendon is completely surrounded with grout.

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January 2011
21.5.16 Grout Injection

(a)
The Contractor shall notify the Project Manager before prestressing tendons
are grouted and when required, shall allow the Project Manager sufficient time
to inspect the tendons which are to be grouted.
(b)
Grouting of prestressing tendons shall be carried out as soon as practicable,

and not more than 5 days, after tensioning of the prestressing tendons.
(c)
Immediately before grouting starts, the ducts shall be thoroughly washed by

pumping clean water through the ducts. The water shall flow through all grout
vents. Partial or complete blockage of grout vents shall be cleared before
grouting starts. After washing, the ducts shall be blown dry with oil-free
compressed air.
(d)
Grout shall be used within 30 minutes of mixing unless a retarding agent

reviewed without objection by the Project Manager is incorporated in the
grout. If a retarding agent is used, the time shall be determined by a test
procedure reviewed without objection by the Project Manager.
The grout pressure applied shall be as low as practicable and shall not
exceed 1 MPa. Grout shall be injected from the lower end of ducts. Grout
injection shall be continuous and steady and shall be at a rate which will avoid
grout segregation and trapping air in the duct. Grout shall be allowed to flow
from each of the grout vents until its consistency is equivalent to that of the
grout injected. After the last grout vent has been closed, the pressure shall be
maintained at 0.5 MPa for 5 minutes. The injection vent shall then be closed
under pressure.
(e)
(f)
If there is any blockage or breakdown or if the grout injection is interrupted,

the duct shall immediately be thoroughly washed with clean water and blown
dry with oil-free compressed air; regrouting shall start as soon as practicable.
(g)
The filled ducts shall be protected to the satisfaction of the Project Manager to
ensure that:
(i)
they are not subjected to shock or vibration within 48 hours of grouting;
(ii)
the grout has achieved a strength of not less than 15 MPa before any
additional load, arising from the movement of Temporary Works or any
construction activity, is applied to concrete containing them; and
(iii)
the temperature of the grout does not fall below 3C for 3 days after its
injection.
(h)
The level of grout in grout vents shall be inspected and made good as
reviewed without objection by the Project Manager. Making good shall not be
carried out until at least 2 days after grouting.
(i)
Ducts shall not be grouted when the air temperature in the shade exceeds
32C or is below 3C. The temperature of the grout at the point of injection
shall not exceed 25C.

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January 2011
(j)
Grouting inlet, outlet and intermediate venting points shall be suitably marked
to enable the tendon, to which they refer, to be identified.
(k)
The Contractor shall radiographically test grouted ducts if directed by the

Project Manager.
21.5.17 Records of Grouting Operations

(a)
Records of grouting operations for prestressing systems shall be kept by the

Contractor on Site and a report shall be submitted to the Project Manager for
review without objection within 3 days of each grouting operation. The report
(i)
location of grouting operations;
(ii)
date and time of starting and completing grouting operations;
(iii)
weather conditions;
(iv)
technical personnel supervising or carrying out grouting operations;
(v)
(vi)
grout mix, including any admixtures;
(vii)
grout injection pressure;
(viii)
volume of grout used; and
(ix)
details of any interruptions and topping up.
21.5.18 Tolerances: Sheaths

The line of sheaths shall be within 5 mm of the specified line as shown on the
Employers Drawings. Sheathing near concrete surfaces shall not infringe the
specified tolerance on concrete cover.
21.6
21.6.1
Trial Mixes for Grout

(a)
A trial mix for grout for prestressing systems shall be made to demonstrate
that the proposed materials, grout mix and methods of production will produce
grout which complies with the specified requirements.
(b)
The trial mixes shall be completed at least 10 days before the grout mix is
used in the Permanent Works.
(c)
The Contractor shall notify the Project Manager before making trial mixes.
(d)
Trial mixes shall be made using the materials, grout mix and methods of
production which have been reviewed without objection by the Project
Manager.

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January 2011
21.6.2
21.6.3
21.6.4
21.6.5
Samples: Trial Mixes for Grout

(a)
One sample of grout shall be provided from the trial mix to determine the
amount of bleeding and free expansion of the grout. The method of sampling
shall be as stated in Clause 21.6.23(b).
(b)
One sample of grout shall be provided from the trial mix to determine the
crushing strength of the grout. The method of sampling shall be as stated in
Clause 21.6.26(b).
Testing: Trial Mixes for Grout

(a)
Each sample of grout taken as stated in Clause 21.6.2(a) shall be tested to

determine the amount of bleeding and free expansion. The method of testing
shall be as stated in Clause 21.6.24(b).
(b)
Each sample of grout taken as stated in Clause 21.6.2(b) shall be tested to

determine the crushing strength. The method of testing shall be as stated in
Clause 21.6.27.
Non-compliance: Trial Mixes for Grout

(a)
If the result of any test for amount of bleeding, free expansion or crushing
strength of trial mixes for grout does not comply with the specified
requirements for the property, particulars of proposed changes to the
materials, grout mix or methods of production shall be submitted to the Project
Manager for review without objection. Further trial mixes shall be made until
the result of every test complies with the specified requirements for the
property.
(b)
If grouting trials are carried out using a non-complying trial mix, further
grouting trials shall be carried out.
Grouting trials
(a)
Grouting trials for grout for prestressing systems shall demonstrate that the
proposed materials, grout mix, methods of production and methods of
construction produce a grouted duct which complies with the specified
requirements.
(b)
Grouting trials shall be completed at least 7 days before grouting starts.
(c)
The Contractor shall notify the Project Manager before carrying out grouting
trials.
(d)
Grouting trials shall be carried out using the materials, grout mix, methods of
production and methods of construction, which have been reviewed without
(e)
The profile of ducts and the method of support for grouting trials shall be
submitted to and reviewed without objection by the Project Manager. Vents
shall be provided in ducts and tendons shall be pulled tight.

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January 2011
21.6.6
Testing: grouting trials

Three sections selected by the Project Manager shall be cut from the grouted duct
and inspected not less than 2 hours after the grout used in the grouting trial has
achieved its final set.
21.6.7
Compliance criteria: grouting trials

The sections of grouted duct cut in grouting trials shall be completely filled and the
prestressing tendon shall be completely surrounded with grout.
21.6.8
Non-compliance: grouting trials

If the result of any test on sections of grouted duct cut in grouting trials does not
comply with the specified requirements for the test, or if in the opinion of the Project
Manager any aspect of the grouting procedure as demonstrated by the grouting trial
is unsatisfactory, particulars of proposed changes to the materials, grout mix,
methods of production or methods of construction shall be submitted to the Project
Manager for review without objection and further grouting trials shall be carried out
until the result of every test on sections of grouted duct complies with the specified
requirements for the test and until in the opinion of the Project Manager every
aspect of the grouting procedure is satisfactory. Further trial mixes for grout shall
be made unless in the opinion of the Project Manager non-compliance of the
grouting trial was not due to the grout mix.
21.6.9
Acceptable Grout Mix

A grout mix which complies with the specified requirements for trial mixes for grout
and for grouting trials is defined as an "Acceptable Grout Mix".
21.6.10 Commencement of Grouting

Grouting shall not proceed until the grout mix and grouting procedures have been
21.6.11 Changes in Materials and Methods of Construction
The materials, grout mix, methods of production or methods of construction used to
produce an "Acceptable Grout Mix" shall not be changed.
21.6.12 Inspection of Prestressing Systems
The Contractor shall allow sufficient time for the Project Manager to inspect the
completed prestressing system before carrying out any work, including concreting
and grouting, which will make access to the prestressing system difficult. The
Contractor shall notify the Project Manager before carrying out such work.
21.6.13 Testing: Prestressed Units
Testing of prestressed units shall comply with Section 20.

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January 2011
21.6.14 Batch: Prestressing Tendons

A batch of prestressing tendons is any quantity of prestressing tendons of the same
type, size and grade, manufactured by the same manufacturer, covered by the
same certificates and delivered to Site at any one time.
21.6.15 Samples: Prestressing Tendons
(a)
Samples of prestressing tendons shall be provided from each batch of

prestressing tendons delivered to Site at least 28 days before installation of
the prestressing tendons starts. The number of samples to be provided from
each batch shall be as stated in Table 21.1.
(b)
The number of specimens in each sample shall be 15.
(c)
Each specimen shall be 1.5 metre long and straight.
(d)
Each specimen shall be taken from different coils or bars in the batch. The
ends of specimens shall be cut square without unravelling of wires and loose
mill scale and rust shall be removed by wire brushing before delivery to the
laboratory.
Table 21.1: Rate of Sampling Prestressing Tendons

Description
Size of batch
No. of samples per

batch
Steel wire
0 - 50 tonnes
exceeding 50 tonnes
1 for each 50 tonnes

or part thereof
Wire strand and alloy

steel bar
0 - 100 tonnes
exceeding 100 tonnes
1 for each 100 tonnes

or part thereof
21.6.16 Testing: Prestressing Tendons

(a)
Each specimen of prestressing tendons shall be tested to determine the

characteristic breaking load, characteristic 0.1% proof load, elongation at
maximum load, diameter, cross-sectional area, unit mass and modulus of
elasticity. Each specimen of prestressing wire shall also be tested to
determine the ductility.
(b)

High tensile steel wire and strand for the prestressing of concrete : BS 5896
Hot rolled and hot rolled and processed high tensile alloy
steel bars for the prestressing of concrete
(c)
: BS 4486.
Tests shall be carried out on specimens having a temperature between 5C

and 30C.

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January 2011
21.6.17 Compliance Criteria: Characteristic Breaking Load, Characteristic 0.1% Proof

Load
(a)
(b)
The standard deviations of the results of tests for characteristic breaking load
and characteristic 0.1% proof load, expressed as equivalent stress values, of
prestressing tendons shall not exceed the following:
(i)
tensile strength : 55 MPa; and
(ii)
0.1% proof stress
: 60 MPa.
The statistical interpretation of the test results shall be in accordance with

BS 2846:Part 3, Table 3 and BS 2846:Part 4, Table E, both for a one-sided
tolerance interval of 0.95 and for a confidence level of 0.95.
21.6.18 Non-compliance : Elongation, Diameter, Cross-sectional Area, Unit Mass,

Modulus of Elasticity, Ductility
(a)
If the result of any test for elongation at maximum load, diameter,

cross-sectional area, unit mass, modulus of elasticity or ductility of
prestressing tendons does not comply with the specified requirements for the
property, one additional sample shall be provided from the same batch and
additional tests for the property shall be carried out.
(b)
The number of specimens in the additional sample shall be 15.
(c)

21.6.19 Testing: Duct Friction

(a)
Unless otherwise stated in the Contract, the Contractor shall test, at an early
stage of the Contract, two in-place tendons in order to accurately determine
friction loss.
(b)
Prestressing tendons shall be tensioned from one end and the tendon force
shall be measured at both the jacking and non-jacking ends.
(c)
The tendon force at the non-jacking end shall be measured by direct-reading

load cells or by a dummy jack of a type reviewed without objection by the
Project Manager. A direct-reading load cell or a dummy jack is considered to
be suitable as a load-measuring device. The load-measuring device shall be
sufficiently rigid to ensure that the movement of the prestressing tendon at the
non-jacking end under the specified tendon force is not excessive. The
deflection of the load-measuring device shall be measured to an accuracy of
0.5 mm. A load-measuring device with a deflection exceeding 10 mm under
the maximum load shall not be used.
(d)
The prestressing tendon shall be tensioned to the specified tendon force in

equal increments and the tendon extensions at the jacking end and the
tendon force and tendon movement at the non-jacking end shall be measured
to within 5 mm. The number of load increments shall be suited to the
tensioning operation but shall be at least five.

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January 2011
21.6.20 Compliance Criteria: duct Friction

The force at the non-jacking end of the prestressing tendon determined in the duct
friction test shall be within +10% and -5% of the calculated value.
21.6.21 Records of duct Friction Tests
(a)
Reports of duct friction tests shall be submitted to the Project Manager for
review without objection within 3 days of each test. The report shall contain
the following details:
(i)
details stated in Clauses 21.4.1 and 21.4.2;
(ii)
(iii)
graph showing tendon forces at jacking end against tendon forces at

non-jacking end; and
(iv)
comparison between the calculated tendon forces at the non-jacking

end and the measured values.
21.6.22 Batch: Grout for Prestressing Systems

A batch of grout for prestressing systems is any quantity of grout produced in one
cycle of operation of a mixer.
21.6.23 Samples: Bleeding and Free Expansion of Grout
(a)
For each grout mix one sample of grout shall be provided from each 25
batches of grout, or from the amount of grout produced in one day, whichever
is the lesser, to determine the amount of bleeding and free expansion of the
grout.
(b)
Samples shall be provided and testing shall commence within one hour after
the grout has been mixed. Samples shall be protected from rain before the
tests.
21.6.24 Testing: Bleeding and Free Expansion of Grout

(a)
Each sample of grout taken as stated in Clause 21.6.23 shall be divided into
three specimens; each specimen shall be tested at a temperature of 20C to
determine the amount of bleeding and free expansion.
(b)
A portion of each specimen shall be placed in a covered cylinder with a

diameter of 100 10 mm, to a depth of 100 5 mm and the amount of
bleeding and free expansion measured by a scale fixed to the outside of the
cylinder.
21.6.25 Non-compliance: Bleeding and Free Expansion of Grout

If the result of any test for amount of bleeding or free expansion of grout for
prestressing systems does not comply with the specified requirements for the
property, particulars of proposed changes to the materials, grout mix or methods of
production shall be submitted to the Project Manager for review without objection.
Upon review further trial mixes shall be made and further grouting trials shall be
carried out.

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January 2011
21.6.26 Samples: Crushing Strength of Grout

(a)
For each grout mix one sample of grout shall be provided from each 25
batches of grout, or from the amount of grout produced in a day, whichever is
the lesser, to determine the crushing strength of the grout.
(b)
Samples shall be provided not more than 1 hour after the grout has been
mixed and shall be protected from rain before test cubes are made.
21.6.27 Testing: Crushing Strength of Grout

(a)
Two 100 mm test cubes shall be made from each sample of grout taken as
stated in Clause 21.6.26 (a). Each pair of test cubes shall be tested to
determine the crushing strength at 7 days.
(b)
The method of making, curing and testing the test cubes, and the calculation
of the test results, shall be as stated in Clause 20.8.12(b), (c), (d) and (e),
except that compaction of the grout is not required.
21.6.28 Non-compliance: Crushing Strength of Grout

If the result of any test for crushing strength of grout for prestressing systems does
not comply with the specified requirements for crushing strength, particulars of
proposed changes to the materials, grout mix or methods of production shall be
submitted to the Project Manager for review without objection. Upon review further
trial mixes shall be made and further grouting trials shall be carried out.

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January 2011
SECTION 22 STEELWORK
22.1
GENERAL
(a)
Allowances shall be made for the deformation due to permanent loads and
the process and sequence of fabrication, erection and construction such that
steelwork is completed to within the specified tolerances.
(b)
The dimensions shown on the Employers Drawings show the required asconstructed position after deflections due to self weight and superimposed
dead loads. The Contractor shall determine any pre-set deflection or camber
that may be necessary to ensure that the as constructed position is within the
specified tolerances.
(c)
The compatibility of the dimensions and setting-out data of steelwork shall be

verified by the Contractor before the materials for steelwork are ordered.
22.2
22.2.1
Steelwork Standards
The use of steelwork shall comply with the Code of Practice for the Structural Use
of Steel, Hong Kong. BS 5950:Part 1 & 2:1990 may be used provided the specific
requirements as outlined in the Practice Note for Authorized Persons and
Registered Structural Engineers (PNAP) No. 160 apply.
22.2.2
Protection of Steelwork
Protection of steelwork against corrosion shall comply with BS 5493.
22.2.3
Amendments to BS 5400 : Part 6

The following amendments shall apply to BS 5400:Part 6:
(a)
Contents page :
Delete '6.3.1 General'.
(b)
Page 2, Clause 3.1.4.1, lines 5, 8 and 14:

Delete 'C of DD21' and insert 'L1 of BS 5996'.
(c)
Page 2, Clause 3.1.4.1, line 10 and Clause 3.1.4.2, line 3:

Delete 'DD21' and insert 'BS 5996'.
(d)
Page 3, Clause 4.2.1, line 2:

Delete '4.4.2' and insert '4.2.2'.

Section 22 - Steelwork
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January 2011
(e)
Page 3, Clause 4.3.3(e), line 1:
(f)
Delete line 1 of text and insert 'the hardness of the edge is reduced to less
than 350 HV 30 of BS 427 by a suitable heat treatment'.
Page 4, Clause 4.7.1, paragraph 2, line 4:
Delete '23 of BS 5135' and insert '20 of BS 5135'.
(g)
Page 5, Clause 4.14:

Delete and insert:
'The Contractor shall determine the dead load camber of beams required to
comply with Section 22.1(a) of this Specification. The camber of plate girders
shall be formed by either of the two following alternatives, whichever is stated
in the Contract:
Type A cambering : camber introduced by welding the flanges pressed
against a web plate cut to a smooth cambered profile; or
Type B cambering : camber introduced by connecting straight sections of
girder with a change of slope at their junctions.
Type A camber shall be used if the alternative to be used is not stated in the
Contract.
With Type B cambering the junctions shall not be positioned at bolted
connections.'
(h)
Page 6, Clause 5.2.2, line 2:

Delete 'DD21' and insert 'BS 5996'.
(i)
Page 7, Clause 5.5.2, paragraph 3, line 3:

Delete 'grider' and insert 'girder'.
(j)
Page 9, Clause 6.3.1:

Delete Clause 6.3.1.
(k)
Page 15, Table 5, column 3, Member component 4 :

Delete 'G=0' and insert 'G=D'.

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January 2011
22.3
MATERIALS
22.3.1
Structural Steel
22.3.2
22.3.3
(a)
Structural steel shall comply with BS 4360, including Clause B7 at

Appendix B, and with BS 5950:Part 2, Section 2.1 with the incorporation of
specific requirements outlined in PNAP 160.
(b)
Hot rolled sections complying with BS 4:Part 1, BS 4848:Part 2, BS 4848:

Part 4 or BS 4848:Part 5 shall not be replaced with sections complying with
other standards unless reviewed without objection by the Project Manager.
Cold formed Sections

(a)
Steel for cold formed sections shall comply with BS 1449:Part 1 with the
quality grades as stated in the Contract.
(b)
Steel for cold formed hollow sections shall comply with BS 6363 with quality
grades as stated in the Contract.
(c)
Pre-galvanized steel sheet shall comply with BS 2989 with quality grades as
Maximum Carbon Equivalent

Steel used in built-up welded assemblies or at welded connections shall have a
carbon equivalent value complying with Table 2 of BS5135.
22.3.4
Steel for Shear Connectors

Steel for headed stud type shear connectors shall have a yield stress of at least
385 N/mm2 and an ultimate tensile strength of at least 450 N/mm2. Steel for other
types of shear connectors shall comply with BS 4360.
22.3.5
Bolts, Screws, Nuts and Washers

(a)
Bolts, screws and nuts shall comply with the British Standards and strength
grades stated in Table 22.1 unless stated otherwise in the Contract.
(b)
Washers for high strength friction grip bolts and nuts shall comply with the
following:
(i)
high strength friction grip bolts and associated nuts and washers for
structural engineering :
general grade
: BS 4395:Part 1;
(ii)
higher grade bolts and nuts and

general grade washers
: BS 4395:Part 2; and
higher grade bolts (waisted shank),

nuts and general grade washers
: BS 4395:Part 3;
load indicating washers for high strength friction grip bolts and nuts shall
be "Coronet" type manufactured by Cooper and Turner or equivalent
reviewed without objection by the Project Manager; and.

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January 2011
(iii)
(c)
plain washers for other bolts, screws and nuts shall comply with
BS 4320; tapered washers for other bolts, screws and nuts shall comply
with BS 3410; spring washers for other bolts, screws and nuts shall
The surface finish for bolts, screws, washers and nuts shall comply with the
following:
(i)
galvanized - BS 729;
(ii)
zinc or cadmium plated - electroplating shall comply with either:

BS 3382 for bolts up to and including 20 mm diameter; or
BS 1706 Class A for bolts over 20 mm diameter; and
(iii)
22.3.6
sherardized - BS 4921.
Welding Consumables
(a)
Welding consumables used in metal-arc welding of grades of steel complying

with BS 4360 shall comply with BS 5135. Welding consumables used in the
fusion welding of steel castings shall comply with BS 4570. Welding
consumables used in metal-arc welding of austenitic stainless steels shall
(b)
Welding consumables and the procedures used shall be such that the
mechanical properties of the deposited weld metal shall not be less than the
respective minimum values of the parent metal being welded.
(c)
Welding consumables used with grades of steel other than those complying
with BS 4360 shall be such that the performance requirements stated in
BS 5400:Part 6, Table 1 or BS 5950:Part 2, Table 1 as appropriate are
achieved.
(d)
Electrodes for welding Grade 50 and Grade S355 steels shall be capable of
depositing no more than 15 ml of diffusible hydrogen per 100 g of deposited
weld metal, as defined in BS 639.
(e)
Covered electrodes for manual metal arc welding shall comply with BS 639.
(f)
Filler wires for gas-shielded welding shall comply with BS 2901:Part 1.
(g)
Electrodes shall be kept in unbroken packets in accordance with BS 5135.

Any drying or baking of consumables before issue shall be carried out in

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January 2011
22.3.7
Rolled Steel Pins

Rolled steel pins, including those made from slabs, shall comply with BS 970:Part 1
or BS 4360, Grades 43, 50 or 55.
Table 22.1 : British Standards And Strength Grades For Bolts, Screws And
Nuts
Type of bolts, screws
and nuts
High strength friction
grip bolts and nuts
Precision bolts, screws
and nuts
Cup head and
countersunk head
bolts, screws and nuts
Black bolts, screws
and nuts
Other types of bolts,
screws and nuts
Hexagon socket
screws
22.3.8
British Standard
BS 4395:Part 1
Strength grade of
bolt
General grade
BS 3692
4.6
Strength grade
of nut
as specified in
BS4395 : Part 1
4.0
BS 4933
4.6
4.0
BS 4190
4.6
4.0
BS 4190
4.6
4.0
BS 4168:Part 1
12.9
12.0
Steel Castings and Cast Steel Pins

Carbon manganese steel castings shall comply with BS 3100.
22.3.9
Steel Forgings and Forged Steel Pins

Steel forgings and forged steel pins shall comply with BS 29.
22.3.10 Stainless Steel

(a)
Wrought stainless steel shall comply with BS 970:Part 1, Grade 316 S 16.
(b)
Flat rolled stainless steel shall comply with BS 1449:Part 2, Grade 316 S 16 in
the softened condition.
(c)
Stainless steel tubes shall comply with BS 6323:Part 1 and BS 6323:Part 8,

designation LW 23 GZF(S).
(d)
Stainless steel bolts and nuts shall comply with BS 6105, steel Grade A4 and
property class 80. Stainless steel washers shall comply with BS 1449:Part 2,
Grade 316 S 31 in the softened condition. The dimensions and tolerances of
bolts and nuts shall comply with BS 3692. The dimensions and tolerances of
tapered washers shall comply with BS 3410 and the dimensions and
tolerances of flat washers shall comply with BS 4320, Form C.
22.3.11 Grout for Column Bases

(a)
Grout for bedding steel bases and for filling bolt pockets and pocket bases
shall be cementitious materials based on OPC and shall have the same or
greater grade strength as the surrounding foundation concrete. The grout
shall contain a non-metallic expanding admixture and shall have a total
chloride content of not more than 0.1% by mass of cement.

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January 2011
(b)
Grout for bedding steel bases and for filling bolt pockets shall not contain high
alumina cement and shall be a proprietary type where stated on the
Employer's Drawings or reviewed without objection by the Project Manager
and shall be suitable for filling the space by pouring under a suitable head.
The proportions of the grout shall be in accordance with the manufacturer's
recommendations.
(c)
A dry packed mortar may be used for bedding steel bases which exceed
75 mm thick. The mortar shall be cementitious material having the same
grade strength of the surrounding concrete and be suitable for thorough
ramming against supports such that the space is completely filled.
(d)
Grout for filling pocket bases shall be a mix reviewed without objection by the
Project Manager with a nominal maximum aggregate size of 10 mm and have
the same grade strength as the surrounding concrete.
22.3.12 Lubricant for Nut Threads of HSFG Bolts

Lubricant for lubricating nut threads of HSFG bolts shall be a wax based type
reviewed without objection by the Project Manager. Machine oil and other free
flowing lubricants shall not be used.
22.3.13 Paint for Steelwork
(a)
Unless otherwise stated in the Contract paint for steelwork shall comply with
BS 5493, Section 2, Table 4. Organic zinc-rich paint shall comply with
BS 4652. Lead-based paint shall not be used for finishing coats.
(b)
Paint shall be supplied in sealed containers of not more than 5 litres capacity.
Each container shall be marked on the side to show the following:
(i)
the name of the manufacturer;
(ii)
the paint manufacturer's reference number;
(iii)
intended purposes, type of pigment and binder;
(iv)
batch number, date of manufacture, expiry date and pot life; and
(v)
colour, gloss, drying times and flash point.
22.3.14 Marking Steelwork

(a)
All steelwork shall be clearly marked for identification and erection purposes
as:
(i)
identification: The Contractor shall identify all steel elements in

accordance with BS 4360 or BS EN 10025 as applicable, indicating
grade, cast number and manufacturers identification mark;
(ii)
Grade 50 and Grade S355 steel: In addition to marking in accordance

with BS 4360 or BS EN 10025 the Contractor shall mark steel with a
continuous pale blue water paint line. The Contractor shall mark
immediately, with light blue water paint, any part cut from Grade 50 or
S355 steel which does not have a light blue marking;

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January 2011
(iii)
cold worked steel: The Contractor shall mark cold worked areas of steel
members with orange water paint;
(iv)
marking for erection purposes: The Contractor shall tag, hard stamp or
pencil weld each member with an individual identification mark, which
can not be obliterated by surface coatings. The Contractor shall submit
a Contractors Drawing identifying markings and indicating the positions
of members in structures; and
(v)
permanent identification: The Contractor shall supply and fix to each

structure after erection, a brass identification plate. The plate shall
indicate with lettering not less than 15 mm high, etched or punched to a
depth not less than 1.5 mm, the following:
grade of steel in structure; and
date of fabrication.
22.3.15 Handling and Transport of Steelwork

(a)
Steelwork shall not be subject to rough handling, shock loading or dropping

from a height.
(b)
During handling and transport of coated steelwork, the steelwork shall be

separated from wires, lashings, supports and other steel by rubber padding in
such a manner that the coatings are not damaged or discoloured. The
Contractor shall take such measures to prevent permanent distortion such as
stiffening free ends and protecting machined surfaces.
(c)
Steelwork shall not be lifted from the painting bed until the last applied coating
is sufficiently dry or cured for handling.
(d)
Rivets, bolts, nuts, washers, screws and small plates and articles shall be
packed in containers marked to identify the contents.
(e)
For road transport the Contractor shall:
(f)
(i)
provide intermediate supports to which a component can be tied with

strops to prevent oscillation; and
(ii)
sit components on softwood supports covered with soft clean pads.
For sea transport the Contractor shall:

(i)
containerise all steelwork;
(ii)
pack containers so that no components touch;
(iii)
use softwood with soft padding and man-made fibre ropes and strops to
prevent movement and contact;
(iv)
bag fasteners and accessories;
(v)
bundle small components and prevent contact; and
(vi)
chromate dip galvanized steel, which is not to be overcoated, when it

will be containerised for longer than three weeks.

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January 2011
22.3.16 Storage of Steelwork

(a)
Steelwork shall be stored off the ground on level supports in well drained
areas in a manner which will not result in damage or deformation to, or in
contamination of, the steelwork or coatings. Packing shall be placed between
steelwork which is stacked.
(b)
Covered places in which steelwork is stacked shall be ventilated.
(c)
Different types and sizes of steelwork shall be stored separately.
(d)
Steelwork shall not be stored on or adjacent to concrete surfaces which form

part of the Permanent Works.
(e)
Steelwork shall be protected from exposure to conditions which may affect the
steelwork or coatings.
(f)
Wet paint films, steelwork surfaces which are to be primed or overcoated and
joint surfaces which are to be assembled shall be protected from exposure to
conditions which may affect the film or surface.
(g)
Except as stated in Section 22.3.16(h) and (i), steelwork shall be stored in an

enclosed workshop and protected from conditions which may affect the
steelwork after it has been cleaned as stated in Section 22.5.12 until the
following times:
(i)
when the second undercoat to painted steelwork has hard dried;
(ii)
when the coating process to galvanized, electroplated or metal sprayed

steelwork has been completed;
(iii)
when the sealer to metal sprayed and sealed steelwork has been
completely absorbed; and
(iv)
when the first undercoat to metal sprayed and painted steelwork has
hard dried.
(h)
Primed steelwork surfaces may be exposed outside the enclosed workshop

for a period not exceeding two weeks.
(i)
Micaceous iron oxide undercoats to steelwork may be exposed outside the

enclosed workshop for the minimum period necessary to move the steelwork
from one part of the workshop to the other. Undercoated surfaces shall be
covered when the steelwork is being moved.
(j)
All painted steelwork shall be checked for undercoat contamination prior to

the application of subsequent coats.
(k)
Steel members shall be stored and stacked such that markings are clearly
visible.

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January 2011
22.3.17 Storage of Paint

Paint and associated materials shall be stored in sealed containers marked as
stated in Section 22.3.13(b) and protected from exposure to conditions which may
affect the material. The materials shall be stored in accordance with the
manufacturers' recommendations and shall not be used after the recommended
expiry date. The materials shall be stored in a locked store.
22.3.18 Metal Coatings to Steelwork
(a)
Galvanized coatings shall be applied by hot-dip galvanizing in accordance

with BS 729. The coating thickness shall comply with BS 729, Table 1.
(b)
Sherardized zinc coatings shall comply with BS 4921, Table 1, Class 1.
(c)
Sprayed zinc and aluminium coatings shall comply with BS 2569:Part 1. The
nominal coating thickness shall be 100 m. The sprayed metal shall be
pre-treated with product CP1 and sealed with product CP3C in accordance
with BS 5493.
(d)
Electroplated zinc and cadmium coatings on threaded components with a

diameter not exceeding 36 mm shall comply with BS 3382:Parts 1 and 2. The
coating thickness shall be at least 5 m.
(e)
Metal coatings which will be overcoated with paint shall not be passivated and
shall be treated in accordance with the manufacturer's recommendations for
the specific coating system selected.
(f)
Allowance for the thickness of the metal coating shall be made in the sizes of
the threads of metal coated threaded components. Nuts shall not be tapped
oversize by more than 0.4 mm. Metal coated HSFG bolts and nuts shall not
be tapped oversize.
(g)
Damaged areas of metal coatings shall be rubbed down to remove excessive

roughness, cleaned and made good with a compatible coating of a type
(h)
Metal coatings required on part of a component shall be completed before the

rest of the component is painted.
(i)
Chromium plating shall comply with BS 4641.
22.3.19 Painting Systems for Steelwork

(a)
The painting system to be used for steelwork shall be as stated in the

Contract.
(b)
The different types of paints within each painting system shall be compatible
with each other and shall be manufactured by the same manufacturer.
Successive coats in a painting system, including stripe coats, shall be in
contrasting colours to aid identification.

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January 2011
22.4
SUBMISSIONS
22.4.1
Particulars of Steel
22.4.2
(a)
The original or certified true copy of the manufacturer's mill certificates for
steel shall be submitted to the Project Manager for review without objection in
accordance with BS 4360, Clause 12 and Appendix B 6.
(b)
The mill certificates shall be submitted to the Project Manager not more than
7 days after the steel has been delivered to the place of fabrication.
Particulars of Shop Drawings

(a)
Two sets of Contractors Drawings of the steelwork shall be submitted to the

Project Manager for review without objection at least 6 weeks before
fabrication of the steelwork starts. These Contractors Drawings shall show
details of the following:
(i)
general arrangement drawings including plans, elevations and sections

showing the location and setting out of all members and assemblies;
(ii)
drawings showing the individual members and assemblies, including

dimensions, member sizes, precambers, splice positions, bolts,
penetrations, fixings and all other information to fully describe the
intended fabrication;
(iii)
welds, including any stud welds, marked with the relevant welding
procedures;
(iv)
joints or non-standard welds proposed by the Contractor;
(v)
locations and method of removal of any temporary welded attachments

proposed by the Contractor;
(vi)
edges of steelwork complying with BS 5400:Part 6 to be formed by

flame cutting or shearing procedures complying with BS 5400:Part 6,
Clause 4.3.3(a), (d) or (e) with the edges marked with the procedures to
be used;
(vii) parts of steelwork complying with BS 5400:Part 6 to be worked by hot

processes complying with BS 5400:Part 6, Clause 4.8, 4.9 or 4.10 with
the parts marked with the processes to be used; and
(viii) details of holding down bolts and fittings to be cast into the concrete or
masonry.
(b)
Fabrication work shall not commence until the Contractors Drawings and the
associated method statements have been reviewed without objection by the
Project Manager.

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January 2011
22.4.3
Particulars of Method of Erecting Steelwork

(a)
22.4.4
22.4.5
The following particulars of the proposed method of erecting steelwork shall

(i)
sequence and method of erection of steelwork;
(ii)
method of lifting and handling the components;
(iii)
method of preventing damage to protective coatings on steelwork during

handling;
(iv)
procedure for aligning, levelling and plumbing steelwork, including

temporary supports and method of making beddings for column bases;
(v)
sequence of casting concrete bonded to the steelwork; and
(vi)
calculations of erection stresses.
Welder Certificates
(a)
Certificates endorsed by an independent HOKLAS accredited inspecting

authority shall be submitted to the Project Manager for review without
objection to show that each welder has been approved in accordance with
BS 4570, BS 4871:Part 1 or BS 4872:Part 1 as appropriate. The extent of
approval of the welder shall be appropriate to the categories of welds which
he will carry out.
(b)
The welder certificates shall be submitted at least 2 weeks before fabrication

of the steelwork starts.
Particulars of Welding Procedures

(a)
The following particulars of the proposed welding procedures shall be

(i)
welding procedures in accordance with BS 5135, Clause 20 for each

type and size of weld;
(ii)
documentation endorsed by an independent HOKLAS accredited

inspecting authority to show that the welding procedure has complied
with the procedure trial requirements stated in the Contract in previous
tests, or that the welding procedure for steel castings complies with the
exemption criteria stated in BS 4570, Clause 20.1.1; and
(iii)
records of approval tests as stated in Clause 22.6.7 (a) if procedure

trials are required under Clause 22.6.1 (a).

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January 2011
22.4.6
Particulars of Stud Welding, Flame Cutting and Shearing Procedures

(a)
The following particulars of the proposed stud welding, flame cutting and
shearing procedures for steelwork complying with BS 5400:Part 6 shall be
(i)
(ii)
(iii)
22.4.7
procedures for stud welding, flame cutting and shearing processes

complying with BS 5400:Part 6, Clause 4.3.3(a), (d) or (c);
documentation endorsed by an independent HOKLAS accredited
inspecting authority to show that the stud welding, flame cutting or
shearing procedure has complied with the procedure trial requirements
stated in the Contract in previous tests; and
report of procedure trials as stated in Clause 22.6.7 (a) if procedure
trials are required under Clause 22.6.1 (a).
Particulars of Vent Holes for Galvanizing

Particulars of the method of plugging vent holes required for hot-dip galvanizing
hollow or box sections shall be submitted to the Project Manager for review without
objection.
22.4.8
Particulars of Method of Non-destructive Testing

Particulars of the proposed method for carrying out non-destructive testing on welds
shall be submitted to the Project Manager for review without objection.
22.4.9
Particulars of Inspecting Authority and Testing Consultant

(a)
The name of the proposed independent HOKLAS accredited inspecting

authority endorsing welder certificates and records of approval tests for
welding procedures shall be submitted to the Project Manager for review
without objection.
(b)
The name of the proposed testing consultant stated in Section 22.6.13 shall
22.4.10 Particulars of Paint

(a)
The following particulars of the proposed paints and associated products shall
(i)
name of manufacturer;
(ii)
duplicate copies of the manufacturer's data sheets including

temperature, humidity, method of application and other conditions at the
workshop or on Site under which the paint is to be applied; and
(iii)
manufacturer's product specifications, product range and technical

information.

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January 2011
22.4.11 Representative Samples of Materials

(a)
A representative sample of blast cleaned steel plate shall be submitted to the

Project Manager for review without objection.
The sample shall be
150 mm x 150 mm x 6 mm and shall be enclosed in a sealed, colourless,
transparent wrapping. The grade of steel and the method of blasting shall be
representative of those which will be used in the Permanent Works.
(b)
Two representative samples of painted metal plates for each painting system
shall be submitted to the Project Manager for review without objection. Each
plate shall be 150 mm x 75 mm x 1 mm and shall have smooth edges and
10 mm corner radii. The plates shall be brush cleaned and painted on one
face with the painting system in such a manner that each coat is stepped back
from the underlying coat in equal strips. The degree of gloss of the finishing
coat shall be reviewed without objection by the Project Manager.
(c)
Representative samples of each type of nut, bolt, washer, stud and rivet shall
22.5
WORKMANSHIP
22.5.1
Fabrication of Steelwork
Fabrication of steelwork shall comply with BS 5400:Part 6, Clauses 4.1 to 4.16 or
BS 5950:Part 2, Sections 3 and 4 as appropriate except as stated in Sections
22.5.2 to 22.5.11 and 22.6.12.
22.5.2
Welding, Heating and Cutting

(a)
Welding shall only be carried out by welders who possess a valid welding
certificate for the appropriate category of welding. A welder shall cease to
carry out welding if any of the circumstances stated in BS 4570, Clause 21.1,
BS 4871:Part 1, Clause 11 or BS 4872:Part 1, Clause 6 as appropriate occur.
(b)
Pre-setting, pre-bending, skip welding, back-step techniques and other

measures shall be taken as necessary to counteract shrinkage or distortion
due to welding, gouging, thermal cutting or heat treatment.
(c)
Butt welds shall be complete penetration butt welds made between fusion
faces.
(d)
Butt welds in each component part shall be completed before the final
assembly of built-up assemblies.
(e)
To ensure full throat thickness at the ends of butt welds run-on and run-off
plates shall be used. These plates shall comply with the following :
(i)
identical material to that being welded;
(ii)
prepared in the same manner as the parts being joined;
(iii)
removed by cutting after completion of welding;

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January 2011
(iv)
the surfaces where plates were attached shall be ground smooth and
inspected for cracks;
(v)
welding of austenitic stainless steel shall be carried out in accordance

with BS 4677;
(vi)
temporary welded attachments for either fabrication or erection shall

comply with BS 5135 and shall be reviewed without objection by the
Project Manager;
(vii) welding, heating or thermal cutting processes which give off toxic or
irritant gases shall not be used;
(viii) tack welds shall comply with BS 5135;
22.5.3
(ix)
materials, procedures, fixing and equipment for shear studs shall be in

accordance with the manufacturer's recommendations; and
(x)
slag shall be removed by light hammering, wire brushing or other

methods which will not deform the surface of the weld.
Length of Bolts
The length of HSFG bolts shall comply with BS 4604:Part 1 or BS 4604:Part 2 as
appropriate. The length of bolts complying with BS 3692, BS 4190 and BS 4933
shall be such that the end of the bolt shall project above the nut by at least one
clear thread, but by not more than one nominal bolt diameter, and at least one clear
thread plus the thread run out is clear between the nut and the unthreaded shank of
the bolt, after tightening.
22.5.4
Length of Threads
The length of threads on bolts shall be determined in accordance with BS 3692,
BS 4190, BS 4395:Part 1, BS 4395:Part 2, BS 4395:Part 3 or BS 4933 as
appropriate. If additional locknuts or other nuts are specified, the thread length
shall be increased by one nominal bolt diameter for each additional nut.
22.5.5
Bolt Holes
(a)
Bolt holes shall be formed by drilling, punching or reaming.
(b)
Except in steel base plates or where otherwise noted on the Employer's

Drawings the size of holes for ordinary bolts shall be of diameter not more
than 2 mm greater than the diameter of the bolts for bolts up to 24 mm
diameter, and not more than 3 mm greater than the diameter of the bolt for
bolts over 24 mm diameter.
(c)
Holes for HSFG fasteners shall comply with BS 4604.
(d)
Bolt and vent holes in hollow sections shall be sealed to prevent the ingress of
moisture. Where not specified on the Employer's Drawings the method shall
be proposed on the Contractors Drawings submitted in accordance with
Section 22.4.2.

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January 2011
22.5.6
22.5.7
22.5.8
Use of Nuts
(a)
Nuts shall not be used with bolts or screws which comply with a different
standard.
(b)
Bolt assemblies shall be in such a condition immediately before installation

that the nut turns freely on the bolt.
(c)
Nuts in galvanized assemblies shall be re-tapped after galvanizing.
(d)
Nuts shall be secured in connections subject to vibration or reversal of

stresses to prevent loosening. If not shown on the Employer's Drawings, the
proposed method shall be shown on the Contractors Drawings submitted in
accordance with Section 22.4.2.
Use of Washers
(a)
Washers for HSFG bolts shall be provided in accordance with BS 4604:Part 1

or BS 4604:Part 2 as appropriate. Washers shall be provided for bolts
complying with BS 3692, BS 4190 and BS 4933 under the nut or bolt head,
whichever is rotated during tightening, if the parts to be connected are to be
coated with protective coatings before assembly. Washers shall be provided
under the nuts and heads of bolts in oversized and slotted holes.
(b)
Tapered washers shall be used under bolt heads and nuts bearing on
surfaces sloping 3 or more from a plane at right angles to the bolt axis.
(c)
Bolt assemblies containing spring washers shall be tightened until the spring
washer is completely flattened.
Tightening of Bolts
Bolts shall be tightened in accordance with BS 5950:Part 2 and in such a manner
that the contact surfaces of permanent bolted joints are drawn into close contact.
22.5.9
Tightening of HSFG Bolts

(a)
The degree of preliminary tightening of bolts and nuts complying with

BS 4395:Part 1 which are tightened by the part turn method shall be torque
controlled. The tightening equipment for preliminary tightening shall be
calibrated with a bolt load meter. The value of bedding torque for the
preliminary tightening shall be within 10% of the values stated in Table 22.2.
(b)
Bolts and nuts at each joint with bolts or washers with load indicating devices
shall be initially tightened to bring the faying surfaces into close contact over
the full area. The range of the average gap after initial tightening shall be
reviewed without objection by the Project Manager. The bolts and nuts shall
be re-tightened if necessary to close the average gap back to the agreed
range. After all bolts and nuts at the joint have been initially tightened, the
bolts and nuts shall be finally tightened to attain the shank tension stated in
BS 4604:Part 1 or BS 4604:Part 2 as appropriate. The range of average gap
corresponding to the required shank tension shall be established for each
batch as defined in BS 4395:Part 1 or BS 4395:Part 2 as appropriate by
testing at least three bolt, nut and washer assemblies in a bolt load meter and
shall be reviewed without objection by the Project Manager. The average gap
after final tightening shall be within the established range.

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January 2011
(c)
The threads of nuts for HSFG bolts which are to be tightened by the part turn
method or the load indicating method shall not be lubricated unless reviewed
without objection by the Project Manager. If the use of lubricant is permitted
in the part turn method, the bedding torque shall be established by a bolt load
meter and shall be reviewed without objection by the Project Manager. The
lubricant shall be applied at the place of manufacture and shall only be
applied to the nut threads. The bearing surfaces of the nuts and the faying
surfaces shall not be contaminated with the lubricant.
(d)
The bolt load meter for measuring bolt shank tension in the part turn, torque
control or load indicating methods of tightening shall be calibrated by a
laboratory reviewed without objection by the Project Manager before
tightening of bolts and nuts starts and at regular intervals reviewed without
objection by the Project Manager. During re-calibration, a replacement
calibrated bolt load meter shall be provided on Site. Calibration results shall
be submitted to the Project Manager for review without objection at least one
week before the bolt load meter is used.
(e)
If after tightening, a bolt or nut is slackened-off for any reason, the complete
bolt assembly shall be discarded and not re-used in the Permanent Works.
(f)
The faying surfaces for HSFG fasteners shall be in accordance with the
following :
(i)
mill scale shall be removed;
(ii)
free from distortion, deformities or contaminants which may reduce the

slip factor below the design value; and
deformed surfaces shall be machined flat and tested in accordance with
BS 4604 to determine the slip factor after machining.
(iii)
(g)
Following complete assembly of all bolted connections, the fit and tightness of
the bolts shall be checked at locations reviewed without objection by the
Project Manager.
(h)
Prior to Site painting of HSFG bolted connections the following shall be

confirmed :
(i)
minimum shank tension has been obtained; and
(ii)
appropriate hardened washers have been fitted in accordance with the

requirements of BS 6404.
Table 22.2 :
Bedding Torque For HSFG Bolts
Nominal diameter of bolt

)
16(
20
22
24
27
30

16/36
Bedding torque (N.m)

80
160
210
270
340
460
January 2011
22.5.10 Movement Connections

(a)
Where slotted holes are provided for movement connections, the joints shall
be free to move.
(b)
Bolted movement connections shall be formed as follows:

(i)
the slotted hole shall be wider than the unslotted hole;
(ii)
shouldered bolt shall be used with a spring washer under the head and
shoulder bearing on the faying surface of the unslotted member; and
(iii)
a flat washer shall be provided under the nut and the nut tightened into
the unslotted member.
22.5.11 Defects in Steelwork

Defective components for steelwork shall not be used in the Permanent Works
unless repair of the defects is permitted by the Project Manager. If permitted,
defective components shall be repaired by methods reviewed without objection by
22.5.12 Cleaning of Steelwork and Coated Surfaces
(a)
Soil, concrete and other adherent matter shall be removed immediately from
steelwork or coated surfaces and the surfaces shall be made good by
(b)
Dust, soot, grit, detritus, metallic or other loose particles shall be removed by
vacuum cleaning after steelwork surfaces have been blast cleaned or before
coated surfaces are washed or steam cleaned.
(c)
Oil and grease shall be removed by emulsion cleaners, by steam cleaning or

by high pressure water jets before removing rust and mill scale or
overcoating. Oil and grease shall not be removed by turpentine or other
solvents. If steam cleaning is used, steam cleaning shall be carried out after
the greasy deposits have been removed by scraping and a detergent shall be
added to the feed water of the steam generator.
(d)
Salts, chemicals, corrosion or paint degradation products, including zinc salts

on zinc coatings or zinc-rich paints, shall be removed by washing with
detergent solution and rinsed with fresh water before coating steelwork
surfaces or overcoating.
(e)
Rust spotting on blast cleaned surfaces shall be rejected and steel shall be reblasted to the required standard before any coating is applied.
(f)
Residual salts resulting in measurements higher than 90 ppm shall be

removed by high pressure fresh water washing.
(g)
The final shop coats on external surfaces shall be thoroughly washed with a
detergent solution at Site before being overcoated.

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January 2011
(h)
(i)
(j)
Finished coated surfaces shall be cleaned as stated in Sections 22.5.4(b) to

(d) not more than 14 days before application for the Completion Certificate for
the Works.
Cleaning agents to be used shall be reviewed without objection by the Project
Manager. Surfaces which have been cleaned using cleaning agents shall be
rinsed with water to remove all traces of the cleaning agent.
Cleaning tools shall not damage the surfaces being cleaned. Wire brushes
and brooms shall not be used for cleaning coated surfaces.
22.5.13 Preparation of Steelwork Surfaces

(a)
Bare metal surfaces of steelwork which are to be painted or metal coated

shall be treated before rust and mill scale are removed in accordance with the
(i)
burrs, arrises and serrations shall be smoothed by grinding or filing. All

surface irregularities shall be removed, including sharp edges and
laminations, by grinding until smooth; and
(ii)
weld spatter, weld slag and raised metal laminations shall be removed
by grinding or chipping and the surface shall be made good.
(b)
At no time shall steel surfaces have rusted beyond Rust Grade C of Swedish
Standard S1S 05 59 00.
(c)
Rust and mill scale shall be removed from steelwork which is to be metal
coated in factories by a pickling process compatible with the metal coating
process.
(d)
Rust and mill scale shall be removed from steelwork which is to be metal
sprayed by blast cleaning carried out in accordance with BS 2569:Part 1,
Clause 3.
(e)
Rust and mill scale shall be removed from steelwork to be painted by blast
cleaning as stated in Section 22.5.14 unless the use of acid-pickling,
mechanical cleaning or flame cleaning as stated in Sections 22.5.15 to
22.5.17 has been reviewed without objection by the Project Manager.
(f)
Excess acid or other chemicals used in the pickling process shall be removed
from steelwork which has been prepared by pickling before the application of
the metal coating. Pickling shall not be carried out for longer than is
necessary to remove the rust and mill scale.
(g)
After surface preparation has been completed, the surface roughness shall be
compatible with the specified coating and at no location should the peak-totrough amplitude exceed 80 m.
(h)
All defects in the substrate surface exposed during surface preparation which
are not
acceptable in accordance with BS 4360 shall be rectified in
accordance with BS 4360.
(i)
Defects which are acceptable in accordance with BS 4360 but which will
prevent the satisfactory coating of the steelwork shall be rectified and

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January 2011
(j)
Steelwork which has rusted to Rust Grade B of Swedish Standard SIS 05 59

00 at any stage before surface preparation, and steel which has been subject
to significant contamination prior to blast-cleaning, shall be tested in
accordance with Appendix G of BS 5493 after surface preparation, to
demonstrate that the prepared surface is substantially free of salts.
(k)
Prefabrication coatings may be applied but this coating will be considered

additional to the main protective-system. If a prefabrication coating is to be
applied the Contractor shall provide evidence that it is fully compatible with
the main protective system.
22.5.14 Blast Cleaning of Steelwork

(a)
Blast cleaning of steelwork shall be carried out to second quality of surface

finish in accordance with Sa2 in Swedish Standard SIS 05 59 00 using
chilled iron abrasive.
(b)
Chilled iron grit shall be graded in accordance with BS 2451. The maximum
size of grit shall be G17 for use in automatic impeller type equipment and
shall be G12 for manual or compressed air equipment. The difference in level
between a peak and the adjacent trough of the blasted surface profile shall
not exceed 0.1 mm or in accordance with the paint manufacturer's
recommendation.
(c)
All compressed air for grit blasting shall be passed through aftercoolers and
oil separation equipment to ensure that the air is dry and oil free. Air shall be
tested each day by placing a white cloth at the compressed air outlet for one
minute. The cloth shall remain clean after one minute.
(d)
Abrasives shall not contain materials which may contaminate the steel
surfaces and shall be cleaned and free of chloride, dust, dirt, grease, oil and
moisture. Sand shall not be used except in a wet cleaning system.
Expandable abrasive shall be used once only. Recyclable steel abrasive shall
be cleaned and free of contaminants before re-use. Recyclable abrasives
shall be discarded when the particle size fails to achieve the specified profile.
(e)
Blast cleaning shall be carried out in a fully enclosed environmentally

controlled space separated from the place of painting. The enclosed space
shall be fitted with dust extractors and filters to prevent the dispersal of dust
outside the enclosed space.
22.5.15 Acid-pickling of Steelwork

Acid-pickling of steelwork shall be carried out by the Footner process in accordance
with BS 5493, Clause 14.3.2. The first priming coat of paint shall be applied as
soon as the steel has dried and is still warm.
22.5.16 Mechanical Cleaning of Steelwork
Mechanical cleaning of steelwork shall be carried out using carborundum grinding
discs or other power-driven tools followed by steel wire brushing and dusting to
remove all loosened material which is not firmly bonded to the metal surface.
Excessive burnishing of the metal through prolonged application of rotary wire
brushes shall not be carried out. Visible peaks and ridges shall be removed.
Pneumatic chipping hammers shall not be used.
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January 2011
22.5.17 Flame Cleaning of Steelwork

(a)
Flame cleaning of steelwork shall not be carried out at the following locations:
(i)
within 2 m of HSFG bolts, cold worked high tensile steel and surfaces
already coated with paint or cadmium, lead-based or carbonaceous
materials, or
(ii)
on sections thinner than 0.5 mm.
(b)
Flame cleaning shall be carried out without distorting the steelwork and
without adversely affecting the properties of the steel. The temperature of the
steel surface being flame cleaned shall not exceed 200C.
(c)
Loose materials shall be removed from the flame-cleaned surface by wire

brushing followed by blowing dry air or vacuum cleaning. The priming coat
shall be applied when the surface temperature of the steel is between 35C
and 40C. Surfaces with temperatures of less than 35C shall be reheated.
22.5.18 Cleaning of Bolts, Nuts and Washers

Bolts, nuts and washers for steelwork shall be kept free from dirt and deleterious
material. Oil and grease on bolts, nuts and washers, other than lubricants reviewed
without objection by the Project Manager for nuts of HSFG bolts, shall be removed
before assembling and coating the exposed parts of assembled bolts, nuts and
washers.
22.5.19 Inspection of Surface Preparation
Surfaces shall not be coated until the cleaning and preparation of the surfaces has
been carried out. The Contractor shall notify the Project Manager when the surfaces
are available for inspection.
22.5.20 Application of Paint to Steelwork
(a)
Surfaces which are to be painted shall be dry immediately before paint is

applied.
(b)
Paint shall be taken from the paint store ready for application. Thinning, if
necessary, shall be carried out in the paint store using the type of thinner in
the ratio stated in the manufacturer's data sheets.
(c)
Paint shall be applied by brush, by air pressure spray or by airless spray.

Sealer and primers shall be applied by continuous spraying.
Each coat in the paintwork system shall be sufficiently dry or cured before the
next coat is applied. The time between application of successive coats shall
be within the limits recommended by the manufacturer and the limits stated in
Section 22.5.22.
(d)
(e)
Paints having a pot life specified by the manufacturer, including two pack
paints and moisture cured paints, shall be discarded on expiry of the pot life or
at the end of each working day, whichever comes first. Other paints in
opened containers shall be kept in sealed containers with not more than 10%
ullage in store after each day's work and shall not be thinned or mixed with
fresh paint when re-issued for another day's work.

20/36
January 2011
(f)
All connections, including fasteners, items of bracketry and other small pieces
fabricated separately to the main steelwork shall be prepared and protected
using an equivalent standard to the adjacent steel unless otherwise stated in
the Contract. If the Contractor proposes to use a different protective system
for any part of a connection to that used for the adjacent steel, evidence shall
be submitted to the Project Manager which demonstrates compatibility.
(g)
Paint shall not be applied to friction grip interfaces. The faying surfaces shall
be masked to prevent rusting beyond Rust Grade C of Swedish Standard SIS
05 59 00. If galvanizing or other metal coatings have been applied, evidence
shall be provided to demonstrate that a slip factor not less than the design
value shall be achieved.
(h)
Bolt connections in externally exposed steelwork, other than friction grip

connections, shall be assembled with a coat of primer still wet on the contact
surfaces.
(i)
Plated, galvanized or sherardized bolt assemblies shall be primed with a

compatible etch primer or treated with a mordant solution prior to overcoating.
(j)
After erection some parts of the steelwork may not be accessible for the
application of site-applied coatings. The complete system shall be applied
prior to erection of these areas.
22.5.21 Working Conditions for Painting

(a)
(b)
Paint shall not be applied to steelwork under the following conditions:

(i)
when the ambient temperature falls below 4C or the relative humidity

rises above 90%;
(ii)
for outdoor work, during periods of inclement weather including fog,

frost, mist and rain or when condensation has occurred or is likely to
occur on the metal;
(iii)
when the surface temperature of the metal to be painted is less than

3C above the dew point of the ambient air; or
(iv)
when the amount of dust in the air or on the surface to be painted is in

the opinion of the Project Manager excessive.
Two pack paints of the epoxide resin type shall not be applied and cured
when the temperature is below that recommended by the manufacturer.
22.5.22 Priming and Overcoating Time Limits

(a)
Blast cleaned steel shall be primed or metal coated within 4 hours after blast
cleaning and before any visible signs of oxidations appear on the prepared
surface. Prepared surfaces shall be blown clean with dry, oil free compressed
air to remove dust, dirt and grit residues before coating.
(b)
Primed steel surfaces shall be overcoated within 8 weeks after priming.
(c)
Second undercoats shall be applied within 72 hours after application of the

first undercoat.

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January 2011
(d)
Sealer or etch primer to sprayed metal shall be applied within 4 hours after
spraying. The etch primed surfaces shall be overcoated within 72 hours after
priming.
(e)
Etch primer to galvanized steelwork shall be applied within 14 days after

delivery of the steelwork to Site. The etch primed surfaces shall be
overcoated within 48 hours after priming. Prior to application of the etch
primer to galvanized steelwork the surface shall :
(f)
(i)
be treated with "T"-wash in accordance with BS 5493, Section 2, Clause

11.3.2;
(ii)
have the "T"-wash removed in accordance with BS 5493; and
(iii)
be completely dry.
Overcoats to two pack paints of the epoxide or polyurethane type shall be

applied within 48 hours after application of the two pack paint. If it is not
possible to overcoat within 48 hours, the two pack paint shall be abraded to
produce a roughened surface and shall be given a flash coat of primer of a
type reviewed without objection by the Project Manager; the primer shall be
allowed to dry for at least 4 hours before application of the next coat of the
system.
22.5.23 Stripe Coats to Steelwork

Immediately after the first undercoat of the painting system to steelwork has dried, a
stripe coat of undercoat paint shall be applied by brush to edges, corners, crevices,
exposed parts of bolts, nuts, rivets and welds. Another stripe coat of finishing paint
shall be applied in the same manner after the last undercoat has dried.
22.5.24 Paint Coats to Steelwork
(a)
The dry film thickness of the paint coats to steelwork shall be measured using
a magnetic dry film thickness gauge. The total dry film thickness shall be
measured at spacings of approximately 1.0 m. If the measured dry film
thickness is less than 75% of the specified nominal dry film thicknesses or if
more than 10% of the measured dry film thickness are less than 95% of the
specified nominal dry film thickness, repair work shall be carried out as stated
in Clause 22.5.26.
(b)
Dry film thickness readings on structural members shall be taken at three

points for each linear metre. Wet film thickness gauges shall not be used as a
means of predicting the dry film thickness, but only as an indication that
sufficient material has been applied at the time of application.
(c)
Each coat of paint shall be free from embedded foreign matter, mechanical
damage and surface defects, including bittiness, blistering, brush marks,
bubbling, cissing, cracking, cratering, dry spray, floating, pinholing, rivelling,
runs, sagging, spotting and spray mottle as defined in BS 2015. The finished
paintwork system shall have an even and uniform appearance.
(d)
Each coat of paint shall adhere firmly to the substrate without blistering,
chipping, flaking or peeling. Adhesion tests in accordance with BS 3900:Part
E6 shall be carried out on representative areas to confirm that the adhesion of
the completed paint scheme is equivalent to classification 2 of that standard.
The test area shall be repaired in accordance with the Specification.

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January 2011
22.5.25 Etch Primers and Blast Primers

Etch primers and blast primers shall not be applied on phosphated steel and shall
not be overcoated with zinc-rich primers.
22.5.26 Repairs to Damaged Areas of Paint
(a)
Areas of paint to steelwork which have been damaged shall be cleaned to

bare metal or to the metal coating. The edges of the undamaged paint shall
be bevelled.
(b)
The full specified painting system shall be restored in such a manner that
each new paint coat overlaps the existing paint by at least 50 mm all round
the affected part.
22.5.27 Protection of HSFG Bolted Joints

(a)
The faying surfaces of HSFG bolted joints in steelwork which is metal sprayed
overall and sealed or metal sprayed and painted overall, shall be coated with
the sprayed metal. The sealer on the parent material shall extend for a
distance of between 10 mm and 20 mm inside the perimeter of the faying
surfaces. Free surfaces and edges of the joint material shall be coated with
the same sealer.
(b)
The joint material and the faying surfaces on the parent material of steelwork
which is metal sprayed only at joints and painted overall shall be metal
sprayed. The sprayed metal on the parent material shall extend for a distance
of between 10 mm and 20 mm outside the perimeter of the faying surfaces.
The primer on the parent material shall extend for a distance of between
10 mm and 20 mm inside the perimeter of the faying surfaces. Sprayed metal
on the free surfaces and edges of the joint material shall be coated with a
sealer which is compatible with the painting system.
(c)
The primer on the parent material of steelwork which is painted overall and
uncoated at faying surfaces of HSFG bolted joints shall extend for a distance
of between 10 mm and 20 mm inside the perimeter of the faying surfaces.
22.5.28 Protection of other Shop-bolted Joints

Blast primer for painted steelwork or sprayed metal plus sealer for metal sprayed
steelwork shall be applied to the joint and parent material of shop-bolted joints other
than HSFG bolted joints; joints for painted steelwork shall be assembled after the
first undercoat of the painting system has been applied to the contact surfaces and
while the undercoat is still wet.
22.5.29 Protection of other Site-bolted joints
Surfaces of the parent and joint material of Site-bolted joints other than HSFG
bolted joints shall be coated with the same protective system as the parent material.
22.5.30 Protection of Welded Joints
Welds and steelwork surfaces which have been affected by welding shall be coated
with the same protective system as the parent material.

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22.5.31 Joints made after Coating the Parent Material

(a)
Hot-dip galvanizing and electroplating to steelwork shall not be carried out

until all welds for the steelwork which is to be galvanized or electroplated have
been completed.
(b)
Except as stated in Section 22.5.31(d), sprayed metal on the parent material

shall be kept at least 15 mm, but not more than 300 mm, clear of areas which
are to be welded. The restricted area shall be masked during metal spraying.
(c)
Except as stated in Section 22.5.31(d), successive coats of paint on the

parent material shall be stepped back at 30 mm intervals commencing at
100 mm from welded joints and at 10 mm from the perimeter of HSFG bolted
joints.
(d)
If the parent metal in the welding procedure reviewed without objection by the
Project Manager is coated with the pre-fabrication primer or sprayed metal
such coatings are permitted to cover the area to be welded. After welding the
pre-fabrication primer or sprayed metal adjacent to the weld shall be made
good.
(e)
The parent material, joint material, exposed parts of bolts, nuts and washers,
welds and weld affected areas shall be cleaned, prepared and brought up to
the same protective system as the adjoining surfaces not more than 14 days
after the joints have been made.
22.5.32 Sealing of Joints in Steelwork

(a)
The different parts of joints in steelwork shall be dry immediately before the
joints are assembled.
(b)
Gaps around the perimeter of bolted joints and load indicator gaps of HSFG
bolts in steelwork painted overall shall be sealed by brush application of the
same painting system as the parent material; gaps shall be plugged if
necessary with soft solder wire without flux core as a backing before sealing
with paint.
22.5.33 Protection of Hollow Steel Sections

The ends of hollow steel sections shall be sealed by welding mild steel plates, at
least 2mm thick, over the open ends. Immediately before hollow steel sections are
sealed, porous bags containing anhydrous silica gel shall be inserted in each void
at the rate of 0.25 kg/m of void.
22.5.34 Protection of Bearing Surfaces for Bridge Bearings
Dirt, oil, grease, rust and mill scale shall be removed from the metal bearing
surfaces for bridge bearings. The surfaces shall be masked with tape and shall not
be primed or painted until the bonding agent has been applied.

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January 2011
22.5.35 Protection of Uncoated Steelwork Surfaces

The coated surfaces of steelwork coated over part of the surface shall be protected
from rust which may form on the uncoated surfaces. Temporary coatings which
may affect the bond between concrete and uncoated surfaces against which the
concrete is to be placed shall be removed and the uncoated surfaces shall be
cleaned before the concrete is placed. The full coating system shall extend 25 mm,
or 75 mm for steel piles, into areas against which concrete is to be placed.
22.5.36 Temporary Supports and Fastenings to Steelwork
(a)
Steelwork shall be secured in position by temporary supports and fastenings

until sufficient permanent connections are complete to withstand the loadings
liable to be encountered during erection. The temporary supports and
fastenings shall be capable of withstanding loadings which may be
encountered during erection and shall not damage the steelwork or the
protective coatings.
(b)
Riveted and bolted connections shall be aligned using drifts complying with
BS 5400:Part 6, Clause 4.12 and shall be temporarily fastened using service
bolts.
(c)
The Contractor shall design and fabricate all temporary attachments for use
as assembly and erection aids to ensure their use will not damage the
structure of its surface protection.
22.5.37 Falsework
Falsework shall be designed, constructed and dismantled in accordance with BS
5975.
22.5.38 Alignment of Steelwork
(a)
Steelwork shall be erected in such a manner that the alignment and levels of
the steelwork comply with the tolerances stated in Section 22.5.49. The
Contractor shall make allowance for the effects of temperature on the
steelwork.
(b)
Measures shall be taken to ensure that the steelwork will remain stable before
temporary supports and fastenings are slackened or removed for lining,
levelling, plumbing or other purposes. The temporary supports and fastenings
shall be re-tightened or replaced as soon as the adjustments are complete
and at the end of each continuous period of working.
(c)
Permanent connections shall be made as soon as a sufficient portion of the

steelwork has been lined, levelled and plumbed. Temporary supports and
fastenings shall be replaced by permanent connections progressively and in
such a manner that the parts connected are securely restrained in the aligned
position at all times.

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January 2011
22.5.39 Foundation Bolts for Steelwork

(a)
Foundation bolts for steelwork shall be held firmly in the set position during
fixing. Measures shall be taken to ensure that the full movement tolerances
are achieved and the bolts are not displaced during concreting. Bolts and
nuts, including the threads, shall be protected against damage, corrosion and
contamination.
(b)
Bolt pockets shall be kept dry and clean. Tubes which are cast in concrete for
grouting bolt pockets shall be securely fixed and sealed to prevent ingress of
grout during concreting.
(c)
Bolts in bolt pockets shall be installed to allow the bolt movement inside the
pocket as designed without hindrance.
22.5.40 Supporting Devices for Steelwork

The material, size, position and cover of packs, shims and other supporting devices
for steelwork which are to be embedded shall be as reviewed without objection by
22.5.41 Bedding and Grouting of Column Bases
(a)
Column bases for each portion of steelwork shall not be bedded or grouted
until the portion has been lined, levelled, plumbed and permanently
connected. Spaces below the steel shall be dry, clean and free from rust
immediately before bedding or grouting.
(b)
Proprietary types of grout shall be used in accordance with the manufacturer's

recommendations.
(c)
Temporary timber wedges holding steel columns in position shall not project
into pocket bases by more than one-third of the embedded length of the steel
column. The pocket shall be initially concreted up to the underside of the
wedges and the steel column shall be left undisturbed until 48 hours after
concreting; the wedges shall then be removed and the remainder of the
pocket shall be concreted.
22.5.42 Sliding Surfaces

Sliding surfaces of uncoated expansion joints shall be treated with molybdenum
disulphide grease before making the connection.
22.5.43 Thermal Cutting
Thermal cutting equipment shall not be used on Site unless reviewed without
22.5.44 Erectors
The Contractor shall carry out all work by trained and experienced erectors. The
Contractor shall submit to the Project Manager for review without objection
evidence of the erectors competence.

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January 2011
22.5.45 Safety
The Contractor shall not carry out complex operations at height except from safe
platforms large enough to support operators and equipments. Platforms and safe
access shall be maintained until work has been completed.
22.5.46 Stability
Stability of structures shall be checked by calculations submitted to the Project
Manager for review without objection. The design criteria assumed in the
calculations shall be maintained at all stages of construction.
22.5.47 Tolerances: Fabrication of Steelwork
(a)
Unless otherwise stated in the Contract, steelwork shall be fabricated to within

the tolerances stated in Sections 22.5.47(b) to (i).
(b)
Steelwork shall be fabricated to an accuracy that will enable erection within

the specified limits to take place without inducing excessive stresses,
deflection or distortion into the structure.
(c)
Built-up members, including castellated beams shall comply with BS

5950:Part 2.
(d)
The length of members with both ends prepared for contact bearing shall not
deviate from the detailed length by more than 1 mm.
(e)
The length of members without ends prepared for contact bearing, which are
to be framed to other steel parts of the structure, shall not deviate from the
detailed length by more than 2 mm for members 10 m or less in length, and 4
mm for members greater than 10 m in length.
(f)
The deviation of a member from a straight line drawn between adjacent points
of subsequent effective lateral restraint shall not exceed the greater of 3 mm
or 0.1% of the distance between restraints.
(g)
The deviation from the specified or proposed camber shall not exceed the
greater of 12 mm or 0.1% of the length of the member.
(h)
The gaps in joints which depend on contact bearing when assembled during
fabrication shall not exceed 0.75 mm.
(i)
Fabrication tolerances shall comply with the following British Standards:

(i)
BS 5400:Part 6 for plates and sections in bridgework;
(ii)
BS 5950:Part 2 for hot rolled sections in building; and
(iii)
BS 5950:Part 7 for cold rolled sections in building.
22.5.48 Tolerances: Foundation Bolts

The position of cast-in foundation bolts at the top of base plates shall be within
3 mm of the specified position. The position of foundation bolts in bolt pockets at
the top of base plates shall be within 5 mm of the specified position. The line of
bolts shall not be tilted from the specified line by more than 1 in 40.
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January 2011
22.5.49 Tolerances: Erection of Steelwork

(a)
(b)
(c)
(d)
Unless otherwise stated in the Contract, steelwork shall be erected to within

the tolerances stated in Sections 22.5.49(b) to (j) after lining, levelling,
plumbing and making the permanent connections.
The position in plan of vertical components at the base shall be within 10 mm
of the specified position along either principle setting out axis.
The level of the top of base plates and the level of the lower end of vertical or
raking components in a pocket base shall be within 10 mm of the specified
level.
The thickness of bedding shall be within one-third of the nominal thickness or
10 mm, whichever is less, of the specified nominal thickness.
(e)
The line of vertical or raking components other than in portal frames shall be
within 1 in 600 and within 5 mm of the specified line in every direction.
(f)
The line of vertical or raking components in portal frames shall be within 1 in

600 and within 5 mm of the specified line in every direction.
(g)
The position and level of components connected with other components shall
be within 5 mm of the specified position and level relative to the other
components at the point of connection.
(h)
The position of components supported on a bearing shall be within 5 mm of

the specified position relative to the bearing along both principal axis of the
bearing.
(i)
The difference in level between adjacent sloping or horizontal components

connected by a deck slab shall be within 10 mm of the specified difference in
level.
(j)
Gaps in joints which depend on contact bearing after alignment shall not
exceed 0.75 mm.
22.5.50 Cast-in components

(a)
Welding of any attachment to cast-in components shall not take place less
than 7 days after casting of the concrete. Where welding is requested to a
cast-in item, the Contractor shall demonstrate that the heat generated at the
interface with the concrete will not have a detrimental effect on the
mechanical properties of the concrete and will not compromise the capacity of
the cast-in detail.
(b)
Where part of a cast-in component is required to have corrosion protection,

the full protection system shall be applied for an overlap of not less than
50mm extending into the concrete encased zone.
(c)
For cast-in fixings designed by the Contractor, the Contractor shall design and
install reinforcement which shall be additional to that shown on the Employers
Drawings and capable of transmitting the fixing imposed loads into the
structure without adversely affecting the structural integrity of the surrounding
concrete.

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January 2011
22.6
22.6.1
Procedure Trials for Welding, Flame Cutting and Shearing
22.6.2
(a)
If the proposed welding procedure submitted as stated in Section 22.4.5 or

the proposed stud welding, flame cutting or shearing procedure for steelwork
complying with BS 5400:Part 6 submitted as stated in Section 22.4.6 has not
complied with the procedure trial requirements for the procedure stated in the
Contract in previous tests, a procedure trial shall be carried out as stated in
Sections 22.6.1 (b) to (h).
(b)
Procedure trials for welding for structural steel shall comply with
BS 5400:Part 6, Clauses 4.7.3, 5.4.1.1 and 5.4.1.2.
(c)
Procedure trials for welding for steel

BS 5400:Part 6, Clauses 4.7.3 and 5.4.2.
(d)
Procedure trials for welding of studs shall comply with BS 5400:Part 6,

Clauses 4.7.4 and 5.4.4.
(e)
Procedure trials for flame cutting and shearing shall comply with
BS 5400:Part 6, Clauses 4.7.3 and 5.4.3.
(f)
Welds for grade A steels complying with BS 4360 are not required to comply
with the requirements for Charpy V-notch impact tests. The temperature of 20C stated in BS 5400:Part 6, Clause 5.4.1.2(a)(3) shall be amended to 0C.
(g)
If in a welding procedure one or more of the parts to be welded is coated with

a prefabrication primer or metal coating before welding, the same primer or
coating shall be applied to the sample before the procedure trial for the
welding procedure is carried out.
(h)
The thickness of the sample of material to be used in procedure trials for

flame cutting shall be:
castings
shall
comply
with
(i)
20 mm for material not exceeding 20 mm thick;
(ii)
40 mm for material exceeding 20 mm and not exceeding 40 mm thick;

and
(iii)
T mm for material exceeding (T-10) mm and not exceeding T mm thick,

where T is any multiple of 10 from 50 up.
Inspection of Procedure Trials for Welding, Flame Cutting and Shearing

Procedure trials for welding, flame cutting and shearing shall be carried out in the
presence of an independent HOKLAS accredited inspecting authority.
22.6.3
Results of Procedure Trials for Welding, Flame Cutting and Shearing

If a procedure trial for welding, flame cutting or shearing does not comply with the
specified requirements for the procedure trial, the cause of failure shall be
established by the Contractor and particulars of proposed changes shall be
submitted to the Project Manager for review without objection. Further procedure
trials shall be carried out to establish the amended procedure.

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January 2011
22.6.4
22.6.5
Acceptable Procedures for Welding, Flame Cutting and shearing

(a)
A welding, flame cutting or shearing procedure which complies with the

specified requirements for the procedure trial is defined as an "Acceptable
Procedure".
(b)
If a procedure trial is not required, the procedure for welding, flame cutting or
shearing submitted as stated in Sections 22.4.5 and 22.4.6 shall become an
"Acceptable Procedure".
Commencement of Welding, Flame Cutting and Shearing

Welding, flame cutting or shearing shall not commence until the procedure has
22.6.6
Changes in Procedures for Welding, Flame Cutting and Shearing

"Acceptable Procedures" for welding, flame cutting or shearing shall not be
changed. Further procedure trials shall be carried out to demonstrate proposed
changes to the procedure.
22.6.7
22.6.8
22.6.9
Records of Procedure Trials for Welding, Flame Cutting and Shearing

(a)
A record of the approval test for welding procedures shall be submitted to the
Project Manager for review without objection. The record shall be in the form
stated in BS 4870:Part 1, Appendix B or BS 4570, Appendix A as appropriate
and shall be endorsed by the independent HOKLAS accredited inspecting
authority.
(b)
Reports of procedure trials for stud welding, fl ame cutting and shearing shall
Painting Trials
(a)
A painting trial shall be carried out for each painting system which will be
applied to areas exceeding 10 m2 to demonstrate that the proposed materials
and methods of application will produce a painted surface which complies with
the specified requirements.
(b)
Painting trials shall be carried out at the place where painting to the
Permanent Works will be carried out and using the labour and equipment
which will be used to carry out painting to the Permanent Works.
(c)
Painting trials shall be carried out on steel cleaned in accordance with the
requirements of the Contract.
Results of Painting Trials

The painted surface produced in a painting trial shall be tested in accordance with
BS 3900 and in the event that the test piece does not comply with the specified
requirements for the paintwork, the cause of failure shall be established by the
Contractor and particulars of proposed changes shall be submitted to the Project
Manager for review without objection. Proposed changes to the paint formulation,
other than an adjustment in the amount of thinners, shall be carried out at the paint
manufacturer's works before the final painting trial and before the first batch of paint
is delivered.

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January 2011
22.6.10 Commencement of Painting

Painting shall not commence until the painted surface produced in painting trials
complies with the specified requirements for paintwork.
22.6.11 Changes in Materials and Methods of Application for Painting
The materials and methods of application used in a painting trial which complies
with the specified requirements shall not be changed.
22.6.12 Inspection of Fabricated Steelwork
(a)
Fabricated steelwork shall not be:

(i)
covered with protective coatings, concrete or other materials;
(ii)
erected; or
(iii)
dispatched from the place of fabrication if fabricated off Site,
until the steelwork, complies with the specified test and inspection
requirements and has been reviewed without objection by the Project
Manager.
22.6.13 Independent Testing Consultant
Tests which are stated in this section to be carried out by an independent testing
consultant shall be carried out by a HOKLAS accredited testing consultant reviewed
22.6.14 Testing: Tests on Steelwork at Manufacturer's Works
(a)
Tests shall be carried out on structural steel in accordance with

BS 5400:Part 6, Clauses 5.2.1, 5.2.2 and 5.3.
(b)
Tests shall be carried out on bolts, nuts and washers in accordance with
BS 3692, BS 4190, BS 4395:Part 1, BS 4395:Part 2 or BS 4933 as
appropriate; the tests shall be carried out on full size bolts. The rates of
sampling and testing shall be in accordance with BS 4395:Part 1.
(c)
The tests shall be carried out by the manufacturer at the manufacturer's works
on samples selected by the Project Manager if the manufacturer's works are
in Hong Kong and on samples selected by the independent testing consultant
reviewed without objection by the Project Manager if the manufacturer's works
are not in Hong Kong.
22.6.15 Batch: Steelwork

(a)
A batch of steelwork is the amount of steelwork which is completed or

delivered to Site at any one time.
(b)
The Contractor shall submit to the Project Manager for review without
objection a list of the components included in each batch at least 7 days
before testing starts.

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January 2011
22.6.16 Samples: Steelwork

(a)
Samples to be tested shall be selected by the Project Manager if testing is to

be carried out in Hong Kong and shall be selected by the independent testing
consultant if testing is not to be carried out in Hong Kong.
(b)
Samples shall be selected from positions which, in the opinion of the Project
Manager or the independent testing consultant, are representative of the
batch as a whole.
(c)
The Project Manager will inform the Contractor of the samples selected for
testing at least 3 days before testing is programmed to commence.
22.6.17 Testing: Steelwork

(a)
The relevant tests stated in Sections 22.6.21 to 22.6.24 shall be carried out on
each batch of steelwork.
(b)
The Contractor shall notify the Project Manager at least 7 days before tests in
Hong Kong are carried out.
22.6.18 Reports of Tests on Steelwork

(a)
(b)
Records of tests on steelwork and a report shall be submitted to the Project

Manager for review without objection at least 7 days before the Project
Manager's notification of no objection is required. The report shall contain the
following details:
(i)
procedure under which the testing took place and the exact test location
in the steelwork;
(ii)
results of tests compared to

non-complying results highlighted;
(iii)
any tearing, cracking or other defects; and
(iv)
conclusion as to the overall acceptability of the parts of steelwork

examined by the testing consultant.
the
required
values,
with
any
Reports shall be certified by the Contractor and by the independent testing

consultant, who carried out the tests.
22.6.19 Non-compliance: Steelwork

(a)
If the result of any test on steelwork stated in Sections 22.6.21 to 22.6.24

does not comply with the Specification for the test, the test shall be carried out
on additional samples from the batch. The number of additional tests shall be
twice the number of original tests.
(b)
If the result of every additional test complies with the Specification, the part of
the batch on which the original tests were carried out shall be considered as
complying with the specified requirements for the test.
(c)
The batch shall be considered as not complying with the Specification if the
result of any additional test does not comply with the Specification for the test.

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January 2011
22.6.20 Samples: Steel

Samples of steel shall be provided from each batch of steel within 3 days after
delivery of the batch to the fabricator's works or to Site. The rate of sampling and
the position and direction of the samples shall be in accordance with BS 4360.
22.6.21 Testing: Steel
(a)
The tensile test and the impact test shall be carried out on each sample of
steel. The method of testing shall be in accordance with BS 4360.
(b)
Where stated in the Contract the material shall be subject to the following
additional tests :
(i)
ultrasonic grading in accordance with BS 5996, Grade 4; and
(ii)
through thickness tensile tests to BS 6780, Level Z25.
(c)
Quality grading of structural steel shall be carried out on steel which has not
been tested for quality grades by the manufacturer. Quality grading shall be
carried out in accordance with BS 5400:Part 6, Clause 3.1.4 or
BS 5950:Part 2, Clause 2.1.6 as appropriate.
(d)
Testing and quality grading shall be carried out by the independent testing
consultant.
22.6.22 Testing: Welds

(a)
Examination and testing of welds shall be carried out after post-weld heat
treatment and before the application of corrosion protective coatings. Deburring, dressing, grinding, machining and peening shall be carried out after
the visual inspection for cracks, surface pores and joint fit-up and before other
inspections and tests are carried out.
(b)
Where the Specification requires that butt welds are subject to non-destructive
examination, the following shall apply:
(c)
(i)
visual inspection in accordance with BS 5289;
(ii)
penetrant test in accordance with BS 6443 or magnetic particle test in

accordance with BS 6072;
(iii)
ultrasonic examination to BS 3923 : Part 1, Part 2; and
(iv)
radiographic examination to BS 2600:Part 1, Part 2 or BS 2910.
Where the Specification requires that fillet welds are subject to the nondestructive examinations, the following shall apply:
(i)
visual inspection in accordance with BS 5289;
(ii)
penetrant test in accordance with BS 6443 or magnetic particle test in

accordance with BS 6072; and
(iii)
for welds with a leg length equal to or greater than 12 mm ultrasonic

examination to BS 3923:Part 1.

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January 2011
(d)
Welds subject to visual examination shall satisfy the following criteria:

(i)
no evidence of cracks, spattering, inclusions, tears or lack of fusion;
(ii)
weld sizes and lengths shall not be less than those dimensions
specified in the Specification;
any undercut shall be intermittent and not greater than 0.5 mm deep;
(iii)
(iv)
full penetration shall be achieved unless otherwise specified in the

Contract. For connections welded from one side only, any lack of
penetration shall be intermittent and not greater than 1.5 mm deep;
(v)
root gap in fillet welds shall not exceed 1.0 mm and shall only exceed
0.5 mm intermittently;
(vi)
excess penetration shall not exceed 3 mm;
(vii) weld reinforcement shall blend smoothly with the parent metal with no
signs of overlap; and
(viii) linear misalignment shall not exceed t/10 where t is the thickness of the
thinner part or 3 mm, whichever is the lesser.
(e)
Welds subject to ultrasonic examination shall satisfy the following criteria:

(i)
the weld shall have no reflectors which could be interpreted as planar

defects such as cracks, tears, lack of fusion or lack of penetration. A
planar defect is any flaw whose thickness is less than 25% of its width.
In the case of partial penetration welds, the nominated unfused
thickness shall not be subject to rejection. The amount of unfused
thickness shall be measured and recorded and shall not exceed the
nominated width;
(ii)
all volumetric defects, where the thickness is equal to or greater than

25% of its width, shall be sized and the weld rejected if:
(iii)
the width exceeds 6 mm or T/6, which ever is the lesser; or

where the width exceeds 1.5 mm, but is less than 6 mm or T/6
whichever is lesser, the length exceeds 20 mm (T equals the plate
thickness in mm);
two adjacent defects, if not separated by at least twice the length of the
longer defect, shall be regarded as one continuous defect; and
(iv)
(f)
a defect shall not begin at a distance less than twice its own length from
the end of the weld.
Welds subject to magnetic particle or penetrant examination shall satisfy the
following criteria :
(i)
the weld shall have no cracks, tears, or lack of fusion;
(ii)
any undercut shall be intermittent and not greater than 0.5 mm deep;
(iii)
the sum of diameters of piping or porosity shall not exceed 10 mm in

any linear 25 mm of weld and 20 mm in any 300 mm length of weld;

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January 2011
(iv)
maximum length of a single defect shall be less than 2/3 of the effective
throat of the weld up to a maximum of 20 mm;
(v)
the defect shall be further than three times the larger of its own width or
length from the end of the weld or from an adjacent defect;
(vi)
any indication which is believed to be spurious shall be regarded as a

defect unless on re-evaluation by the same method or by an alternative
technique subsequent to surface dressing the indication has been
removed; and
(vii) any defects which appear to be subsurface shall be exposed by surface

grinding to display their nature, full size, and shape.
(g)
(h)
The frequency of weld examination shall be in accordance with requirements

in PNAP 160 or the following, whichever is the greater.
(i)
all welds shall be visually inspected; and
(ii)
for non-destructive examination the frequency shall be as follows :

full penetration butt welds:
100% ultrasonic; and
100% magnetic particle or penetrant inspection;
partial penetration butt welds and fillet welds with leg length equal to
or greater than 12 mm:
20% minimum ultrasonic; and
20% minimum magnetic particle or penetrant inspection; and
Fillet welds with leg length less than 12 mm:

10% minimum magnetic particle or penetrant inspection.
Testing of stud welding shall be as follows :

(i)
all stud welds shall be visually inspected;
(ii)
any stud weld which does not exhibit full 360 degree "flash" shall be
subjected to a 15 degree bend test at locations to be reviewed without
objection by the Project Manager. Under this test the weld is to show
no visible signs of cracking;
(iii)
a minimum of 5% of studs which have satisfied the visual inspection

shall be subject to a 15 degree bend test at locations to be reviewed
without objection by the Project Manager. Under this test the weld shall
show no visible signs of cracking;
(iv)
where the bend test reveals an unsatisfactory stud weld, an additional

stud on each side of the defective stud shall be tested; and
(v)
all defective studs shall be replaced and re-tested.
(i)
Testing of welds shall be carried out by the independent testing consultant.
(j)
Records of weld testing shall be on HOKLAS endorsed certificates and shall

be submitted to the Project Manager for review without objection in a form
suitable for submission to the Buildings Department.

35/36
January 2011
22.6.23 Testing: Fabrication Tolerances

(a)
Rolled and built-up sections of steelwork complying with BS 5400:Part 6 shall

be tested to determine compliance with fabrication tolerances in accordance
with BS 5400:Part 6, Clauses 5.6.1 to 5.6.6.
22.6.24 Testing: Repairs

Defects which have been repaired and adjoining areas which in the opinion of the
Project Manager may have been affected by the repair shall be retested.

36/36
January 2011
SECTION 23 BRIDGEWORKS
23.1
GENERAL
23.1.1
Movement Joints Formed in Place

Movement joints formed in place shall comply with Section 20 except as stated in
this Section.
23.2
23.2.1
Schedule of Bearings
Schedule of bearings is the schedule of bearings stated in the Contract.
23.2.2
Type of Bridge Bearing

Type of bridge bearing is a term used to identify bridge bearings of exactly the
same design and same capacity for all bearing loads, movements and rotations.
23.2.3
Batch: Bridge Bearings

A batch of bridge bearings is any quantity of bridge bearings of the same type
fabricated by the same manufacturer and which for the purpose of testing
elastomeric bearings contains the same type of elastomer.
23.2.4
Fabricated Movement Joint

Fabricated movement joint is a manufactured assembly, including nosings, designed
to carry traffic smoothly over a movement joint and to seal the joint against the
ingress of water and debris.
23.2.5
Movement Joint
Movement joint is a permanent joint or hinge throat which allows expansion,
contraction or angular rotation to occur.
23.2.6
Movement Joint Formed in Place

Movement joint formed in place is a movement joint formed during construction of a
structure to permit adjacent structural elements to move relative to each other
without damage.
23.3
23.3.1
Design of Bridge Bearings

(a)
Bridge bearings shall be designed by the Contractor unless otherwise stated

in the Contract.

Section 23 - Bridgeworks
1/18
January 2011
23.3.2
23.3.3
(b)
The design and manufacture of bridge bearings and the materials used shall
comply with BS 5400:Part 9, including the guidance notes, except as stated in
Clauses 23.3.2 and 23.3.3. Inspection and maintenance of bridge bearings
shall be easy to carry out and the bearings shall be easily replaceable.
(c)
The maximum bearing stress in concrete underlying or overlying a bridge

bearing under the design load at the ultimate limit state shall not exceed 40%
of the specified grade strength of the concrete. Higher bearing stresses may
be adopted provided that sufficient steel reinforcement is provided to resist the
resulting bursting forces and that the bearing stresses are within the limits
stated in Clause 7.2.3.3 of BS 5400:Part 4.
(d)
The deflection of bridge bearings which have a specified zero horizontal

movement in a particular direction shall not exceed 1 mm in that direction
under the maximum horizontal loadings
Design of Sliding Bearings

(a)
Clause 4.3.4.2 of BS 5400:Part 9:Section 9.2 shall not apply to sliding

bearings.
(b)
Stainless steel sliding surfaces of sliding bearings which are attached to

backing plates by mechanical fasteners instead of continuous welding along
the edges shall be bonded to the backing over the full area and supplemented
with peripheral sealing if necessary. Mechanical fixing by peripheral sealing
only shall not be used.
(c)
The design of sliding bearings shall prevent sliding surfaces becoming

contaminated with dirt that would increase the friction coefficient and increase
the rate of wear.
Design of Elastomeric Bearings

The requirements for use of elastomer in elastomeric bearings at subzero
temperatures stated in Clause 3.7.1 of BS 5400:Part 9:Section 9.2 shall not apply.
23.3.4
Design of Guides for Bridge Bearings

The clearance between guides and complementary sliding surfaces of a guided
bearing shall not exceed 1 mm.
23.3.5
Design of Fixings for Bridge Bearings

(a)
Except for elastomeric bearings, bridge bearings, including bearings which are
not required to provide horizontal restraint, shall be fixed to the superstructure
and substructure with mechanical fixings or by other methods reviewed
without objection by the Project Manager. The Contractor may propose to use
friction between the bearing and the superstructure or substructure to resist
the horizontal forces provided he shall apply a factor of safety of at least 2 to
the proven coefficient of friction and that the worst combination of vertical load
and horizontal load is considered.
(b)
The ultimate capacity of the mechanical fixings for bridge bearings shall not be
less than the worst combination of loading at ultimate limit state stated in the
schedule of bearings.

2/18
January 2011
23.3.6
Design of Fabricated Movement Joints

(a)
Fabricated movement joints shall be a proprietary type reviewed without

(b)
Fabricated movement joints shall be capable of withstanding the following

loads, either separately or in combination:
(i)
(ii)
vertically: two 112.5 kN wheel loads, 1 m apart, each spread over a

contact area giving an average pressure of 1 MPa and applied in such a
manner as to produce the worst possible effect; and
horizontally: a traction force of 75 kN/m run of the joint applied
perpendicular to the alignment of the joint, together with any forces
arising from strain of the joint.
Allowance for additional loading due to impact is not necessary.
23.3.7
(c)
Fabricated movement joints shall accommodate the movements and rotations

stated in the Specification without damaging the joint and without loading the
supporting structure with forces which arise from strain of the joint exceeding
5 kN/m run of the joint.
(d)
Fabricated movement joints shall either be watertight or provided with a

drainage layer or channel to collect water passing through the joint and to
divert the water away from the underlying structure.
(e)
Fabricated movement joints shall provide easy clearance of grit or silt entering
slots, grooves or channels forming or associated with the joint.
(f)
Surfaces of fabricated movement joints which will be exposed at finished road

level shall provide a resistance to skidding not less than that of the adjacent
road surface.
(g)
Fabricated movement joints shall not impair the riding quality of the road
surface for vehicular traffic and the passage of vehicular traffic shall not cause
undue noise or vibration. The size of gaps, including gaps sealed with flexible
material, on the riding surface of the joint shall not exceed 65 mm.
(h)
The passage of pedestrians and cyclists shall not be impeded or endangered

by fabricated movement joints.
Design of Fixings for Fabricated Movement Joints

(a)
The holding down and fixing arrangements for fabricated movement joints
shall be capable of withstanding the loads stated in Clause 23.3.6(b). The
diameter of bolts fixed as double row bolts on one side shall be at least 12 mm
and the diameter of other holding down bolts and studs shall be at
least 16 mm.
(b)
Fixings for fabricated movement joints shall be compatible with the

reinforcement in the underlying concrete. Any revisions to the reinforcement
required to suit the fixings shall be designed by the Contractor and submitted
to the Project Manager for review without objection.

3/18
January 2011
23.4
MATERIALS
23.4.1
Prefabricated Sheeting
23.4.2
23.4.3
(a)
Prefabricated sheeting for waterproofing shall be a proprietary type reviewed

(b)
Prefabricated sheeting shall not rot or support the growth of mildew and shall
be compatible with the materials with which it is in contact. Prefabricated
sheeting which will be exposed to sunlight after installation shall be of a type
unaffected by ultraviolet light.
(c)
Prefabricated sheeting shall have a tensile strength, pliability and puncture

resistance such that the sheeting will withstand the stresses induced during
handling and laying without damage.
The elongation properties of
prefabricated sheeting shall be such that the sheeting can accommodate the
creep, shrinkage and thermal movements of concrete without distress.
(d)
Prefabricated bituminous sheeting shall be a self-adhesive, self-sealing type

and shall have a thickness of at least 1.2 mm.
(e)
Prefabricated rubberised base sheeting shall be of a type which is unaffected

by fuels, oils or grease.
(f)
Primers and mastic for prefabricated sheeting shall be a proprietary type

recommended by the sheeting manufacturer and reviewed without objection
Bentonite Panels
(a)
Bentonite panels shall consist of bentonite filler enclosed in self-degradable

boards. The panels shall have a permeability of less than 1 x 10-7mm/sec
under simulated test conditions similar to those of the as-built conditions. The
performance of bentonite panels shall not be affected by contaminants present
in the groundwater.
(b)
Bentonite panels for slabs less than 200 mm thick or with soil cover of less
than 450 mm shall be special panels with specific provision for swelling to
prevent lifting of the slab.
(c)
Bentonite joint seal and bentonite granules shall be a proprietary type

recommended by the bentonite panel manufacturer and reviewed without
(d)
Polyethylene sheeting for use with bentonite panels shall be a heavy duty
type.
Delivery of Bentonite Panels

Bentonite panels shall be delivered in original unbroken packages bearing the
manufacturer's label.

4/18
January 2011
23.4.4
23.4.5
Storage of Materials for Waterproofing Systems

(a)
Prefabricated sheeting and bentonite panels shall be stored in accordance

with the manufacturers' recommendations in a dry weatherproof store with a
raised floor.
(b)
Bituminous paint shall be stored in sealed containers

contents and protected from exposure to conditions
bituminous paint. The bituminous paint shall be stored
manufacturer's recommendations and shall not
recommended shelf life has been exceeded.
marked to identify
which may affect
in accordance with
be used after
the
the
the
the
Bituminous Paint
Bituminous paint for waterproofing shall be cut-back bitumen complying with
BS 3690:Part 1. The bitumen shall have a viscosity grade as determined by a
standard tar viscometer within the range 25 - 50 seconds with a coverage of
0.5 L/m2. Primers for bituminous paint shall be a proprietary type recommended by
the bituminous paint manufacturer and reviewed without objection by the Project
Manager.
23.4.6
Holding Down Bolts for Bridge Bearings

Holding down bolts for bridge bearings shall be a proprietary type reviewed without
23.4.7
23.4.8
Cement Mortar, Grout and Adhesive for Bridge Bearings

(a)
Cement mortar for bedding and construction of unreinforced plinths for bridge
bearings shall be a proprietary non-shrink type with a grade strength of at
least 50 MPa reviewed without objection by the Project Manager.
(b)
Chemical-resin mortar for the construction of plinths for bridge bearings shall
be a proprietary non-shrink type with a grade strength of at least 50 MPa
(c)
Grout for grouting base plates and holding down bolts shall be a proprietary
non-shrink cementitious type with a grade strength of at least 50 MPa
reviewed without objection by the Project Manager. The grout shall readily
flow under base plates and shall not bleed or segregate. The suitability of the
grout shall be demonstrated by Site trials and reviewed without objection by
(d)
Adhesives and chemical resin mortars for locating and bedding elastomeric
bridge bearings shall be a proprietary type reviewed without objection by the
Project Manager. They shall be compatible with the elastomer.
Dowel Bars for Bridge Bearings

Dowel bars for bridge bearings shall be Grade 316 S 31 or 316 S 33 stainless steel
complying with BS 970:Part 1.

5/18
January 2011
23.4.9
Protective Coatings to Bridge Bearings

Metal components of bridge bearings shall be protected against corrosion by a
protective coating complying with, and selected in accordance with, BS 5493. For
the purpose of selecting the coating system, the environment shall be classified as
'exterior exposed - polluted coastal' and the typical time to first maintenance shall be
'very long' (20 years or more).
23.4.10 Marking of Bridge Bearings

(a)
Bridge bearings shall be marked by the manufacturer either with the type
numbers stated in the schedule of bearings or with the manufacturer's own
type or other numbers. A schedule shall be provided which relates the
manufacturer's own type or other numbers to the type numbers stated in the
schedule of bearings.
(b)
The design movement directions and magnitudes and the axes of bearing
shall be marked on the upper faces of bridge bearings to facilitate checking of
the installation. Movement indicators shall be provided for sliding and roller
bearings to permit checking of movements of the bearings before and after
installation.
23.4.11 Vehicular Parapets

(a)
Vehicular parapets shall be of the types stated in the Contract.
(b)
Steel for vehicular parapets, including welding, shall comply with Section 18
except that the requirements for testing shall not apply.
(c)
Protective treatment to steel for vehicular parapets shall comply with

Section 18 and shall be applied after welding, drilling and cutting is complete.
(d)
Aluminium for vehicular parapets shall comply with the following:

Wrought aluminium and aluminium alloys for general engineering purposes
(i)
: BS 1470
(ii)
rivet, bolt and screw stock
: BS 1473
(iii)
bars, extruded round tubes and sections
: BS 1474.
(e)
(f)
Welding of aluminium for vehicular parapets shall comply with the following:
(g)
TIG welding of aluminium, magnesium and their alloys

BS 3019:Part 1; and
(h)
Aluminium and aluminium alloys
(i)
Stainless steel bolts, nuts and washers for vehicular parapets shall be Grade
A4-80 and shall comply with BS 6105.

6/18
: BS 3571:Part 1
January 2011
23.4.12 Holding Down Bolts for Vehicular Parapets

Holding down bolts for vehicular parapets shall be a proprietary type reviewed
23.4.13 Grout for Vehicular Parapets
Grout for holding down bolts for vehicular parapets shall be based on polyester
resins and shall be a proprietary type reviewed without objection by the Project
Manager.
23.4.14 Joint Filler
Joint filler for movement joints formed in place shall be non-absorbent.
23.4.15 Joint Sealant
(a)
Joint sealant for movement joints formed in place shall be a polysulphidebased sealant. Polyurethane-based sealant shall not be used.
(b)
Joint sealant shall be resistant to attack by petrol, diesel oil, dilute acids and
alkalis, synthetic and mineral oils, hydraulic fluids and paraffin. The sealant
shall have a transverse butt joint movement range for repeated cyclic
movement of at least 25% of the width of the joint.
23.4.16 Compression Seals

Compression seals shall be a proprietary type reviewed without objection by the
Project Manager and shall be manufactured from natural rubber, neoprene or other
synthetic material. Compression seals shall have the dimensions specified by the
manufacturer for each joint width.
23.4.17 PVC Capping Strip
PVC capping strip shall be a proprietary type reviewed without objection by the
Project Manager.
23.4.18 Holding-down Bolts for Movement Joints
Holding-down bolts for movement joints shall be a proprietary type reviewed without
23.4.19 Grout for Movement Joints
Grout for holding-down bolts for movement joints shall be based on polyester resins
and shall be a proprietary type reviewed without objection by the Project Manager.

7/18
January 2011
23.5
SUBMISSIONS
23.5.1
Particulars of Waterproofing Systems

(a)
The following particulars of the proposed waterproofing systems shall be

(i)
manufacturer's literature and a certificate for prefabricated sheeting

and showing that the prefabricated sheeting complies with the
Specification including results of tests for:
23.5.2
(ii)
manufacturer's literature and a certificate for bentonite panels showing

showing that the bentonite panels comply with the Specification
including results of tests for permeability;
(iii)
manufacturer's literature and a certificate for bituminous paint showing

showing that the bituminous paint complies with the Specification
including results of tests for viscosity;
(iv)
particulars of primers and mastic for prefabricated sheeting, bentonite

joint seal and bentonite granules and primers for bituminous paint; and
(v)
methods of laying prefabricated sheeting and bentonite panels.
Representative Samples of Materials for Waterproofing Systems

(a)
23.5.3
tensile strength;
pliability;
puncture resistance; and
elongation;
Representative samples of the following proposed materials for waterproofing

systems shall be submitted to the Project Manager for review without
objection:
(i)
prefabricated sheeting; and
(ii)
bentonite panels.
Particulars of Bridge Bearings

(a)
The following particulars of the proposed bridge bearings shall be submitted to

the Project Manager for review without objection:
(i)
details of type of bridge bearings, including materials, and the name and
address of the manufacturer;
(ii)
design calculations, including calculations of bearing stresses above

and below the bearings and calculations for bursting or other necessary
additional or revised reinforcement;
(iii)
Contractors Drawings of bearings including installation thereof and any

additional or revised reinforcement details;

8/18
January 2011
(iv)
a certificate for each type of bridge bearing showing the manufacturer's

name, the date and place of manufacture and showing that the bridge
bearings comply with the Specification including results of:
friction tests;
load tests;
tests on elastomers;
quick production tests; and
stiffness tests;
(v)
values of stiffness in compression and in shear of elastomeric bearings;
(vi)
details of fixings to superstructures and substructures;
(vii) details of protective coatings;

(viii) methods of installation; and
(ix)
23.5.4
programme of manufacture, testing and delivery, including name and

address of testing laboratory.
Representative Samples of Materials for Vehicular Parapets

Representative samples of the proposed posts and rails for vehicular parapets shall
23.5.5
Particulars of Movement Joints

(a)
The following particulars of the proposed movement joints shall be submitted

to the Project Manager for review without objection:
(i)
details of type of movement joint and the name and address of the
manufacturer;
(ii)
design calculations and Contractors Drawings;
(iii)
details of fixings, including the size, length and spacing of holding down
bolts and any necessary revisions to the reinforcement;
(iv)
details of materials for making good adjoining road surfaces and

nosings, including reinforcement, jointing and curing details;
(v)
programme of manufacture, testing and delivery; and
(vi)
for fabricated movement joints, a written undertaking from the Contractor

stating that the movement joint supplier shall install the proposed
movement joint.

9/18
January 2011
23.6
WORKMANSHIP
23.6.1
Installation of Waterproofing Systems
23.6.2
23.6.3
(a)
Surfaces on which waterproofing systems will be laid shall be clean, dry and
free from voids, loose aggregate, sharp protrusions, projecting tying wire,
release agents and other items or substances which are likely to damage or
affect the waterproofing system.
(b)
Waterproofing systems shall be laid in accordance with the manufacturer's

recommendations.
(c)
Before waterproofing systems are laid on concrete surfaces, the concrete

surface shall have been cured for at least 7 days and shall be cleaned with a
broom and sealed with one coat of primer. Primed surfaces shall not be
covered until the solvent constituent has evaporated. Water shall be allowed
to evaporate from primers containing bituminous emulsion before the surface
is covered. Primed surfaces shall be protected from contamination
Installation of Prefabricated Sheeting

(a)
Prefabricated sheeting shall be laid one sheet at a time from low points and
drains, towards high points. The sheeting shall be firmly and tightly brought
into contact with the primer or underlying sheeting.
(b)
Laps shall be formed at joints between individual sheets of prefabricated

sheeting. End laps shall be at least 150 mm and side laps shall be at least
100 mm. Joints shall be arranged in such a manner that the number of layers
of sheeting at any joint does not exceed three.
(c)
The perimeter of prefabricated sheeting laid each day shall be sealed with a
trowelled bead of mastic.
(d)
A double layer of prefabricated sheeting shall be laid around pipes, posts or

other components which pass through the sheeting and the edges shall be
sealed with a trowelled bead of mastic.
Installation of Bentonite Panels

(a)
Bentonite panels shall not be laid in water or during wet weather.
(b)
Immediately before bentonite panels are laid on a surface, joints and cracks in
the surface shall be sealed with bentonite joint seal.
(c)
Polyethylene sheeting shall be laid below and above bentonite panels to

prevent prehydration. Laps of at least 100 mm shall be formed at joints in the
sheeting.
(d)
Laps shall be formed at the edges of bentonite panels or the edges shall be
closely butted together and the seam filled with loose bentonite granules.
(e)
Bentonite panels shall not be fixed to the underlying surface unless permitted
by the Project Manager. If permitted, the method of fixing shall be by 25 mm
masonry washerhead nails or by other methods reviewed without objection by

10/18
January 2011
23.6.4
(f)
Bentonite panels shall be laid continuously around wall bases and corners.
Flat panels shall not be folded or bent if the panels will be damaged or
bentonite filler will be lost.
(g)
Bentonite which is exposed at the edges of bentonite panels cut to fit around
pipes, posts or other components which pass through the panel shall be taped
or sealed by other methods reviewed without objection by the Project Manager
to prevent loss of the bentonite filler. The joint between panels and the pipe,
post or component shall be sealed with a continuous bentonite seal.
(h)
Exposed bentonite panels shall be protected from moisture by polyethylene

sheeting unless panels with a water repellent coating are used. The sheeting
shall be removed before fill material is deposited. As soon as practicable after
each course of panels has been laid, fill material shall be deposited and
compacted up to a level which is within 50 mm of the top edge of the panel.
(i)
Damaged or expanded bentonite panels shall be not be used.
Bituminous Paint Waterproofing Systems

Surfaces to which bituminous paint will be applied shall be treated with a primer
before the paint is applied if recommended by the paint manufacturer. Bituminous
paint shall be applied in two coats; the first coat shall be allowed to dry before the
second coat is applied.
23.6.5
Installation of Bridge Bearings

(a)
Bridge bearings shall be installed as recommended in BS 5400:Part 9 and as

stated in Clauses 23.6.5(b) to (g).
(b)
Bridge bearings which have been pre-assembled shall not be dis-assembled.
(c)
The levels of substructures stated in the Contract on which bridge bearings

will be installed shall be adjusted to suit the thickness of the bearing so that
the superstructure will be at the specified level after completion.
(d)
Bridge bearings, other than elastomeric bridge bearings, shall be set level on
substructures using only a thin layer of cementitious mortar, unless the Project
Manager permits the bearings to be set on plinths. If setting on plinths is
permitted, the plinths shall be constructed of cementitious mortar or grout,
unless otherwise reviewed without objection by the Project Manager, and the
thickness of such plinths shall be at least 25 mm and shall not exceed 40 mm.
If reviewed without objection by the Project Manager, the plinths may be
constructed of chemical resin mortar, having a thickness of at least 5 mm and
not exceeding 10 mm.
(e)
Elastomeric bearings shall be set directly on the substructure. A thin layer of

cementitious mortar may be used to level the surface if the substructure is
concrete. Elastomeric bearings shall not be set in position by grouting
between the substructure and the underside of the bearing.
(f)
The top surface of bridge bearings which will support precast concrete or other
prefabricated beams shall be covered with a thin layer of cementitious mortar
immediately before the beam is placed. The beam shall be temporarily
supported on folding wedges until the mortar has achieved sufficient strength
to transmit the weight of the beam to the bearings. Thereafter the temporary
supports shall be removed.

11/18
January 2011
(g)
23.6.6
23.6.7
23.6.8
Temporary locking devices for bridge bearings shall be removed before

post-tensioned superstructures are stressed. Temporary locking devices for
other types of superstructures shall be removed at times reviewed without
Tolerances: Bridge Bearings

(a)
The centreline of bridge bearings shall be within 3 mm of the specified

position.
(b)
The level of bridge bearings shall be within 0.0001 times the adjacent span or
the lesser of the adjacent spans or within 5 mm of the specified level,
whichever is less.
(c)
The inclination of bridge bearings shall be within 1 in 200 of the specified

inclination.
(d)
The horizontal axis of bridge bearings shall be within 0.005 radian of the
specified alignment.
(e)
Departure from the common plane between twin or multiple bridge bearings
shall be within the tolerances stated in the Contract.
Installation of Vehicular Parapets

(a)
Vehicular parapets shall be installed to a smooth alignment and with the posts
vertical.
(b)
Grouting shall be carried out by setting the vehicular parapets in position and
grouting the gap between the vehicular parapets and the structure. Vehicular
parapets shall be held in position until connections and fixings are complete
and until the fixings have gained sufficient strength.
Tolerances: Vehicular Parapets

Vehicular parapets shall be within 10 mm of the specified position and height.
23.6.9
Installation of Fabricated Movement Joints

(a)
Fabricated movement joints shall be installed in accordance with the

manufacturer's recommendations. The Contractor shall provide that
installation of the movement joint shall be carried out by the supplier of the
movement joint.
(b)
The vertical faces of recesses in bridge decks for fabricated movement joints
shall be formed by saw-cutting. Holding-down bolts shall be cast into the
concrete for direct mounting of the joints unless the Project Manager permits
the bolts to be grouted. If grouting is permitted, the grouting shall be carried
out by setting the movement joint in position and grouting the gap between the
movement joint and the structure. Rebates and pockets for subsequent
trimming to line and level or for holding-down bolts shall not be used.
(c)
The bedding to fabricated movement joints shall be formed such that there
shall be no gaps between the joint and the bedding.

12/18
January 2011
(d)
Relative movement between components and supports of a fabricated

movement joint shall be prevented during installation of the joint and during
placing and hardening of concrete and mortar under the components. Joint
components shall be free to move longitudinally relative to each other.
(e)
When one side of a fabricated movement joint is being set, the other side shall
be free from longitudinal restraint. Strongbacks or templates used to locate
the sides of a joint shall not be fixed to both sides at any one time.
23.6.10 Road Surface Adjoining Fabricated Movement Joints

(a)
The gap between fabricated movement joints and the adjoining road surface
or nosing shall be made good after installation of the joint with material which
has properties as similar as practicable to those of the material in the adjoining
road surface.
(b)
Bituminous road surfaces shall be made good with a bituminous mixture or

elastomeric concrete. Concrete road surfaces shall be made good with a
cementitious matrix reinforced with metal or glass fibres or with elastomeric or
polymer concrete. Epoxy resin mortar shall not be used.
(c)
Elastomeric and polymer concrete shall be prepared, laid and cured in

23.6.11 Protection of Fabricated Movement Joints

(a)
The Project Manager shall be notified before Contractor's Equipment or other

vehicles cross a fabricated movement joint or the adjacent road surface.
(b)
Contractor's Equipment or other vehicles shall not cross fabricated movement

joints or adjacent road surfaces until installation of the joint is complete unless
reviewed without objection by the Project Manager. Ramps shall be provided
to allow the vehicles to cross without loads being applied to the joint.
23.6.12 Forming Movement Joints

Gaps forming part of movement joints formed in place shall be filled with joint filler
fixed in position with adhesive. The edge of the joint filler shall be covered with
bond breaker tape or a PVC capping strip.
23.6.13 Forming Grooves
Grooves for joint sealant and compression seals for movement joints formed in
place shall be formed by saw cutting.
23.6.14 Sealing Grooves
Grooves for movement joints formed in place shall be sealed with joint sealant or
with a compression seal.
23.6.15 Tolerances: Fabricated Movement Joints
The surface of fabricated movement joints shall be at least 1 mm, and not more than
3 mm, below the surrounding road surface.

13/18
January 2011
23.7
INSPECTION TESTING AND COMMISSIOINING
23.7.1
Testing: Bridge Bearings
23.7.2
(a)
Bridge bearings shall be tested by the Contractor at a laboratory reviewed

(b)
The Contractor shall inform the Project Manager of the date and place of
testing at least 28 days before testing starts.
(c)
The procedures for testing bridge bearings shall be submitted to the Project
Manager for review without objection and thereafter shall not be changed.
(d)
The reports of tests on bridge bearings shall include load/deflection graphs

and shall be submitted to the Project Manager for review without objection at
least 28 days before installation of the bridge bearings is programmed to start.
Samples: Friction Test for Bridge Bearings

One sample of bridge bearing shall be provided from each batch of sliding bearings
and from each batch of other types of bridge bearings which contain sliding parts.
23.7.3
23.7.4
Testing: Friction Test for Bridge Bearings

(a)
The friction test shall be carried out on each sample of bridge bearing
provided as stated in Clause 23.7.2 to determine the coefficient of friction,
flatness, bonding properties and resistance to mechanical damage. The
method of testing shall be in accordance with Appendix A23.1.
(b)
The friction test shall be carried out at room temperature.
Compliance Criteria: Friction Test for Bridge Bearings

(a)
The results of friction tests for bridge bearings shall comply with the following
requirements:
(i)
the coefficient of friction in any test position shall not exceed 0.04;
(ii)
the flatness of the stainless steel shall be within the specified limits
after testing;
(iii)
the bond to the backing plate shall be unaffected by the friction test;
and
(iv)
23.7.5
PTFE shall be free from mechanical damage after testing.
Samples: Bridge Bearings other than Elastomeric Bearings

One sample of bridge bearing shall be provided from each batch of bridge bearings
other than elastomeric bearings.

14/18
January 2011
23.7.6
Testing: Bridge Bearings other than Elastomeric Bearings

Vertical load tests and horizontal load tests shall be carried out on each sample of
bridge bearing provided as stated in Clause 23.7.5. The test loads shall be the
serviceability limit state loads. The method of testing shall be in accordance with
Clause 7.2(b)(1) of the guidance notes to BS 5400:Section 9.2.
23.7.7
Compliance criteria: Bridge Bearings other than Elastomeric Bearings

The results of tests on bridge bearings other than elastomeric bearings shall comply
with the requirements stated in Clause 7.2(b)(1) of the guidance notes to
BS 5400:Section 9.2.
23.7.8
23.7.9
Samples: Elastomeric Bearings

(a)
Except as stated in Clause 23.7.8(b), one sample of elastomeric bearing shall

be provided from each batch of elastomeric bearings for testing by the "Quick
Production Test".
(b)
If the Contractor considers there is sufficient evidence that Quick Production

Tests have been successfully completed on identical materials in the previous
18 months he may submit the evidence to the Project Manager and propose
that the tests are not necessary. The Project Manager will respond within 14
days of the date of receipt of the submission.
(c)
Two samples of elastomeric bearings shall be provided from each batch of ten
or part thereof of elastomeric bearings to determine the stiffness in
compression and stiffness in shear.
Testing: Elastomeric Bearings

(a)
Each sample of elastomeric bearing provided as stated in Clause 23.7.8(a)

shall be tested to determine the physical and weathering properties of the
elastomer and the bond of the elastomer to metal. The method of testing shall
be the "Quick Production Test" in accordance with the guidance notes to
BS 5400:Section 9.2.
(b)
One sample of elastomeric bearing provided as stated in Clause 23.7.8(c)

shall be tested to determine the stiffness in compression and the other sample
shall be tested to determine the stiffness in shear. The method of testing to
determine the stiffness in compression shall be in accordance with
Clause 7.2(b)(2) of the guidance notes to BS 5400:Section 9.2. The method
of testing to determine the stiffness in compression shall be in accordance
with BS 5400:Section 9.2, Appendix A.
23.7.10 Compliance Criteria : Elastomeric Bearings

(a)
The results of tests on elastomeric bearings shall comply with the following
requirements:
(i)
Pthere shall be no evidence of surface flaws in the bearings during or

after the test;
(ii)
there shall be no irregularities in the deflected shape of laminated

bearings during or after the test;

15/18
January 2011
(iii)
the stiffness in compression shall be within 20% of the value quoted by

the manufacturer and reviewed without objection by the Project
Manager; and
(iv)
the stiffness in shear shall be within 20% of the value quoted by the
manufacturer and reviewed without objection by the Project Manager.

16/18
January 2011
APPENDIX A23.1
FRICTION TEST FOR BRIDGE BEARINGS
A23.1.1 Scope
This method covers the determination of the coefficient of friction, flatness, bonding
properties and resistance to mechanical damage of bridge bearings by means of a
friction test.
A23.1.2 Equipment
(a)

(i)
compression testing rig;
(ii)
test loads;
(iii)
equipment for measuring the loads applied, readable and accurate to

within 2% of the measured load;
(iv)
equipment for measuring movement, readable and accurate to

0.01 mm; and
(v)
lubricant of the same type as will be used in service.
A23.1.3 Procedure
(a)

(i)
the PTFE surface of the bearing shall be lubricated with the lubricant;
(ii)
two sets of sliding surfaces shall be mounted back to back between

the platens of the compression testing rig with the stainless steel
sliding surfaces in the center;
(iii)
a vertical load equal to the permanent load stated in the schedule of

bearings shall be applied for 1 hour;
(iv)
a horizontal load shall then be applied steadily and without shock to

the pair of stainless steel sliding surfaces and shall be increased at a
rate of 0.2% of the vertical load per minute until movement occurs
between the sliding surfaces;
(v)
the maximum horizontal load sufficient to cause movement of at least

25 mm between the stainless steel and PTFE sliding surfaces at a rate
not exceeding 50 mm/min shall be recorded;
(vi)
the loads shall be removed; and
(vii)
the sliding surfaces shall be removed from the rig and inspected.

17/18
January 2011
A23.1.4 Calculation
(a)
The coefficient of friction shall be calculated from the equation:

Maximum horizontal force
Coefficient of friction =
2 x vertical load

(a)

(i)
name of bearing manufacturer;
(ii)
details of bearing and sliding surfaces;
(iii)
the vertical load applied;
(iv)
the maximum horizontal force applied;
(v)
the total movement and rate of movement at the maximum horizontal

force applied;
(vi)
the coefficient of friction to two significant figures;
(vii)
details of any damage to the sliding surfaces; and
(viii)
that the test method used was in accordance with this General

18/18
January 2011
SECTION 24 WATER RETAINING STRUCTURES
24.1
GENERAL
(a)
The works and materials specified below shall comply with the sections
(i)
earthworks shall comply with Section 7;
(ii)
formwork and finishes to concrete shall comply with Section 18;
(iii)
steel reinforcement shall comply with Section 19;
(iv)
concrete shall comply with Section 20;
(v)
joints in concrete shall comply with Section 20; and
(vi)
drainage systems shall comply with Section 6.
24.2
24.2.1
Water Retaining Structure

Water retaining structure is a structure, or part of a structure, including walls, floors,
roofs, columns and footings, which is stated in the Contract to be constructed for
storing, conveying or excluding water, sewage or other aqueous liquids.
24.3
MATERIALS
24.3.1
Sliding Layers
Sliding layers below floor slabs of water retaining structures shall be a proprietary
type of polyethylene sheeting reviewed without objection by the Project Manager.
1.1 mm.
24.4
SUBMISSIONS
24.4.1
Particulars of Sliding Layers

Particulars of the source and type of proposed sliding layers for water retaining
structures shall be submitted to the Project Manager for review without objection.

Section 24 Water Retaining Structures
1/7
January 2011
24.4.2
Particulars of Materials and Methods of Construction for Water Retaining

Structures
(a)

construction for water retaining structures shall be submitted to the Project
(i)
(ii)
sequence and method of concreting bays in floor slabs, walls and roof
slabs and in columns and footings;
details of alternative locations of construction joints if required;
(iii)
details of type and size of waterstops at construction joints and boxouts;
(iv)
sequence and method of testing roofs for watertightness; and
(v)
details of method of testing water retaining structures for watertightness

including:
24.4.3
arrangement of pumps and equipment;

source of water;
equipment for measuring fall in water level;
device for dampening the oscillatory motion of the water surface;
filling rate; and
method of correction for evaporation and rainfall.
Representative Samples of Sliding Layers

Representative samples of the proposed sliding layers for water retaining structures
shall be submitted to the Project Manager for review without objection.
24.5
WORKMANSHIP
24.5.1
Drainage Systems
Measures shall be taken to prevent concrete and deleterious material from being
deposited in drainage systems under floors and on roofs of water retaining
structures. After construction and before testing, the drainage system shall be
thoroughly cleaned by rodding and flushing to remove any deleterious material
which may impede the flow of water into or through the drainage system. The lines
and levels of drainage systems shall be within 20 mm of the specified horizontal
alignment and within 10 mm of the specified vertical alignment.
24.5.2
Laying Sliding Layers

Polyethylene sheeting in sliding layers below floor slabs of water retaining
structures shall be laid flat without creases. Laps shall be at least 225 mm and
there shall be no gaps at the edges of bays.

2/7
January 2011
24.5.3
Floor Slabs of Water Retaining Structures

Except as otherwise stated on the Employer's Drawings, if reinforcement is
continuous across the joint between bays in the floor slab of water retaining
structures, the bays shall be concreted contiguously, in sequence, with a minimum
period of 48 hours between completion of concreting one bay and commencement
of concreting the adjacent bay.
24.5.4
24.5.5
Walls of Water Retaining Structures

(a)
Except as otherwise stated on the Employer's Drawings, if reinforcement is

continuous across the joint between bays in the wall of water retaining
structures, the bays shall be concreted contiguously, in sequence, with a
minimum period of 72 hours between the completion of concreting the lift in
one bay and commencement of concreting the adjacent lift in the adjacent
bay.
(b)
The first lift in each bay in the walls of water retaining structures shall be
concreted within seven days after completion of concreting the adjacent base
of the wall. Individual lifts shall be concreted in one continuous operation
without cold joints, whether or not the full height of the wall is concreted in one
lift. If the full height of the wall is not placed in one lift, succeeding lifts shall
be concreted within seven days from concreting of the adjacent lift.
Roof Slabs of Water Retaining Structures

If reinforcement is continuous across the joint between bays in the roof slab of
water retaining structures, the bays shall be concreted contiguously, in sequence,
with a minimum period of 48 hours between completion of concreting one bay and
commencement of concreting the adjacent bay.
24.5.6
Built-in Pipes in Water Retaining Structures

Unless otherwise stated in the Contract, puddle flanges on built-in pipes in water
retaining structures shall be located centrally within the formwork. Waterstops shall
be fixed around the perimeter of box-outs to the built-in pipes.
24.5.7
24.5.8
Protection of Water Retaining Structures

(a)
Immediately after the roof slab of water retaining structures has been tested,
the slab shall be protected with damp sacks or by other methods reviewed
without objection by the Project Manager from exposure to conditions which
may affect the slab; the protection shall be continued until the roof drainage
system has been constructed or the fill material has been deposited and
compacted.
(b)
Materials shall not be stockpiled on roof slabs of water retaining structures.

Contractor's Equipment or other vehicles shall not stand or run on floor slabs
or roof slabs of water retaining structures.
Deposition of Fill Material

(a)
Fill material shall not be deposited behind sections of walls of water retaining
structures until at least seven days after completion of concreting to the
section of wall.

3/7
January 2011
24.5.9
(b)
Fill material shall be spread out evenly and shall not be stockpiled on roofs to
water retaining structures. Weed killer or other chemicals shall not be applied
to fill material on the roofs of water retaining structures for potable or fresh
water.
(c)
Deposition of fill material on or adjacent to water retaining structures shall be

carried out after the watertightness test on the structure has been completed.
Cleaning and Sterilisation of Water Retaining Structures

(a)
Immediately before water retaining structures are tested for watertightness, all
dust, debris, unused materials and equipment shall be removed from the
structure and the interior of the structure shall be washed and brushed down
with water.
(b)
Water for washing water retaining structures for potable or fresh water shall
be fresh, potable water incorporating a mixture of sterilising chemicals added
before the structure is washed at a concentration reviewed without objection
by the Project Manager. The structure shall be maintained in a clean condition
after cleaning.
24.6
INSPECTION TESTING AND COMISSIONING
24.6.1
Testing: Drainage Systems for Water Retaining Structures

(a)
24.6.2
(i)
water shall be poured at different locations directed by the Project

Manager along the drainage system and the flow of water observed at
junction pits, outfalls and other discharge points; and
(ii)
a mandrel shall be pulled through each completed section of pipeline of

300 mm diameter or less. The mandrel shall be 750 mm long and
12 mm less in diameter than the nominal diameter of the pipe.
Compliance Criteria: Drainage Systems for Water Retaining Structures

(a)
24.6.3
Drainage systems under floors and on roofs of water retaining structures shall
be tested in accordance with the following requirements:
The results of tests on drainage systems for water retaining structures shall
comply with the following requirements:
(i)
water shall be freely discharged by the drainage system; and
(ii)
bore, linearity and jointing of pipes shall comply with the specified
requirements.
Non-compliance: Drainage Systems for Water Retaining Structures

If the result of any test on the drainage system for water retaining structures does
not comply with the specified requirements for the test, the Contractor shall
investigate the reason. Remedial or replacement work reviewed without objection
by the Project Manager shall be carried out and the drainage system shall be
retested.

4/7
January 2011
24.6.4
24.6.5
Testing: Watertightness of Roofs

(a)
The roofs of water retaining structures shall be tested for watertightness over
the complete area of the roof, including perimeter joints. Roofs shall not be
tested in sections.
(b)
Water shall be ponded on the roof for a period of three days and topped up to
maintain a depth of at least 75 mm. The test shall be carried out before fill
material is deposited or drainage systems are constructed on the roof.
Compliance Criteria: Watertightness of Roofs

There shall be no leaks or damp patches visible on the soffits of roofs of water
retaining structures during or at the end of the test for watertightness.
24.6.6
Non-compliance: Watertightness of Roofs

If the result of any test for watertightness of the roof of a water retaining structure
does not comply with the specified requirements for the test, the Contractor shall
investigate the reason. Remedial or replacement work reviewed without objection
by the Project Manager shall be carried out and the roof shall be retested.
24.6.7
Testing: Watertightness of Structures

(a)
Water retaining structures shall be tested for watertightness as stated in

Clause 24.6.7 (b) to (g). Each compartment of structures which incorporate
division walls shall be tested separately with adjoining compartments empty
and the complete structure shall also be tested.
(b)
The structure shall be filled with water at an approximately uniform rate not
exceeding 2 m depth in 24 hours to the levels stated in Table 24.1. The water
used for testing water retaining structures for potable or fresh water shall be
fresh potable water. The Project Manager shall be notified before filling starts.
The structure or each compartment of the structure being tested shall be kept
full for 7 days before testing to allow for absorption.
(c)
After the period for absorption, the water shall be topped up to the specified
level and the test shall begin. During testing, the oscillatory motion of the
water surface shall be dampened. The test period shall be 7 days.
(d)
The equipment for recording water levels shall be installed in a temporary

enclosure of minimum dimensions 2 m x 2 m x 2.5 m high with a lockable
door; the enclosure shall be located over stilling wells, manhole openings or
other points of recording water levels. The temporary enclosure shall be
removed on completion of the test. The equipment shall be calibrated before
testing starts and at regular intervals reviewed without objection by the Project
Manager and shall be readable and accurate to 0.5 mm.
(e)
The fall in water level in water retaining structures shall be measured at hourly
intervals between 8 a.m. and 5 p.m. each day; the total fall shall be measured
at the end of the test period.

5/7
January 2011
24.6.8
(f)
Except as stated in Clause 24.6.7(g), structures shall be emptied after

completion of testing and maintained in a clean and dry condition. The water
shall be removed at an approximately uniform rate not exceeding 2 m depth in
24 hours. The Project Manager shall be notified before emptying starts.
(g)
The water used for the final tests on water retaining structures for potable or
fresh water shall be retained in the structure and shall not be wasted or
contaminated.
Compliance Criteria : Watertightness of Structures

(a)
24.6.9
The results of tests for watertightness of water retaining structures shall

comply with the following requirements:
(i)
the total fall in water level at the end of the test period, after adjustment
for evaporation and rainfall, shall not exceed 1/500 times the maximum
specified depth of water in the test or 10 mm, whichever is less; and
(ii)
there shall be no leaks or damp patches visible on the surface of the

structure, including any division walls, during or at the end of the test.
Non-compliance: Watertightness of Structures

If the result of any test for watertightness of a water retaining structure does not
comply with the specified requirements for the test, the Contractor shall investigate
the reason. Remedial or replacement work reviewed without objection by the
Project Manager shall be carried out and the structure shall be retested.
Table 24.1: Test on Water Retaining Structures
Type of structure
Water retaining
structures other than for
sewage
Part of structure tested
Test water level
Structure with division wall
100 mm below top of
- each compartment of structure
division wall

- complete structure
Top water level of

structure
Structure without division wall

- each compartment of structure
Water retaining
structures for sewage
Top water level of

structure
- complete structure
Structure without division wall
24.6.10 Samples: Water Sterilisation

After the test for watertightness of a water retaining structure for potable or fresh
water has been completed, samples of the water in the structure shall be taken by
the Contractor in the presence of the Project Manager. The number of samples and
location of sampling shall be reviewed without objection by the Project Manager.

6/7
January 2011
24.6.11 Testing: Water Sterilisation

Each sample of water shall be tested to determine the bacteriological content.
24.6.12 Compliance criteria: Water Sterilisation
The results of tests for bacteriological content of the water shall demonstrate that
the structure has been adequately sterilized in compliance with the requirements of
the Contract and the Relevant Authorities.

7/7
January 2011

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GENERAL

MATERIALS AND WORKMANSHIP

CIVIL AND STRUCTURAL WORKS

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GENERAL MATERIALS AND WORKMANSHIP SPECIFICATION

CIVIL AND STRUCTURAL WORKS

General Civil and Structural Works

Carriageways: Sub-base Material and Bituminous Materials

Traffic Signs, Road Markings and Road Studs

Work for Electrical and Mechanical Installations

Water Supply Pipeworks

Formwork and Finishes to Concrete

Concrete and Joints in Concrete

Water Retaining Structures

General Architectural Works

Masonry and Blockwork

Waterproofing and Tanking

Roofing and Wall Cladding

General Materials & Workmanship Specification

GENERAL MATERIALS AND WORKMANSHIP SPECIFICATION

ARCHITECTURAL WORKS (CONTD)

Internal Cladding Systems

Carpentry and Joinery

Internal Cladding Systems

Linings, Sheathings, Drywall Partitions and Toilet Cubicles

Architectural Metalwork (Including Metal Doors and Shutters)

Hard Floor Finishes

Flexible Floor Finishes

Painting and Decoration

Fire Protection and Fire Stopping Systems

ELECTRICAL AND MECHANICAL WORKS

General Electrical and Mechanical Works

Low Voltage Switchboards

Sub-Mains Electrical Distribution Equipment

Wiring and Cables

Cable Management Systems

Wiring Accessories and Miscellaneous Electrical Equipment

General Lighting Systems

Uninterruptible Power Supply System (UPS)

High Voltage Electrical Services

Earthing and Bonding System

Lighting Protection System

Inspection, Testing and Commissioning - Electrical Services

General Materials & Workmanship Specification

GENERAL MATERIALS AND WORKMANSHIP SPECIFICATION

ELECTRICAL AND MECHANICAL WORKS (CONTD)

Air Handling units

Fan Coil Units

Split Type Air Conditioning Unit

Window Type Air Conditioning Unit

Air Cooling Coils

Dampers and Air Volume Control Devices

Registers, Diffusers and Grilles

Ductwork and Fittings

Water Handling Equipment

Pipeworks, Fittings and Valves

Noise and Vibration Control

Electrical Equipment and Installation

Testing, Inspection and Commissioning Mechanical Services

Automatic Sprinkler System

Hydrant and Hose Reel System

Gaseous Fire Extinguishing System (FM200)

Fire Alarm and Detection System