Specification C&S

TECHNICAL SPECIFICATION
CIVIL AND STRUCTURAL

PROPOSED SHIP TO SHIP (STS) PORT DEVELOPMENT FOR STS PORT SDN BHD
TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL
1. INTRODUCTION ........................................................................................................................ 4
1.1. SURVEYS - DATUM ............................................................................................................................................. 4
1.2. BATHYMETRIC SURVEY....................................................................................................................................... 4
1.3. MARINE W ARRANTY SURVEYOR .......................................................................................................................... 5
1.4. SOIL INVESTIGATION .......................................................................................................................................... 5
1.5. SETTING OUT .................................................................................................................................................... 7
1.6. AS-BUILT SURVEY ............................................................................................................................................. 8
2. CONCRETE................................................................................................................................ 8
2.1. GRADE ............................................................................................................................................................. 8
2.2. STANDARDS ...................................................................................................................................................... 8
2.3. MATERIALS FOR CONCRETE MARINE CONSTRUCTION ............................................................................................ 8
2.4. CONCRETE DESIGN MIX ................................................................................................................................... 14
2.5 MIXING CONCRETE .......................................................................................................................................... 20
2.6 UNSUITABLE W EATHER .................................................................................................................................... 22
2.7 HOT W EATHER CONCRETING ............................................................................................................................ 22
2.9 CONCRETE SURFACE FINISH............................................................................................................................. 23
2.10 COMPACTION OF CONCRETE ............................................................................................................................. 25
2.11 PRECAST CONCRETE ....................................................................................................................................... 26
2.12 PREPARATION FOR CONCRETING....................................................................................................................... 28
2.13 TRANSPORTING OF CONCRETE.......................................................................................................................... 29
2.14 CONCRETE PLACEMENT ................................................................................................................................... 29
2.15 UNDERWATER CONCRETING ............................................................................................................................. 29
2.16 CONCRETING W ITHIN THE TIDAL RANGE ............................................................................................................ 30
2.17 CURING .......................................................................................................................................................... 30
2.18 DEFECTIVE W ORK ........................................................................................................................................... 31
2.19 PROGRESS INFORMATION ................................................................................................................................. 31
2.20 FORMWORK .................................................................................................................................................... 31
2.21 REINFORCEMENT ............................................................................................................................................. 34
3 STEEL TUBULAR PILING WORKS........................................................................................ 35

3.1 GENERAL ........................................................................................................................................................ 35
3.2 MANUFACTURING AND DELIVERY ....................................................................................................................... 35
3.3 FABRICATION................................................................................................................................................... 36
3.4 SPLICING ........................................................................................................................................................ 37
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3.5 DELIVERY ....................................................................................................................................................... 37

3.6 MARKING ........................................................................................................................................................ 37
3.7 PILE INSTALLATION AND TESTING ...................................................................................................................... 37
3.8 PILE DRIVING EQUIPMENT ............................................................................................................................... 38
3.9 PILE SURVEY .................................................................................................................................................. 38
3.10 HANDLING OF PILES ......................................................................................................................................... 39
3.11 PITCHING AND DRIVING .................................................................................................................................... 39
3.12 ACCURACY OF PITCHING AND DRIVING ............................................................................................................... 39
3.13 PILE DRIVING RECORDS ................................................................................................................................... 39
3.14 DEFINITIONS ................................................................................................................................................... 40
3.15 OBSTRUCTIONS ............................................................................................................................................... 40
3.16 PILE ANCHORS ................................................................................................................................................ 40
3.17 DEFECTIVE AND DAMAGED PILES ...................................................................................................................... 41
3.18 CUT OFFS AND HEAD PREPARATION .................................................................................................................. 41
3.19 PILE TEST ....................................................................................................................................................... 41
3.20 PRE-BORING FOR FOUNDING PILES (W HERE REQUIRED) ..................................................................................... 42
3.21 TEMPORARY BRACING OF PILES ........................................................................................................................ 43
3.22 AS-BUILT PLANS ............................................................................................................................................. 43
4 ACCESSORIES........................................................................................................................ 43
4.1 ACCESS LADDERS ........................................................................................................................................... 43
4.2 HANDRAILS ..................................................................................................................................................... 43
4.3 FENDERS ........................................................................................................................................................ 44
4.4 QUICK RELEASE HOOKS AND CAPSTANS ............................................................................................................ 51
4.5 ALUMINIUM GANGWAY ...................................................................................................................................... 61
5 CORROSION PROTECTION ................................................................................................... 62

5.1 PAINTING ........................................................................................................................................................ 62
5.2 CATHODIC PROTECTION SYSTEM (CP) .............................................................................................................. 68
5.3 QUALIFIED PAINTING INSPECTOR ....................................................................................................................... 71
6 STRUCTURAL STEEL ............................................................................................................ 71

6.1 SCOPE ........................................................................................................................................................... 71
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6.2 GENERAL ........................................................................................................................................................ 71

6.3 APPLICABLE CODES AND STANDARDS ................................................................................................................ 71
6.4 MATERIALS ..................................................................................................................................................... 72
6.5 SUPPLY AND SUBSTITUTION .............................................................................................................................. 73
6.6 SHOP AND W ORKING DRAWINGS ....................................................................................................................... 73
6.7 FABRICATION W ORK ........................................................................................................................................ 73
6.8 WORKMANSHIP ................................................................................................................................................ 74
6.9 CLEARANCES AND TOLERANCES........................................................................................................................ 75
6.10 DETAILS OF CONNECTIONS ............................................................................................................................... 75
6.11 MARKING ........................................................................................................................................................ 75
6.12 ERECTION ....................................................................................................................................................... 76
6.13 FRP PULTRUDED GRATING .............................................................................................................................. 76
6.14 WELDING ........................................................................................................................................................ 77
7 WORKING UNDER TIDAL / WATER CONDITION ................................................................ 83
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1. INTRODUCTION
This Specification is read in conjunction with the other Specification and drawings provided in
the Tender Document. In case of any discrepancy between Technical Specification and
drawings, the Specification shall prevail.
The Contractor shall submit the plans and the method statements to be adopted including
Temporary Works involved for Engineer review at least 30 days prior to commencement of
construction activities. The method statement for each item of the Works shall be provided in
sufficient detail to allow the Engineer to understand fully how the Works are to be executed.
1.1. Surveys - Datum

The level datum adopted is chart datum (CD). This datum shall be used during the construction
of Marine works. The Contractor shall provide and maintain minimum two survey pegs at
convenient locations and intervals for the checking and monitoring of the works.
1.2. Bathymetric Survey

The above survey shall be as follows:
a) Marine Magnetometer Survey Services
A magnetometer measures variation in the earth's magnetic field and can be used to detect
anthropogenic features on the seabed, buried on land or alternatively to assist in the mapping
of geological features. Marine magnetometer survey shall be carried out over area of
approximately 800 Ha. The survey lines at 50m interval over the proposed survey area.
b) Multi Beam Echo Sounder (MBES) System

A Multi Beam Echo Sounder (MBES) is a type of sonar that is used to map the seabed.
Multi beam systems use beamforming to extract directional information from the returning
soundwaves, producing a swath of depth readings from a single ping.
The coverage of MBES data shall be approximately 800 Ha within the project limit. Single
beam Echo Sounder (SBES) shall be use as a quality check for this multi beam survey. SBES
shall be calibrated by bar checks to correct for index error, set the correct draught setting and
ensure that the instrument records the correct depths from the water surface. Bar check shall
be carried out twice a day, before start and at the end of day.
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1.3. Marine Warranty Surveyor

The Contractor shall provide Marine Warranty Surveyor from an approved accredited Marine
Surveyor Company to undertake full time supervision and certify all Marine survey works. The
Contractor to submit details of Marine survey Company to be engaged and curriculum vitae of
Marine Warranty Surveyor for the approval of the Engineer. All Marine survey works to
comply with the Technical Specification and Authority requirements accordingly.
1.4. Soil Investigation

The Contractor shall carry out additional soil investigation to verify the substructure design if
required by Engineer. Soil investigation works shall be carried out prior to the construction
to determine sub-soil profile and subsoil engineering parameters for the geotechnical
design works for the dolphin structures. Geotechnical designs will include consideration
for suitable piling foundations and dredging.
The soil investigation program includes field works e.g. boreholes, CPT and laboratory
testing. All works shall be done as outlined in the Specification.
a) Borehole / CPT
For this soil investigation work, Twenty Four (24) CPT points and Twenty Four (24) boreholes
shall be carried out in offshore deep seas. Approximate locations of these boreholes are
shown in the Soil Investigation Layout Plan. These locations are indicative only and may
be relocated on site to suit site conditions and confirmed by the Engineer’s representative.
Termination depths for the boreholes shall be determine based on the Geophysical report
approximately 60m from the sea bed. Termination depths shall be confirmed by the
Engineer’s representative.
CPT is used to determine the geotechnical engineering properties of soils and soil strata.
Continuous profile of soil parameters, with data recorded at intervals typically of 20 cm but as
small as 1 cm. The strength of the soil at these areas will be assessed by CPT data which will
enable foundation design for the structures to be carried out.
In the event of soft soils being encountered, undisturbed samples shall be collected by
thin- walled tube sampler or piston sample if necessary. For medium stiff soil, undisturbed
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sample shall be collected using thin wall tube sampler. Undisturbed and disturbed soil
samples and rock cores obtained from sampling in boreholes will be sent to the laboratory
for classification strength and chemical tests and report preparation.
b) Laboratory Testing
The type and quantity of the laboratory testing are provisionally covered in the Bill of Quantity
based on the expected soil/water samples collected. The actual testing will be scheduled
after the samples are collected and recorded in the preliminary borehole logs. The
appointed Contractor shall forward to the Engineer the field logs immediately after
completing the borehole for laboratory tests’ scheduling. The types of tests and
standards to be complied with are outlined in the Specification.
c) Setting Out of Borehole

The Contractor shall liaise with the appointed licensed Surveyors for accurate setting out
of borehole and CPT locations and locations of temporary bench mark (TBM) in the open
sea contract area.
A summary of the soil investigation programme is given below:
Type of Investigation
Purpose of
Structures
Investigation Field Laboratory
Breasting dolphin Boreholes taken to bedrock or Classification test,

Piling foundation
and Mooring approximately up to 60m. strength test &
design
dolphin Obtain undisturbed samples chemical test
d) Submission of Report
The Contractor shall submit a preliminary field log to the Engineer once the tests at a
single testing location within the site are completed.
On the completion of the Works, the Contractor shall submit a master copy and additional
copies of the investigation report to the Engineer. Draft report shall be submitted for
Engineer’s comment before final report with all amendment incorporated is submitted.
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The content of the report shall include the followings:

x Scope of work
x Summary of works
x Number of Exploratory Boreholes / CPT including coordinates, reduced levels, depths,
instrumentations, field tests, etc.
x Dates and duration of work
x Procedures of platform at sea and special testing carried out
x Equipment and procedures used (including details of calibrations)
x Key plan and location plans
x Summary of coordinates for every field works done
x Borehole logs
x CPT profiles including soil interpretation
x Summary of quantities of laboratory test
x Laboratory test summary of each Exploratory Holes
x Photographs (progress of work, site conditions, soil samples, rock core etc.)
The draft and final report and all the test results shall be checked, verified and signed by
a Professional Engineer having adequate experiences in geotechnical engineering.
1.5. Setting Out

The Contractor shall submit for the approval by the Engineer, his proposed methods of setting
out the works, establishing a base marks and control during execution. The Contractor shall be
responsible for establishing and locating all lines, levels and limits for the Marine structure works.
The Contractor shall engage a licensed surveyor for the above work. The Contractor shall allow
in his cost for providing all necessary arrangements to allow for the Engineer to monitor and
verify the survey carried out by Contractor’s licensed surveyor.
However, the Contractor shall note that the checking of the setting out by the Engineer shall not
relieve the Contractor of his responsibility of all remedial works required as a result of any error or
inaccuracy.
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1.6. As-Built Survey

On completion of the Works prior to the Taking-Over Certificate, the Contractor shall carry out
survey in presence of the Engineer to determine the as-built work. The Contractor shall make all
necessary arrangement required for the presence of Engineer during survey.
The Contractor shall be required to rectify any defects that may be determined and to re-survey
as necessary till the Works can be certified satisfactory. The Contractor shall also carry out as-
built survey at the end of Defects Notification Period if required by the Employer.
2. CONCRETE
2.1. Grade
The grade of concrete shall be as specified in the drawings.
2.2. Standards
Concrete for the Marine construction shall comply in all respects with BS 6349-1 and BS
8500-2.
2.3. Materials for Concrete Marine Construction

All materials used for the construction of Marine structural elements shall comply with the
requirements for exposure to the Marine environment. Materials for concrete construction
shall conform to the clauses given below.
2.3.1 Type of Cement

Combine sulphate resistance with chloride resistance, are to use combinations of Portland
cement with at least 29% pulverized-fuel ash (pfa) or 40% ground granulated blast furnace
slag (ggbs).
The Contractor shall provide manufacturer’s test certificates showing all cement has been
sampled tested and conforms in all respects with Codes stipulated in table below. The
Contractor shall also provide test certificates for the cement used in ready mix concrete by the
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concrete supplier. Cement more than three months old shall be re-tested for conformance.
Cement showing evidence of deterioration or hardening shall not be used.
Unless otherwise permitted by the Engineer, the product of only one mill of any one brand
and type of cement shall be used on the project.
Codes for Cements
Type Standard Other Requirements
Tricalcium aluminate
a) Portland cement:
C3A content by mass
- Portland BS12
not more than 10%.
- Low heat Portland BS1370
See 58.4.1.
b) Sulphate resisting Portland

cement
c) Cement containing ground

granulated blast furnace slag(ggbs)
or pulverized fuel sh (pfa) :
- Portland blast furnace cement BS146

- High slag balst furnace cement BS4246
- Portland pulverized fuel ash cement BS6588
- Pozzolanic pulverized fuel ash BS6610
cement
d) Combinations made in the concrete Combination

mixer from Portland cement and should conform
ggbs or pfa[56]: to:
- Portland cement conforming to

BS12 in combination with ggbs BS146 or
conforming to BS6699 BS4246
- Portland cement conforming to

BS12 in combination with pfa BS6588 or
conforming to BS3892-1 BS6610
The Engineer reserves the right to order any consignment of cement which is intended for use
in the permanent works to be tested, before delivery onto the Site, for compliance with the
appropriate BS.
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Any cement which, after testing, in the opinion of the Engineer fails to comply with the
Specification through improper storage or for any reason will be rejected.
The Contractor shall provide suitable means of storing and protecting the cement against
dampness. Bagged or bulk cement which has been stored for more than 60 days or which
has become partially set or which contains lumps of caked cement shall be rejected.
The use of cement reclaimed from discarded or used bags will not be permitted. If rapid
hardening cement is used, it shall at all times be clearly labelled to distinguish it from ordinary
cement and shall at all times be stored separately from ordinary cement.
2.3.2. Aggregates
Aggregates for concrete shall be obtained from a source approved by the Engineer. Concrete
aggregates shall conform to the specification stated hereunder. The fine aggregates shall
consist of sand conform in all respects to the requirements of BS882 or BS3797, subject to
the approval of the Engineer in writing.
Fine aggregates from different sources of supply shall not be mixed or placed in the same
stockpile nor used alternately in the same class of construction. The coarse aggregate for
concrete shall consist of crushed stone, gravel, free from undesirable adherent coating. They
shall conform in all respects to the requirements of BS882.
The soundness loss should not be greater than 12%. In accordance with BS812-2, water
absorption should not exceed 3%, or 2% in critical conditions, such as highly aggressive
chloride.
Aggregates shall be specified and tested in accordance with BS882. The acid soluble chloride
ion limits and testing frequency should conform to BS882. Chloride ion limits should be
considered for both corrosion of reinforcement and their contribution to the alkali level as they
affect alkali aggregate reactivity.
Special care is required in the selection and quality control of aggregates of marine origin to
ensure conformity with BS5328.If severe abrasion of the concrete by pebbles or sand is
expected, the coarse aggregate should be at least as hard as the material causing the
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abrasion and the fines aggregate of the mix should be kept as low as is compatible with
appropriate mix design.
The flakiness index of any size of coarse aggregate, determined in accordance with BS812
shall not exceed 30mm for any size of coarse aggregate. All aggregate shall be cleaned and
free from dust and dirt and shall be stored in such a way that they shall be kept free from
contact with deleterious matter. Aggregates of different sizes shall be stored separately and
in such a way that segregation is maintained.
Where the specified compressive strength of concrete is 40N/mm2 or more at 28 days, the
“ten percent fines'” value of the coarse aggregate determined in accordance with BS812 shall
be not less than 100kN and for other structural concrete not less than 50kN.
The shell content of the aggregate included as calcium carbonate as determined by the
method in BS812: Part 106 shall not exceed the following amounts:
Nominal size (mm) Percent (%)
40 2
20 5
10 15
fines 30
Chloride levels shall be determined daily in accordance with BS812 or as otherwise agreed by
the Engineer.
2.3.3. Water
All water used in concrete shall be subject to the approval of the Engineer. It shall be fresh,
reasonably clear and free from oil, acid, alkali, vegetable substance and any other deleterious
substances.
Water should be free from harmful matter and, where tests are required, these should be as
described in BS3148. Seawater should not be used in reinforced concrete or grout. Seawater
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can be used in unreinforced concrete, although this increases the alkali content and risk of alkali
aggregate reaction.
It also accelerates set and enhances the risk of early thermal cracking. For the same reason
admixtures containing chlorides should not be used.
Water shall not contain chlorides in excess of 500mg/kg nor sulphates (expressed as SO3) in
excess of 500mg/kg, nor dissolved solids in excess of 2000mg/kg. The pH of the water shall be
greater than 5.
2.3.4. Admixtures
Admixture shall be used to enhance workability or set and the setting time of the cement.
All pumped concrete, tremie concrete, architectural concrete, concrete required to be watertight
and concrete with a water/cement ratio below 0.38. All admixtures shall comply with BS5075-1,
BS5075-2 and BS5075-3.
The total alkali contribution levels (measured as Na2O equivalent) of all admixtures used in a
mix should not exceed 0.20 kg/m³. Total Na2O equivalent from admixtures may exceed 0.20
kg/m³ subject to the overall limit of 2.8 kg/m³ Na2O equivalent for concrete is not exceeded.
Unless agreed by the Engineer neither admixtures nor cements containing additives shall be
used. The Contractor shall submit samples of any additive or admixture he proposes to use to
the Engineer at least 35 days prior to the date of commencement of construction of the
particular structure or portion of structure or portion of the structure which he intends to use
such admixture or additive.
Trial mixes or any other tests incorporating the proposed admixture or additive shall be made
by the Contractor at his own expense and the results shall be approved by the Engineer
before use in the works. Any approval if otherwise given under this Clause shall in no way
relieve the Contractor of his obligation to produce concrete with the specified strength,
workability and durability as required under the Contract.
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Approved admixtures shall be introduced into the mix at the time of adding water by a method
ensuring an even and accurate dispersion throughout the mix. The use of admixtures
containing calcium chloride in any form is strictly prohibited.
2.3.5. Corrosion Inhibiting Admixtures

Migrating corrosion inhibiting admixture shall be used for ALL reinforced concrete elements
including pile plug and deck.
The migrating corrosion inhibitor shall be organic amine-carboxylate base, with a fixed
dosage rate irrelevant to chloride levels, and must have the following qualities:
a) Meeting all the requirements of ASTM C1582/C1582M with accredited third-party verification
of compliance with ASTM C1582;
b) Be proven effective when tested in accordance to ASTM G109 for a testing period not less
than 3 years;
c) Be proven effective at cracks as per ASTM G109 modified cracked beam testing;
d) Have an established successful international for a period in excess of 20 years;
e) Contain non-flammable organic corrosion inhibiting admixture;
f) Be certified for use with potable water structures by Underwriters Laboratories as per
requirements of NSF Standard 61;
g) Protect both anodic and cathodic components of the corrosion cell;
h) The manufacturer shall be ISO 9001:2015 and ISO 14001:2004 certified for the design and
manufacturing of corrosion inhibitors systems with valid certificate; and
i) The Contractor must submit a certificate of supply for each and every concrete pour with
corrosion inhibitor and must mention the following:
x Project Details (Name, Location, Contractor, etc...)

x Quantities supplied by supplier to the ready mix company with dates and location of deliveries
x Batch number’s and expiry dates of the material
x Company Stamp and it’s authorized representative signature
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2.4. Concrete Design Mix

The design mix shall follow the British Building Research Station publication: "Design of Normal
Concrete Mixes”. All design mixes proposed to be used for any construction shall be tested at
the Site in the presence of the Engineer.
The class of concrete to be used in the Works shall comply with BS6349-1 and shall have
following properties:
Concrete Classes
Max. Minimum Minimum

Water /
Concrete Aggregate Cement Concrete
Cement
Grade Size 3 Cover
(kg/m ) Ratio
(mm) (mm)
C40/50 20 370 0.38 60
Note 1:
Cement content is weight of cement in kg to produce one cubic meter of fully compacted
concrete.
In accordance with BS8110-1, special variations in mix design might be necessary to overcome
differences in the characteristics of local aggregate, i.e. shape and texture (with the consequent
effect on water demand) and alkali–aggregate reactivity.
The class of concrete is denoted by the minimum 28 days working cylinder strength and the
maximum size of aggregate. Unless specified to the contrary or otherwise permitted by the
Engineer all cement shall be combined sulphate resistance with chloride resistance, are to use
combinations of Portland cement with at least 29% pulverized-fuel ash (pfa) or 40% ground
granulated blast furnace slag (ggbs).
The cement content in any mix shall not exceed 550 kg per cubic metre of concrete. The
quantity of water used shall not exceed that required to produce a dense concrete with sufficient
workability to be placed and compacted where required, and in no case shall the water/cement
ratio be greater than 0.4 for all exposed concrete unless otherwise specifically approved by the
Engineer.
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The current margin for a concrete mix shall be determined by the Contractor and shall be taken
as the lesser of :-
a) 1.64 times the standard deviation of cube tests on at least 100 separate batches of concrete of
nominally similar proportion of similar materials and produced over a period not exceeding 12
months, by the same plant under similar supervision, but not less than one sixth of the
characteristic strength for concrete up to Grade 15 or 3.75N/mm2 for concrete of Grade 20 or
above;
b) 1.64 times the standard deviation of cube tests on at least 40 separate batches of concrete of
nominally similar proportions of similar materials and produced over a period exceeding 5 days
but not exceeding 6 months, by the same plant under similar supervision, but not less than one
third of the characteristic strength for concrete up to Grade 15 or 7.5N/mm2 for concrete of
Grade 20 above;
c) Where there is sufficient data to satisfy sub-clauses (a) or (b) above, the margin for the initial mix
design shall be taken as two thirds of the characteristic strength for concrete up to Grade 20 or
above;
d) This margin shall be used as the "current margin" until sufficient data is available to the
Engineer's approval, when the specified characteristic strength approaches the maximum
possible strength of concrete made with a particular aggregate, a smaller margin not less than
one third of the characteristic strength up to Grade 15 or 7.5N/mm2 for concrete of Grade 20 or
above may be used for the initial mix design; and
e) The total water soluble sulphate content of the mix, expressed as Engineer shall not exceed 4%.
The sulphate shall be calculated as the total from the various constituents of mix.
2.4.1. Grading
a) Coarse Aggregate
The grading of coarse aggregate shall be analysed as described in M.S. 30 and shall be within
the limits given in Table below.
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Coarse Aggregate
% Passing By Weight
B.S. Nominal Size of Nominal Size of

410 Graded Aggregate Single-Sized Aggregate
Test (mm) (mm)
Sieve
(mm) 37.5 to
20 to 5 14 to 5 63 37.5 20 14 10
5
75 100 - - 100 - - - -
63 - - - 85-100 100 - - -
37.5 95-100 100 - 0-30 85-100 100 - -
20 30-70 95-100 100 0-5 0-20 85-100 100 -
14.0 - - 90-100 - - - 85 -100 100
10.0 25-55 25-55 40-85 - 0-5 0-20 0-45 85-100
5.0 0-10 0 -10 0-10 - - 0-5 0-10 0-20
2.36 - - - - - - - 0-5
b) Fine Aggregate
The grading of fine aggregate shall be analysed as described in M.S. 30 and shall be within the
limits of one of the grading zones given in Table below.
Fine Aggregate
% Passing By Weight
B.S 410
Test Sieve
Grading Grading Grading Grading
Zone 1 Zone 2 Zone 3 Zone 4
10.0 mm 100 100 100 100

5.0 mm 90 – 100 90 – 100 90-100 95-100
2.36 mm 60 – 95 75 – 100 85 – 100 90-100
1.18 mm 30 – 70 55 – 90 75 – 100 90-100
600 um 15 – 34 35 – 59 60 – 70 80-100
300 um 5 – 20 8 – 30 12 – 40 15-50
150 um 0 – 10 0 – 10 5 - 10 0-15
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2.4.2 Sampling and Testing of Aggregates

Samples of the fine and coarse aggregates approved by the Engineer shall be kept on Site, and
shall give a fair indication of the general quality of the aggregates for comparison with the
aggregates delivered during the course of the work.
Tests shall be carried out on samples of the latter taken at intervals as required by the Engineer.
The method of sampling and testing shall be in accordance with M.S.30 and other standards as
specified in Table below. Any batch of aggregate rejected by the Engineer shall be removed from
the Site.
Testing of Aggregates
Properties Test Methods Limit

Grading
Tables above
M.S. 30
Elongation Index
not exceeding 30%
M.S. 30
Flakiness Index
not exceeding 25%
M.S. 30
Water Absorption
not exceeding 3.0%
M.S. 30
Clay, Silt and Dust
not exceeding 2%
M.S. 30
Organic Impurities
not exceeding 0.4%
M.S. 30
Aggregate Crushing Value
not exceeding 20%
M.S. 30
Soundness Test
loss not exceeding
(Sodium Sulphate) AASHTO Test
12%
Method T104
Chloride Content
not exceeding 0.06% by weight
B.S. 812 Part 4
of chloride ions
not exceeding 0.4% by weight of

Sulphate Content B.S. 1377 Test 9
SO3
2.4.3 Workability
The concrete shall be of such consistency that it can be readily worked into the corners and
angles of the formwork and around reinforcement without segregation of the materials or
bleeding of free water at the surface.
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The consistency of each batch of concrete shall be checked by means of the slump test.
Procedures for testing for compliance and acceptance testing should conform to BS5328.
Workability of the concrete shall be within one of the following limits:

a) Slump
+ 25 mm or + one-third of the “designed workability”, whichever is the greater.
b) Compacting Factor
+ 0.03 where the “designed workability” is 0.9 or more.
+ 0.04 where the “designed workability” is between 0.8 and 0.9.
+ 0.05 where the “designed workability” is 0.8 or less.
c) Veve
+ 3 seconds or + one-fifth of the "designed workability”, whichever is less.
2.4.4 Trial Mix

The Contractor shall submit details of the mix design for each specified class of concrete to the
Engineer prior to the commencing the trial mix. The mix design shall use only the constituent
materials that have been shown by testing to meet the requirements of this Specification.
The Contractor shall give early notice to enable the Engineer to be present at the making of trial
mixes and preliminary testing of the cubes. The Contractor shall prepare trial mixes, using
samples of approved material typical of those he proposed to use in the work, for all grades to
the approval of the Engineer prior to commencement of concreting.
2.4.5 Testing
All sampling and testing of aggregates for concrete, making and testing of concrete cubes,
determination for compacting factor, etc., shall be carried out by Contractor as provided for in
BS6349-1 and BS8110. Slump testing shall also be carried out as a check on consistency.
The Engineer shall also have the right to require the Contractor to test any completed structure
or member thereof in such manner as the Engineer shall direct. The cost of any such testing
shall be borne by the Contractor.
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Unless specifically provided otherwise in this Specification, the cost of all sampling, testing,
assessment of water content, etc., shall be deemed to be included by Contractor in his price.
2.4.6 Routine Test

Unless otherwise required by the Specification or applicable Standards, not less than six (6)
test cubes shall be taken at each concreting section or division and/or for each grade of
concrete used during the day's work.
Procedures for testing for compliance and acceptance testing should conform to BS5328.
Test cubes for early strength of precast units shall be stored under the same conditions as the
units to which they apply.
When set, cubes shall be marked by Contractor with the date and a consecutive number. A
record shall be kept by Contractor of the concreting section or division represented; the
number of the consignment of cement/concrete from which the cubes are made, particulars of
the aggregates, the water/cement ratio, additives (if any) and the slump of the concrete.
At least three (3) of each batch of six (6) cubes shall be tested by Contractor for crushing strength
and weight; at seven (7) days and the remainder at twenty-eight (28) days. The mean of the
results of the tests on each batch of three (3) cubes shall be equal to or exceed the minimum
crushing strength specified and shall be taken as the strength of the whole of the concrete placed
in that concreting section or division and/or during that day to which the cubes relate always
providing that the difference between the highest and lowest result is not more than 20 per cent
of the mean of the results.
Full details of the results of all crushing tests shall be furnished by Contractor to the Engineer
together with the results of check tests on the grading of the fine and coarse aggregates and the
proportions of cement, aggregates and water in the mix for each grade of concrete within three
days of the tests being made.
Notwithstanding the foregoing routine tests, the Engineer shall have the right all times to make
test cubes and crushing test, sieve analysis of aggregate, and checks on proportions. The
Contractor shall provide all facilities and assistance to the Engineer for this purpose.
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2.4.7 Gauging Concrete Materials

The proportioning of materials and the measuring of the water for each batch of concrete shall
be performed by an adjustable weight batching plant, all materials for each batch being weighed
except the water, which shall be fed into the mixer from a tank provided with means for adjusting
the flow of water so as to supply the quantity determined for each grade of concrete.
In determining the exact quantities of water to be added to the mixer, due allowance shall be
made for moisture in the aggregates; the moisture content of proportions shall be ascertained
daily. The cement per batch may be determined by weight or by the number of bags used. In the
latter case the mix shall be adjusted to whole bags of cement and no splitting of bags will be
allowed.
2.5 Mixing Concrete

Concrete shall be thoroughly mixed to a uniform consistency in approved non-continuous power-
driven rotating drum or pan type mixers of ample capacity. The mixed materials shall not be
discharged from the mixer in advance of the appropriate minimum time for the type of mixer
used.
The concrete shall be discharged from the mixer on to a level, clean, watertight platform or floor
or into watertight receptacles. The area surrounding the mixer shall be paved and kept clean.
Hand mixing of concrete will not be allowed.
The weighing and water-dispensing mechanisms shall be maintained in good order. Their
accuracy shall be maintained within the tolerances described in BS 1305 and checked against
accurate weights and volumes when required by the Engineer.
The weights of cement and each size of aggregate as indicated by the mechanisms employed
shall be within a tolerance of + or - 2 percent of the respective weights per batch agreed by
the Engineer. The weight of the fine and coarse aggregates shall be adjusted to allow for the
free water contained in them.
The water to be added to the mix shall be reduced by the quantity of free water contained in
the fine and coarse aggregates, which shall be determined by the Contractor by a method
20
approved by the Engineer immediately before mixing begins and further as the Engineer
requires.
Unless otherwise agreed by the Engineer, concrete shall be mixed in a batch type mixer
manufactured in accordance with BS1305 or in a batch type mixer a specimen of which has
been tested in accordance with BS3963 and having a mixing performance within the limits of
Table 6 of BS1305.
Where appropriate the batch capacity, method of loading, mixing time and drum speed shall
conform to the details furnished in accordance with the requirements of BS3963 for the mix
which corresponds most closely to the mix proportions being used. The mixing blades of pan
mixers shall be maintained within the tolerances specified by the manufacturer of the mixer
and the blade shall be replaced when it is no longer possible to maintain the tolerances by
adjustment.
Mixers which have been out of use for more than 30 minutes shall be thoroughly cleaned
before any fresh concrete is mixed. Unless otherwise agreed by the Engineer the first batch
of concrete through the mixer shall contain only two thirds of the normal quantity of coarse
aggregate. Mixing plant shall be thoroughly cleaned before changing from one type of
cement to another.
The Contractor shall ensure that the constituents of materials of the concrete are sufficiently
cool to prevent the concrete from stiffening in the interval between its discharge from the
mixer and compaction in its final position.
In order to meet the requirements of the Contract in respect of the temperature of placed
concrete the Contractor shall take such steps as are necessary to minimise the temperature
of the constituents which may include the shading and watering of ice to making water and
the shading and/or reflective painting of plant and vehicles.
According to BS Code concrete to be delivered “within 2 hours after the time of loading where
transported in mixers or agitators or within 1 hour after the time of loading where non-agitating
equipment is used.
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2.6 Unsuitable Weather

Contractor shall always have in readiness on Site, approved framed sheeting, tarpaulins, etc. for
the protection of newly placed concrete. Should any concrete be damaged due to rainstorms, or
other weather conditions, the Engineer may order the cutting out and replacement of the
damaged concrete at the expense of the Contractor.
2.7 Hot Weather Concreting

The maximum gradient of concrete between any two points in the pour shall not exceed 25 ̊ C.
The Contractor shall take necessary measures and means to ensure that this arrangement is
met. The temperature gradient shall be continuously monitored and measured by means of
thermal couples at the appropriate locations.
The Contractor must submit a detailed proposal outlining his methodology to achieve the
required thermal gradient of 25 to the Engineer’s approval before commencing works.
The time from the addition of the cement to the aggregates to concrete placement and
compaction shall not exceed the times in the following table:
Maximum Elapsed Time
Concrete temperature at time of

Maximum elapsed time (minutes)
discharge (°C)
≤ 32 °C 90 minutes
≤ 35 °C 60 minutes
All concrete, at the time it is actually deposited in the forms, shall have a temperature not
higher than 35. All Concrete with temperature higher than 35 shall be rejected.
2.8 Delivery and Storage of Materials

Cement shall be stored in a dry weather-proof shed with a raised wooden floor or in a silo and
shall be delivered in quantities sufficient to ensure that there is no suspension or interruption
of the work of concreting at any time. The delivery and use of bulk cement will only be
22
permitted after the Contractor has submitted particulars of the siting of silos and all other
details of the intended storage arrangements and has obtained the written approval of the
Engineer.
Coarse aggregate, unless otherwise agreed by the Engineer, shall be delivered to the site in
separate sizes (2 sizes when the maximum size is 20mm and 3 sizes when the maximum
size is 40mm or more). Subject to the approval of the Engineer aggregates for structural
concrete may be delivered to the Site as blended materials, including fine aggregate direct
from a blending plant for discharge direct into the mixing or batching plant.
Stockpiling of blended aggregate will not be permitted and the Engineer reserves the right to
withdraw his approval of the use of such aggregate at any time should he not be satisfied that
adequate precautions are being taken to prevent segregation of the material.
All aggregate brought on to the Site shall be kept free from contact with deleterious matter
and in the case of aggregates passing a 5mm sieve they shall be deposited on the site of
mixing for not less than 8 hours before use. Aggregates of different sizes shall be stored in
different hoppers, or different stockpiles which shall be separated from each other on a
concrete floor sloping to the back of the stockpile with adequate drainage.
2.9 Concrete Surface Finish

The class of finish for all concrete elements in the works shall be clearly defined on the drawing.
Formed/unformed concrete surface finishes shall be to the following class of finish:
Class of Finishes
Element of the Work Class of Finish
beams, slabs and walls F2 & U2
piles F3 & U3
granolithic, grouting finish U3
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Note 1:
Buried surfaces shall be painted with 2 coats of approved bituminous paint. No painting shall be
done on the same day as striking of formwork.
Note 2:
Form tie hollow parts exposed F2/U2 finish, water retaining structures and F3/U3 finish shall be
filled with suitable non-shrink grout to equivalent finish class.
Note 3:
All exposed corners of reinforced concrete shall be chamfered at least 25mm x 25mm.
The surface of concrete shall be finished by screed unless otherwise specified. Surfaces to
concrete slabs in floors, decks, etc. shall be covered with screed to within a tolerance of ±3mm
of true level and grade, unless otherwise specified. In making such finish care shall be exercised
so as not to work an excess of fines to the top.
Definition of finishes shall be as follows:

a) Formed Surfaces
Class F1
This finish is for surface against which backfill, or further concrete will be placed. Formwork
shall consist of sawn boards, sheet metal or any other suitable material which will prevent the
loss of grout when the concrete is vibrated.
Class F2
This finish is for surfaces which are permanently exposed to view but where the highest
standard of finish is not required. Forms to provide a Class F2 finish shall be faced with
wrought and thickness boards with square edges arranged in a uniform pattern.
Class F3
This finish is for surfaces prominently exposed to view where good appearance and alignment
are of special importance. To achieve this finish, which shall be free of board marks, the
formwork shall be faced with plywood or equivalent material in large sheet. The sheets shall
be arranged in an approved, uniform pattern.
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b) Unformed Surfaces
Class U1
This is a screeded finish for surfaces of foundations, beds, slabs and structural members to
be covered by backfill, subsequent stages of construction, bonded concrete topping or
cement mortar beds to receive paving, and on exposed surfaces of paving where a superior
finish is not required. It is also the first stage for classes U2 and U3 finish.
Class U2
This is a floated finish for surfaces of beds and slabs to receive mastic paving or block or tile
paving bedded in mastic, and for exposed surfaces of paving where a hard smooth steel-
trowelled surface is not required.
Class U3
This is a hard smooth steel trowelled finish for surfaces of concrete paving, tops of walls,
copings and other members exposed to weathering, and seating for bearing plates where the
metal is in direct contact with the concrete.
2.10 Compaction of Concrete

All concrete shall be compacted to produce a dense homogeneous mass. Unless otherwise
agreed by the Engineer, it shall be compacted with the assistance of vibrators. Sufficient
vibrators in serviceable condition shall be on site so that spare equipment is always available
in the event of breakdown.
Internal vibrators shall be capable of producing not less than 10,000 cycles per minute, and
external vibrators not less than 3,000 cycles per minute. The amplitude of vibrators shall be
sufficient to produce satisfactory compaction.
Vibration shall not be applied by way of the reinforcement. Where vibrators of the immersion
type are used, contact with reinforcement and all inserts shall be avoided, so far as is
practicable.
Concrete shall not be subjected to vibration between 4 and 24 hours after compaction.
Concrete that has partially hardened shall not be vibrated. Accumulation of water on the
25
surface due to any cause during compaction is to be prevented as far as possible and any
such water is to be removed before further concrete is placed.
2.11 Precast Concrete

Precast concrete is defined as any concrete member, unreinforced or reinforced with non-pre-
stressed reinforcement, or pre-stressed with pre-stressing reinforcement, or any combination
thereof in which the concrete is cast in moulds not in the final working location of the member.
Subsequent to curing the member is then lifted, handled, transported and placed in the Works
in its final position as shown in the Contract, or indicated by the Engineer.
The Contractor shall inform the Engineer in advance of the date of commencement and
location of manufacture of each type of member, and no work of concreting shall be permitted
without the Engineer's prior approval.
All concreting operations shall be performed in the presence of the Engineer unless otherwise
agreed in writing by the Engineer. A copy of all 28-day cube test results and any cube tests to
establish concrete transfer strength and transport strength shall be submitted to the Engineer
immediately after cube testing.
Where the Engineer requires tests to be performed on members or their material constituents,
no members to which such tests relate shall be dispatched to the Site until such tests have
been satisfactorily completed and the members accepted by the Engineer.
2.11.1 Marking
All members shall be indelibly marked to show the Member Mark as described in the
Contract, the production line on which they were manufactured, the date on which the
concrete was cast.
If they are symmetrical sections, the face which will be uppermost when the member is in its
correct position in the Works shall be marked `TOP'. All markings shall be located so that
they are not visible when the member is in its final position in the works.
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2.11.2 Manufacturing Tolerances

Manufacturing tolerances for precast concrete members shall not exceed those specified in
BS Code of Practice BS8110. In addition, for beams or planks laid side by side in a deck:
a) the difference in deflections in soffits levels between adjacent units before the in-situ concrete is
placed shall nowhere exceed 6mm for units up to 4m or 10mm for larger span units;
b) the width of the deck soffit shall be within + or - 2.5cm of that described in the Contract;
c) in adjacent spans, the continuity line of the outside beams or planks shall be maintained;
d) the width of gap between individual beams or planks shall not exceed twice the nominal gap
described in the Contract; and
e) the alignment of transverse holes shall permit reinforcement to be placed without distortion.
2.11.3 Surface Finish

Surface finishes shall be compatible with the use of Class F3 formwork except where
otherwise shown. In particular for precast beams, some surfaces which will later be bonded to
in-situ concrete shall have all laitance removed and the coarse aggregates shall be exposed.
2.11.4 Lifting, Handling, Storing and Transportation

Precast members shall only be lifted at points vertically in line with the final bearing positions
unless shown otherwise in the Contract. Members being stored shall only be supported at the
same positions and in the same direction in which they will be supported in the final works
unless shown otherwise in the Contract.
When lifting, handling, storing or transporting members, particular care shall be taken to
ensure that vertical and horizontal axes of the member remain respectively vertical and
horizontal. Care shall be taken to avoid shock, impact, vibration or dynamic loading.
Precast units shall only be moved to a store from the casting position with the Engineer's
approval :
a) For pre-stressed members, after the transfer of initial stressing and grouting of tendons for post-
tensioned systems, and the cutting-off and protection against rust of the tendons for pre-
tensioned systems;
27
b) For non-pre-stressed members, after the concrete has attained 66 percent of the specified 28
day strength;
c) Precast units shall only be transported from the manufacturer's casting yard to the Works with
The Engineer's approval and after;
d) For pre-stressed members, all stressing and grouting and cutting off and protection against rust
has been completed and accepted by the Engineer, and the concrete strength has attained the
strength as specified in the Drawings; and
e) For non-pre-stressed members, the concrete has attained the strength as specified in the
Drawings.
2.11.5 Rejection of Members

Any member considered by the Engineer to have become substandard shall be rejected and
replaced at the Contractor's expense by an acceptable unit.
2.12 Preparation for Concreting

The inside faces of the forms shall be treated with mould oil or other approved preparation, in
either case of a type that will not have a deleterious effect on either the strength or appearance
of the concrete, and care shall be taken to prevent the oil or other approved preparation coming
into contact with the reinforcement.
Before concreting is commenced, all formwork shall be scrupulously cleaned and wetted, and the
Contractor shall adopt all necessary measures to ensure that all debris, dirt, wash water and
other refuse is removed. The reinforcement and formwork shall be inspected by the Engineer
prior to concreting. Such inspection shall not, however, relieve the Contractor of any of his
responsibility for the correctness of the work in every respect.
Before in-situ concreting is commenced all saltwater and dried salt shall be rinsed off the
formwork and reinforcement using water as specified. Before the concrete is deposited in
general, all reinforcement shall be clean and free from all loose mill scale, dust and loose rust,
dried salt and coatings such as paint, cement, grout, etc.
28
2.13 Transporting of Concrete

The concreting shall be done using concrete batching barge or using mixer on barge.
2.14 Concrete Placement

Unless otherwise approved, concrete shall be placed in one operation to the full thickness of
slabs beams and similar members. Concreting shall be carried out in sections and shall proceed
continuously in each section until this is completed.
Concrete shall be consolidated into place by means of a sufficient number of approved internal
mechanical vibrators, having a frequency of not less than 3000 impulses per minute operated by
experience workmen.
Vibrators shall be used only for consolidation and not for moving deposited concrete about in the
formwork. Care shall also be exercised not to cause segregation by excessive vibration and to
avoid contact between vibrator and reinforcement.
The concrete shall be thoroughly worked around the reinforcement and against external shutters
so that all entrained air may be duly expelled and the concrete surface when stripped be found to
be good and free of air pockets, honeycombing or other defects.
The concrete shall be worked into position where placed and not allowed to flow. Layers of
concrete shall be truly horizontal unless otherwise specified.
Except where arrangements are made for placing concrete underwater, the areas on which
concrete is to be deposited shall be made and kept free from standing water during concreting
operations, and running water crossing or entering such areas shall be brought under control
before concreting is commenced and kept under control for at least 24 hours after concreting is
completed.
2.15 Underwater Concreting

The placing of concrete underwater for structural elements is not allowed. Underwater concreting
will only be permitted with the approval of the Engineer. Underwater concreting shall only be
carried out when the water is still and so controlled that there is no flow or agitation.
29
Concrete may be lowered through the water in bottom-opening skips or may be continuously fed
through an approved tremie pipe or pipes provided with suitable hoppers; the position and level
of the tremie pipes shall be readily adjustable, and the pipes shall be of sufficient bore and have
their ends firmly fixed. The cement content of any concrete mix that provides a specified grade
shall be increased by twenty percent (20%) if that mix is placed under water.
2.16 Concreting Within the Tidal Range

When concreting is to be carried out under tidal conditions, the Contractor shall ensure that the
concrete is placed and compacted before the seawater rises to the level of the concrete so
placed. No concrete shall be disturbed after salt water has made contact with it.
The top surface of the concrete shall be covered after the initial set has taken place to protect it
against water action should there be any risk of this occurring. The Contractor shall submit to the
Engineer full details of this proposed procedure to ensure compliance with the foregoing
requirements.
2.17 Curing
Concrete shall be protected during the first stage of hardening from the harmful effects of
sunshine, drying winds, rain or running water.
The protection shall be applied as soon as practicable after completion of placing by one or
more of the following methods:
a) The concrete shall be covered with a layer of sacking, canvas, hessian, straw mats, or similar
absorbent material, or a layer of sand, kept constantly wet for 7 days;
b) After thoroughly wetting, the concrete shall be covered with a layer of proven waterproof paper
or plastic membrane kept in contact with the concrete for 7 days;
c) Except in the case of surfaces to which concrete has subsequently to be bonded, the
concrete shall be cured by application of a proven liquid curing membrane. Rate of spray
should be in accordance with manufacturer's instructions. On horizontal surfaces, the curing
membrane shall be applied immediately after placing the concrete, and on vertical surfaces
30
and soffits, immediately after removing the formwork; and
d) No heavy construction plant will be allowed to traverse finished surfaces without the permission
of the Engineer and unless special precautions are taken.
2.18 Defective Work

Concrete which is defective, from honeycombing or any other cause whatsoever, shall be cut
out by Contractor and the work reconstructed at the Contractor's expense and risk. No
concrete thus cut out shall be reused except as hardcore. The faces of the concrete work
shall be sound and solid, free from honeycombing and excrescences.
2.19 Progress Information

The Contractor shall make plans for each concreting section or division on which to record the
dates of:
a) Completion of erection of formwork;
b) Commencement and completion of concreting;
c) Stripping of formwork; and
d) Removal of formwork supports.
The Contractor shall furnish weekly to the Engineer a return showing, in respect of the previous
week, the quantity of cement used and in stock, the number of mixes and the total volume of
each grade of concrete placed.
2.20 Formwork
The Contractor shall be entirely responsible for the sufficiency and efficiency of the formwork and
also for the safe removal of the same. The formwork shall be designed and constructed so that
the side forms of members can be removed without disturbing the so fit shutters.
All strutting shall be of such design as to allow accurate adjustment and easy removal. All
chamfer and radius strips lines and cores shall be provided where necessary and shall be
true to shape and securely fixed.
31
Removal of formwork shall be done in a regular manner, avoiding sudden loading of the
structure, in conformity with BS8110-1 and without damage to the concrete. Unless otherwise
directed, the minimum time for striking and removal of formwork shall be as follows:
Time for Striking and Removal
Ordinary Portland Rapid Hardening

Description Cement Concrete Portland Cement
(Days) Concrete (Days)
Slab soffit forms (props left under) 3 2
Beam soffit forms (props left under) 7 4
Props to slabs 7 4
Props to beams 16 8
Side forms 1 1
Sawn formwork shall be used for all unexposed faces of concrete, and shall be constructed of
sound timber, closely jointed, so fixed that it makes close contact with adjoining work.
Moulds and formwork shall be fixed in true alignment adequately supported by suitable false-
work and props to withstand without movement or deflection the pressure of concrete as
deposited, the weight of the construction and the movement of men, materials, and plant.
Adjoining boards shall not differ in thickness by more than 1.5mm.
Wedges and clamps shall be used wherever possible in lieu of nails. The use of wire ties which
would become embedded in the concrete will not be permitted. Metal or waterproof plywood
panels may be used in lieu of boards provided that they comply with the above requirements
regarding accuracy of face, stiffness and tightness of joints.
All formwork shall be trued up immediately before inspection and the depositing of concrete.
Wrought formwork shall be used for all exposed faces of concrete except where a special finish
is required.
32
Wrought formwork shall comply with the following requirements:

a) Boards shall be tongued and grooved and shall be wrought on the face in contact with the
concrete to a smooth even surface, accurately planed or curved, or alternatively lined with
closed permitted.
b) Unless otherwise shown on the drawing 25mm x 25mm chamfers or fillets shall be provided at
all angles and arises.
The finished surface of the concrete shall have a smooth and dense finish of uniform texture free
from holes, fins and staining. Minor blemishes shall be removed immediately after striking the
formwork by rubbing down and holes filled with a grout of cement and suitable fine aggregate to
match the colour of the concrete. The grout shall be well worked into the voids and cured.
"Lined" formwork for exposed external faces of concrete shall consist of purpose-made metal or
plywood panels or shall be wrought formwork lined with plastic, hardboard or other approved
material to produce the best possible finish without lips, joint lines, etc. and without any loss of
fines, honeycombing, bulges or other defects. Lined formwork shall also comply with the
preceding requirements for wrought formwork.
2.20.1 Formwork Tolerances

Unless otherwise specified formwork shall be fixed within the applicable tolerance set out below,
and the formwork shall be so constructed that the applicable tolerance is not exceeded during
the placing or concrete. Any change in alignment or variation in dimensions within the specified
tolerances shall be gradual in order to present a uniform finish. The accuracy of the work shall
be the responsibility of the Contractor.
Variations in cross sectional dimension not greater than:
a) Precast beams ±6mm

b) Precast planks ±6mm
c) width ±6mm
d) thickness ±6mm
e) In-situ beams etc. ±6mm
f) Precast roadway element ±6mm
33
Departure from alignment:
a) Precast beams and planks 6mm

b) In-situ beams etc. 13mm
c) Edge beams 13mm
d) Precast roadway element 10mm
Tolerance for finished surface level of in-situ concrete deck slab and in-situ roadway /crosshead
connection shall not be greater than ±3mm.
Any concrete work falling outside these tolerances is liable to rejection and if so rejected shall be
removed from the site or broken up or any necessary modifications shall be undertaken at the
Contractor's expense.
Concrete that is damaged from any cause and concrete that is honey-combed, fractures or
otherwise defective, and concrete which has excessive surface depressions outside the
specified tolerances shall be cut out and built up to bring the surface to the prescribe lines. All
Materials, procedures, and operations used in the repair of concrete shall be submitted to the
Engineer for review.
2.21 Reinforcement
The bars to reinforce concrete shall comply with BS4449. Yield stress for reinforcement shall be
500N/mm2. Welded deformed wire fabric reinforcement shall conform to the requirements of
BS4483. The wire for tying reinforcing bars shall be of a minimum of 16 S.W.G. black annealed
wire. Reinforcement shall not be welded.
Manufacturers test certificates shall be supplied by the Contractor to the Engineer, free of charge.
Test certificates shall be clearly related to delivery batches of reinforcement, which shall be
marked on site for identification.
Stainless steel reinforcement should be of higher grade, equivalent to austenitic steel in

accordance with BS6744, Type 316 S33 (hot rolled austenitic steel). Fusion-bonded epoxy
coated reinforcement should conform to BS7295.
34
2.21.1 Bending Reinforcement

Bending shall be in accordance with BS8110 and bends shall be made cold round a former
having a diameter of four times the diameter of the bars. Stirrups and bidders shall be bent to
the radius of the bars against which they are to be in contact. Heating of the bars for any purpose
whatsoever will not be allowed.
2.21.2 Splicing Reinforcement

Where splices or overlapping in reinforcement are required, it shall be provided in accordance
with BS8110 or other relevant standards. The Contractor shall supply details of the method he
proposes to use to the Engineer.
2.21.3 Bar Schedules

The Contractor shall prepare bar bending and cutting schedules with calculated weights for the
reinforcement and shall supply these schedules in triplicate to the Engineer before bar cutting,
bending and fixing is carried out.
3 STEEL TUBULAR PILING WORKS

3.1 General
All piling works shall be executed in accordance this Specification and all current Codes of
Practice. In either case, the Contractor shall maintain records and perform all tests as the
Engineer may deem necessary for ensuring compliance with various provisions of this
Specification.
3.2 Manufacturing and Delivery

3.2.1 Material
Contractor shall ensure that tubular piles shall conform to the requirements of the BS code
where applicable. For piles up to 25.4mm of thickness only spiral welded pipe piles are allowed.
For steel piles thicker than 25.4mm Contractor must submit type of pile for Engineer’s approval
prior to procurement.
35
The Contractor shall ensure that all material shall be new and shall be free from defects impairing
strength, durability, or appearance and of the best commercial quality for the purpose specified.
The Contractor shall furnish, at his expense, such extra material as will be required to cover
breakage, rejection or other contingencies, which are his responsibility.
The grade of steel shall be S355. All piles shall be protected by a surface treatment system and
a cathodic protection system in accordance with the requirements of these specifications.
3.3 Fabrication
The fabrication of piling shall be done by shop welding. Except where noted, all welding and
testing shall be in accordance with the BS5950 and these specifications. Pile sections shall be
prefabricated to the largest possible length in order to minimize field welding.
Piles shall be spliced with full penetration butt welds all around. Piles made up of short cut-off
lengths are not permitted. The contractor shall prepare details of weld preparations and
procedure proposed for all longitudinal, circumferential or spiral welds for both shop and site
fabrication.
All welds shall be 100% ultrasonic examined, according to EN ISO 10893Ǧ 11, EN ISO 10893Ǧ 8,
EN ISO 10893Ǧ 9, EN ISO 10893Ǧ 10, EN ISO 10893Ǧ 12. The Contractor shall comply in all
respects with the requirements of these specifications with regard to testing and inspection of
welds.
3.3.1 Tolerances in Fabrication

The tolerance in the outside diameter using the circumferential length method shall be as
follows:
a) Pile end: + 0.5% to 0.0%
b) Pile body: +0.75% to 0.0%
The tolerance in pipe wall thickness shall not be more than 10% or less than 0% of the specified
wall thickness.
36
3.4 Splicing
Contractor shall ensure that splicing of pile lengths shall be with full penetration butt welds.
All piles sections shall be joined to match as near as practicable. The maximum allowable
mismatch of the end sections to be butt welded shall not exceed 3mm radically at any location
on the circumference.
The complete pile after welding shall not vary in any direction by more than 1/400 of its length
measured from a straight line joining the centres of head and toe. The piles shall be surface
treated and painted as specified.
3.5 Delivery
Each pile section delivered shall be marked with sufficient unique identification to assure
traceability to the source of manufacture and the grade. The Contractor shall supply
certificates demonstrating compliance with the relevant codes. The Contractor shall provide
the Engineer with a layout drawing indicating the locations of pile sections and his welding
schedule.
3.6 Marking
Contractor shall ensure that each pile shall be clearly marked with its overall length, and prior
to driving, a part length of each pile shall be marked in 100mm intervals to facilitate the making
of piling records. After installation all marks above Mean Low Water Spring shall be covered
or removed.
3.7 Pile Installation and Testing

The installation and testing of all piling shall be carried out by the Contractor in accordance
with this specification.
The Contractor shall submit to the Engineer for approval a pile driving analysis based on the
wave equation method showing the penetration rates and driving stresses to achieve the
required capacity and the practical refusal rates with his proposed pile/hammer combinations.
37
3.8 Pile Driving Equipment

The Contractor shall have all major equipment items available for inspection by the Engineer.
Any deficiencies in quality, quantity or type of equipment shall be corrected prior to
commencing work and such correction shall be deemed to be required for proper fulfilment of
the terms of the Contract.
The Contractor shall ensure that all equipment shall be of good quality and capable of
performing the required work without any unreasonable loss of time due to breakdown or lack
of proper facilities.
The Contractor shall ensure that his equipment is capable of driving the piles through the
substrata in the respective positions to the penetrations required. Hammer energy and ram
weight requirements shall be determined using a wave equation analysis.
Suitable bridles or slings that will prevent excessive bending or damage to the piles, shall be
used for handling piles. The Contractor shall inform the Engineer of the details of the pile
driving plant, temporary work and sequence prior to the start of pile driving.
The inspection and subsequent approval shall in no way relieve the Contractor from his
obligation to provide all equipment required to properly perform the work.
3.9 Pile Survey

The Contractor shall submit to the Engineer for approval the methods and details of the
equipment he proposes to use to determine the required elevation, actual deviation of the pile
centre position, the actual deviation from the true vertical and required rake of the piles.
The Contractor shall submit to the Engineer for approval the methods and details of equipment
he proposes to use for the survey of the position, elevations and actual deviation. The
submissions shall include the accuracy of methods, the accuracy of equipment and the effect
of error accumulation on achieving pile driving tolerance.
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3.10 Handling of Piles

Handling, transporting and pitching of piles shall be carried out by contractor in such a manner
as to ensure that the piles are not damaged. Coatings which have been damaged during
handling and pitching shall be made good by Contractor at his expense.
Holes for lifting will be permitted, provided the section in which the hole is located does not form
part of the finished installed pile.
The Contractor shall submit for the approval be the Engineer proposals for the correct lifting,
handling, storing and securing of the piles. Any methods proposed shall be based on the
requirement that damage to the piles and paintwork is to be avoided.
3.11 Pitching and Driving

Contractor shall ensure that piles shall be set out to the alignment and centres as required.
Each pile shall be driven continuously to the depth required by the acceptance criteria as
determined by the Contractor’s designer during detailed design stage and approved by the
Engineer. Driving shall not however be continued after virtual refusal reaches the maximum
permissible stress as established by the Contractors calculations.
3.12 Accuracy of Pitching and Driving

The Contractor shall ensure that: piles shall be pitched and driven so that the head location
shall not vary by more than 75mm from the theoretical location. In the event of a pile being out
of position, the Contractor shall take such steps as necessary to either replace the pile or carry
out other alterations to the structure at his own expense to accommodate the pile which is out
of position, all subject to approval of the Engineer. The rake of the piles should be within 1 in
25 of the specified rake.
3.13 Pile Driving Records

The Contractor shall keep records of the driving of every pile which shall show the following
information.
a) The date of driving the pile;
b) The location, the dimension and the number of the pile;
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c) The depth driven and the tidal level;

d) The final set for the last 10 blows;
e) The type and size of hammer and its stroke, or with double acting hammers the number of
blows per minute;
f) Blow count for each 250mm of penetration;
g) The type and condition of the packing on the pile head, and of the dolly;
h) The sequence of driving in pile groups;
i) Any deviation from specified location and inclination and any other relevant information;
j) The drilled anchor length and a full boring log over this length;
k) The time when driving commenced, was interrupted, when re-driving commenced and when
penetration was achieved; and
l) The temporary compression at set.
3.14 Definitions
Penetration rate shall be defined as the number of blows/250mm. Refusal rate shall be
defined as the number of blows/50mm.
3.15 Obstructions
Where obstructions make it impossible to install certain piles solely by driving, the Contractor
shall excavate and remove such obstructions or use alternative methods including spudding,
drilling or other means approved by the Engineer. Rock fill obstructions shall be removed by
excavation, including the use of divers where necessary.
3.16 Pile Anchors

When found necessary, pile anchors shall be provided for the piles which encounter rocks at
shallow depth. The Contractor shall provide detailed design and details design the pile anchor
depths and details to satisfy the required capacity of piles and submit for Engineer’s approval.
The Contractor shall also submit detailed method statement for the installation of pile anchors,
if required.
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3.17 Defective and Damaged Piles

Piles which are defective or damaged to an extent as in the opinion of the Engineer to make
them unfit for the work, shall be replaced by Contractor for its own account and risk.
3.18 Cut Offs and Head Preparation

After completion of pile driving of each pile, the Contractor shall record the actual location of
the pile head at cut-off level, the verticality of the vertical piles and the slope of raked pile. The
cut off lengths will remain the property of the Contractor. All driving surfaces shall be cut
square prior to commencement of driving.
3.19 Pile Test

PDA testing and reporting is required on minimum 50nos of the marine piles. The time
between the completion of installation and testing for a pre-formed pile shall be more than 24
hours. The permanent penetration per blow and temporary compression of the pile and soil
system shall be measured independently of the instruments being used to record the dynamic
test data.
The results of PDA test shall include:

a) Date of pile installation;
b) Date of test;
c) Pile identification number and location;
d) Length of pile below commencing surface;
e) Total pile length, including projection above commencing surface at time of test;
f) Length of pile from instrumentation position to toe;
g) Hammer type, drop and other relevant details;
h) Blow selected for analysis;
i) Test load achieved;
j) Pile head movement at equivalent design verification load;
k) Pile head movement at equivalent design verification load plus 50% of specified working load;
l) Pile head movement at maximum applied test load;
m) Permanent residual movement of pile head after each blow; and
n) Temporary compression.
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The Contractor shall submit to the Engineer for his approval, full details of the method and
system he proposes to use. PDA testing, analysis and reporting shall only be carried out by
qualified and experienced personnel. And also 50nos of piles shall be tested for pile drivability
during installation based on wave equation method.
3.20 Pre-Boring for Founding Piles (Where Required)

Pre-drill holes of suitable diameter shall be drilled through the tubular steel piles and into hard
overburden soils and bedrock (shale, siltstone, sandstone) to depths estimated by the
Contractor and agreed by the Engineer, for developing bored piled inserts with load carrying
capacities of not less than that of the design working load. Load capacity from bored pile
insert shall be derived from side friction only.
On completion, the Contractor shall engage a diver to check the seabed levels and submit the
records to the Engineer for approval.
As an alternative, the Contractor may consider an undersized hole (provisionally 50mm

smaller than the internal diameter of the steel tubular pile) may be drilled to remove the
internal soil plug formed inside the steel pipe, and then re-drive the steel pile through
overburden into shale, siltstone, sandstone, or other bed rock to depths estimated by the
Contractor and agreed by the Engineer, for developing load carrying capacities of not less
than that of the design working load.
The loose material shall then be removed by means of air lift or other approved plant and
driving of the pile is then continued until the required set ordered by the Engineer, his
representative or otherwise as instructed. The drilled hole together with the internal core of
the pile (of adequate bond length for load transfer) shall then be concreted with approved
non- shrink concrete and reinforcement bars.
In the event that the pile which has been installed at a location is rejected by the Engineer or
his representative and the Contractor is required to carry out such additional installation at
approved alternative locations for the installation of replacement pile/s.
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3.21 Temporary Bracing of Piles

Contractor shall provide temporary bracing in two directions at right angles to hold it rigidly in
position until such time the pile head has been built into the permanent deck structure.
3.22 As-Built Plans

Upon the completion of the Works at any one site, the Contractor's Professional Engineer shall
jointly with his licensed surveyor, carry out the eccentricity check of the piles installed. The
survey of as-built pile location shall be carried out before construction of any superstructure
works.
The Contractor shall submit 2 sets of the as-constructed piling plan (indicating pile length, pile
set and eccentricity 1 set in linen and 1 set in paper print). The Professional Engineer and
licensed surveyor shall endorse on the plan that the piling work and the checking of eccentricity
had been carried out under their supervision.
4 ACCESSORIES
4.1 Access Ladders
In general, all ladders shall be vertical and minimum width of 850mm. If inclined ladders are
used, the incline forward shall not be more than 15 degrees from the vertical, but shall only be
used where the vertical off-setting of ladders is not practical. Ladders shall be minimum 100mm
below Lowest Astronomical Tide.
Ladder shall be fabricated using stainless steel CHS members grade SS316. Bolts, nuts and
connection shall be stainless steel. Spacing between ladder rungs shall be maintained at
300mm.
4.2 Handrails
Handrails shall be FRP Pultruded Handrail (Square Type). FRP (Fiberglass Reinforced
Plastic) in Isophthalic Resin, E Class Glass Roving with min > 55% glass content, Polyester
surface veil with min > 35 gm. The quality standard shall comply with ASTM G154:
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Fluorescent UV Light test, ASTM E84 Class 1: Flame Retardant test (FSI < 25), ASTM D570:
Sea Water immersion test (Max 0.6%) and Halogen-free during combustion.
FRP Handrail Straight Section size is 50mm(W) x 1200mm(H), come with FRP Top Rail,
Middle Rail and Post in Square Hollow Section 50mm(W) x 50mm(H) x 4.5mm(T), FRP Kick
Plate 100mm(W) x 14mm(H) x 3.0mm(T) and complete with SS 316L Bolt, Nut, Spring
Washer and Flat Washer.
4.3 Fenders
4.3.1 Scope
This section of the Specification covers the fender panels and supply, installation and testing
of fenders.
4.3.2 General
The detailed design of the fender panels and the supply, installation and testing of the fenders
shall be in accordance with the manufacturer's instructions and methods and subject to the
approval of the Engineer.
4.3.3 Functional and Design Requirements

The supplier chosen to provide a fender system must have a proven track record of supplying
fender systems for at least 15 years. They must supply a history of jobs which they have
delivered in the last 15 years which are similar to the project being discussed.
The manufacturer must own its own manufacturing plant and no OEM product is allowed to
protect the owner’s interest. This is to reduce the risk and liability pertaining to the design or
manufacturing issue. The fender supplier has to prove that the manufacturing plant is 100%
owned by providing business certification, QA/QC docs and other relevant documents.
Fenders shall be provided by the Contractor in compliance to the design criteria as set out in
the specification and BS6349 “Maritime Structure”. Fenders shall be provided with fender
panels. Width of the panels shall be designed to the allowable hull pressure under rated
deflection conditions of the fenders. Panels shall be provided with spark proof type low friction
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pads which allow easy replacement. The friction factor between the vessel's hull and any part
of the fender panel face shall be less than 0.20. The fender panels shall have a fully covered
backing plate.
Structural steel of the panel structure, all surfaces of fender panels and chains shall have
2mm corrosion allowance for exposed to the environment. The corrosion allowance shall be
added to the designed steel thickness.
This designed thickness is defined as the thickness to reduce steel stresses under rated
deflection conditions of the fender to 80% of the specified minimum yield strength of the
material. The front of the fender panels shall be vertical and flush with the berthing line of
breasting dolphins.
4.3.4 Fender Element

The fender elements shall be manufactured from 100% natural rubber, 100% SBR or a blend
of NR/SBR compound and resistant to aging, seawater abrasion and UV rays.
The rubber compound of fender shall comply with the specifications stipulated below.
Physical Properties of Rubber Compound
Test Properties Test Method

Tensile ISO 37
Before ageing 15.7 MPa minimum
strength ASTM D412
BS 903 A2
Elongation 350% min
DIN 53504
ISO 7619-1 ASTM D2240

Hardness 84° maximum
BS 903 A2 DIN 53505
Tensile strength Not less than 80% of ISO 37 ASTM D412

After Ageing Elongation original value BS 903 A2 DIN 53504
70° C
x 96 hrs Original value ISO 7619-1 ASTM D2240
Hardness
+8° maximum BS 903 A2 DIN 53505
After
ISO 815 ASTM D395
70° C x 22hrs Compression Set 30% maximum
BS 903 A6
Heat treatment
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Ozone Resistance
ISO 1431-1
50pphm at 20% strain, 40° C, No cracking
ASTM D1149 DIN 53509
100 hours
Seawater Resistance +10% by volume ISO 1817
95° C for 28 days maximum ASTM D471
ISO 34-1
Tear resistance 70 kN/m minimum
ASTM D624
Abrasion resistance
1.5 cc maximum ISO 4649
3000 revolutions
Bond Strength Steel to Rubber 7N/mm minimum BS 903 A21 Method B
The performance of the rubber fender elements must be demonstrated by testing. Testing
shall be performed in accordance with PIANC 2002, Appendix A.
All fender units should have a unique serial number which can be traced back to
manufacturing and testing records. The fenders should be tested under direct vertical
compression. The compression speed is 2~ 8 cm/min. The test temperature is 23°C +/- 5°C.
Sampling is 1 in 10 pieces of fenders.
All testing must be conducted on full scale fenders of the type, rubber grade, and size unit as
to be supplied. The Contractor is required to submit certified test reports or certificates of
conformance furnished by an independent testing agency or witnessed by an authorized third
party.
Test reports shall include the following information as a minimum:

a) serial number of the tested fender;
b) date, time, and location of the fender performance test;
c) name of the test supervisor;
d) signature of the quality manager.
4.3.5 Chemical Composition Specification Table

These parameters can be determined by using analytical techniques known as Infrared
spectroscopy (FTIR) and Thermo gravimetric analysis (TGA).
46
The specification for the table will provide a good indication of good quality rubber materials
are being used for fenders.
Test Standard Specification
Density ISO 2781 or equivalent Max 1.20g/cc
Polymer % ASTM D6370 or equivalent Min 45%
Carbon Balck % (N3 **type) ASTM D6370 or equivalent Min 20%
Calcium Carbonate % ASTM D297 or equivalent Max 5 %
4.3.6 Test Protocol

After production, a sample of 30-50grams of sample will be cut from the final rubber fender
and sent to third party laboratory for testing of the above parameters given in the chemical
composition. The sample cutting must be witnessed by the representative or client
themselves and sealed off in an envelope with signatory on it to prevent sabotage. The
manufacturer shall submit the process and procedure for the Engineer’s approval on the TGA
testing.
4.3.7 Closed Box Steel Panel

Steel panel shall be structured with suitable stiffening members. It shall be appropriately
designed to resist the reaction forces imposed by fender and its supporting chains (if any) and
keep in equilibrium with the vessel berthing force.
Steel design shall be in accordance with BS5950 Design of Steel Structures and by applying
partial safety factors of:
a) Y load = 1.40 (covers +/- 10% manufacturer tolerance, temperature factor and dynamic
effects) Y material = 1.10.
b) It shall be manufactured in steel quality S355 J2 (1.0577) or SM490A / Grade 50B / Q345B or
equivalent.
c) The blind bosses to fix the rubber elements shall be made in stainless steel 1.4401 or SS316
as well as the welding studs, nuts and washers, or equivalent.
d) The steel fender panel shall be protected against corrosion with painting system according to
EN 12944 A8.02, C5Ǧ M high, S7.09 RAL 2009. Steel fender design shall not have water
ponding.
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4.3.8 Painting Systems

Panel must be degreased, undergo surface preparation, painting & testing as listed below:
a) Surface preparation: SA2.5 (ISO8504-2:2000)
b) Painting as per ISO12944, C5-M (Very high, marine)
c) Primer: Interguard 269: 75 microns.
d) Second coat: Interzone 954: 225 microns.
e) Third coat: Interzone 954: 225 microns.
f) Total DFT: 525 micron. Colour: Black.
The equivalent paint systems can be proposed and must comply to the ISO12944, C5-M
requirements.
Testing /Inspection:
i) Visual inspection of steel surface before blast cleaning
ii) Visual inspection of blast cleaned surface
iii) Surface roughness: Press-0-film Method as per ISO8504-2:2000.
iv) Measurements of dry film thickness (DFT).
v) Paint Adhesive test: Dollies pull off test as per ASTM D4541.
4.3.9 Proven High Speed Durability Test Data

Manufacturer shall demonstrate fender durability on Model Scale on the Super Cone or Cell
fender (400mm or more) only:
a) 50% Axial compression & 30% Shear deflection simultaneously.
b) Rated deflection for 15,000cycles 20seconds per cycle.
c) Pass criteria: No cracks or defects after testing.
d) It shall be Witnessed/ tested in third party laboratory separately.
If manufacturer had performed this kind of testing before, the test report will be submitted for
review. The manufacturer does not require to carry out additional test unless specified by
clients.
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4.3.10 UHMW-PE Protective Facing

The front face of the steel fender panel shall be covered by Ultra High Molecular Weight
Polyethylene (UHMW-PE) panels with minimum thickness of 40mm. The friction factor
between the vessel's hull and any part of the fender panel face shall be less than 0.20.
Protective facing shall be made from reclaimed material. Individual panels shall be chamfered
at least 10 mm by 45 degrees along external edges
The UHMW-PE panels shall be drilled and counter-bored at attachment locations. The top of
the mounting hardware shall be a minimum of 10 mm below the edge the UHMW-PE panels.
The pads should be fixed to the fender panel with M16 welding studs, half nuts and washers,
all made of stainless steel, grade 1.4401 or SS316.
The low friction face units shall conform to the minimum requirements shown in table below:
Protective Facing Requirements
Property Test Method Unit Typical Value
Density ISO1183-1 or Equivalent g/cm³ ≥0.94 g/cm³
Tensile Strength ISO527 or equivalent N/mm2 ≥15N/mm2
Elongation at Break ISO527 or equivalent % ≥50 %
Hardness ISO868 or equivalent Shore D 59-63
Compression
ISO604 MPa ≥30
Strength
Notched impact ISO11542-2 or

KJ/m² (Charpy) 80-140
strength (Charpy) equivalent
Abrasion Index IS015527 ≤100
Friction Coefficient ASTM D1894 ≤0.2
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4.3.11 Chain Assemblies

Fenders shall be provided with weight chains, shear and tension chains in accordance with
the manufacturer’s design, applicable standards and industry norms. Chain assemblies shall
be provided as necessary for proper functioning of the fender system within the specified
constraints.
The chain system shall prevent excessive tension, shear, and weight induced deflection of the
fender. The chains and related hardware shall be designed to withstand the maximum shear
and tension forces on the fender system.
Shear forces on the system shall be calculated from the maximum fender reaction and the
coefficient of friction of the UHMW-PE protective facing. Sizing of the weight chains shall
include the friction shear force as well as the weight of the steel frontal panel and one-half of
the weight of the rubber fender element. Tension chains shall be sized considering full
deflection of the fender element from an impact on the opposite length of the steel frame.
All chain related hardware (such as shackles and tensioners) and all anchors required for
mounting the chains to the fender pile shall be provided by the fender manufacturer.
The chains will be open link chain or either grade U2 or U3. These shall be HDG in
accordance with ISO1461. The tensioners and shackles will also be HDG to ISO1461.
Testing & Inspection :

i) Dimensional Check.
ii) HDG thickness check.
iii) Proof load test
iv) Maximum breaking load test on
4.3.12 Attachment Hardware

All hardware for attaching the rubber fender elements to the steel frontal panels and to the
platform shall be provided by the fender system manufacturer. Design of attachment
hardware shall be in accordance with BS code.
50
Threaded embedment for attaching rubber elements to platform as well as to the steel panel
must have a stainless steel socket. Bolts, nuts, washers, and threaded inserts for attaching
fender systems to the steel frontal panels and to the platform shall be of the size and quantity
recommended by the fender system manufacturer. The Anchor bolts shall be embedded into
the in situ part of the concrete deck. All fixings to be stainless steel as per ISO898-1 (bolts)
and ISO898-2 (Nuts).
Testing & Inspection:

i) Mechanical: Yield, Tensile, elongation, Impact test.
ii) Chemical composition test.
iii) Thread inspection as per ISO4014, ISO4017 & ISO4032
4.3.13 Installation and Tolerances

All fenders shall be installed at elevations and positions such that berthing line and strictly in
accordance with the manufacturer's written instructions. Installation shall be such that the final
position of the fender panel face is vertical and parallel to the berthing line within the
tolerances specified.
4.3.14 Guarantee
The Contractor shall have a joint guarantee with the manufacturer that their fenders will
remain functionally adequate for their intended purpose for a period of five (5) years from the
date of Taking-Over Certificate. The Contractor shall ensure that this requirement is
incorporated in orders placed by him and the deed of warranty for rubber fender system
including all costs for replacement and transportation shall be included.
4.4 Quick Release Hooks and Capstans

4.4.1 Scope
The Vendor shall be responsible for the technical integrity of the integrated marine monitoring
system, including design, material, manufacture, assembly, configuration, testing and
performance. The Vendor shall draw upon existing industry accepted standard designs to
supply equipment that fully complies with this specification. The system is to be designed for
a lifetime of twenty (20) years.
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4.4.2 Codes, Standards, Regulations & Specifications

As a minimum, all equipment shall be designed, manufactured and tested in accordance with
the latest revision of all relevant International Codes and Standards including but not limited
to the standards listed in this section. Where appropriate, alternatives may be offered and
these shall be identified and approved by the Owner prior to manufacturing.
All electrical and instrumentation equipment supplied by the vendor for use in hazardous
areas must be certified, by an internationally recognized body, for use within a Class 1 Zone 1
OR Zone 2 OR Class 1 Division 2 hazardous area, whichever is applicable.
Equipment for use in hazardous areas must be ATEX compliant and/or certified to the
CENELEC “EN500xx” standard series or certified to the IEC “60079” standard series or
equivalent including earlier versions of standards where product certification is current.
Where external cable and glands are supplied by the vendor for use in hazardous areas, the
wiring method used shall comply with the IEC60079-14 standard or equivalent. Region
specific hazardous area compliance requirements are as follows:
a) Europe – ATEX Directives
b) Canada – Canadian Electrical Code, Part I (C22.1-06), Section 18
c) USA – NFPA 70 (National Electric Code 2005) Article 501/Article 505
d) In North America, Field Certification by a Nationally Recognized Testing Laboratory (NRTL)
may have to be conducted, where appropriate.
4.4.3 General Description of the Equipment

Mooring and breasting structures shall provide at the berth for the safe breasting, berthing
and mooring of the vessels docked at the facility. The number, size, and location of the
mooring hooks associated with this berth shall be confirmed by the Owner / Marine
Consultant based on the results of a thorough mooring analysis performed for the range of
carriers expected to use the berth.
Each quick release hook assembly shall be a complete unit designed and built to hold the
mooring ropes and to release lines quickly.
a) QUICK RELEASE hooks with INTEGRAL capstans;
b) Reversible type electric capstans vertically mounted on to the hook base with Direct-On Line
52
starter controls, forming an integral part of the quick release assembly

c) Installation Hardware - All holding down bolts, nuts, washers, templates (minimum one per
hook base type) etc. for proper installation of quick release hook assemblies
d) Local QUICK RELEASE facility for each hook comprising of MANUAL mode with a removable
lever handle
e) The quick release hooks with integral capstans and local instrumentation (electric release)
must be procured from a single vendor to ensure seamless integration of all sub-systems and
to avoid any interfacing or operational issues.
4.4.4 Operating Environment

The mooring hook units shall be located outside the normal splash zone. Mooring hook
equipment located within an explosion proof zone of the berth shall be suitable for Class 1
Zone 1 OR Zone 2 OR Division 2 hazardous area operation, as specified in the jetty
hazardous area classification layout. This applies to QRH on the central platform and
breasting dolphins only. The mooring dolphins are in a non-hazardous zone.
4.4.5 Hook Capacity

Quick-release hooks shall be sized to withstand at normal allowable stresses the maximum
safe working load of the strongest mooring line anticipated to be connected. All hooks must
be proof tested to (150%) of the specified Safe Working Load (SWL) and release tested at the
SWL.
The working load capacity of the hook base and anchor bolts shall be as below:
x Support Structure Design Load = Total number of Hooks X Safe Working Load (per hook)
4.4.6 Design Criteria

Hooks must be the latest generation design. Use of any obsolete technology i.e. impact or
sliding plates or rollers are not acceptable.
The hooks shall have low profile, compact design and footprint. Hooks must be cast from low
corrosion alloy steel to minimize rope eye bending stress. Hooks must cantilever above the
jetty surface to avoid impact to the jetty floor under all loading conditions.
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Each hook of the unit shall be capable of being individually released independent of the other
hooks in the unit. The hooks shall not jam nor stick. Each quick release hook shall be fitted
with elastomeric impact blocks in order to prevent sparks during hook release under load.
The hook must be counterbalanced to facilitate resetting with minimal effort. Manual handling
or swinging of the hook body shall not be required to lock up the release mechanism. All
release mechanism must be protected within the hook frame, to avoid damage from adjacent
hooks.
All shafts have lubrication facility and standard automotive grease nipples. Hook design must
allow for easy disassembly for servicing using standard hand tools.
4.4.7 Hook Release Operation

The mooring rope shall be released manually by hand-lever located on the hook, using one
hand, with maximum force of less than 20kgf (45lb) under any amount of load, from zero
tension to maximum safe working load. The hand lever shall be detachable in order to prevent
accidental release. The manual release levers shall be operated from the back of the unit.
4.4.8 Hook Reset and Locking

The hook has to be engineered such that it is either in the ‘locked’ or ‘released’ position and
cannot be partially reset, thus preventing any uncontrolled “hair trigger” release. Therefore,
from a safety view point the hook design must ensure “manual resetting” and “positive
locking”. The operator has to verify each time whether the hook is fully locked.
Hook designs with “self-locking” mechanism are not acceptable as this feature is solely
dependent on the hook tension at the time of release and therefore highly unreliable leading
to a dangerous situation compromising operational safety.
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4.4.9 Hook Operational Envelope
Unit Hook 1 Hook 2 Hook 3 Hook 4
Horizontal Range
Single-Hook -90q to +90q - - -
Double-Hook -90q to +45q -45q to +90q - -
Triple-Hook -90q to +45q -45q to +45q -45q to +90q -
Quad-Hook -90q to +45q -45q to +45q -45q to +45q -45q to +90q
Vertical Range
All Hooks -5q to +45q
4.4.10 Technical Requirements of Quick Release Hooks

a) Material
The hook base construction shall be from Spheroidal Graphite Cast Iron 400-12 to AS1831,
equivalent to ASTM A536 65-45-12. The hook frame shall be manufactured from carbon steel
to AS3678 Grade 350, equivalent to ASTM A572 Grade 50.
The hook body and main pivot block shall be of high strength alloy steel casting to AS2074,
equivalent to ASTM A148. Main shafts shall be made from high tensile allow steel grade SAE
4140 equivalent to ASTM A29 4140. Holding down bolts shall be Grade 8.8 to ISO898-1
equivalent to ASTM A325. Hot dip galvanizing of bolts shall comply with ISO 10684
equivalent to ASTM A153.
b) Surface Preparation and Painting

The paint system must be designed to meet the following requirements:
“A high durability coating specification designed for environments classified by ISO 12944-2
as C5-M very high corrosivity (Marine)”. Further, given the dynamic nature of equipment the
paint system needs to have high impact and abrasion resistance.
55
The mooring equipment shall be provided with the following paint system:
i) Surface Preparation – Class 2.5 Blast (AS1627.4, USA, National Association Corrosion
Engineers, NACE or Society for Protective Coatings, SSPC-SP10 Sweden, Sa 2-1/2)
ii) 1st Coat: nominal 75μ DFT Zinc Rich Epoxy Primer
iii) 2nd Coat: nominal 125μ DFT two Part Epoxy, containing MIO
iv) 3rd Coat: nominal 75μ Re-coatable two part Polyurethane.
v) Colour: Gloss Black
c) Insulation
Each quick release hook and capstan shall be electrically insulated from the dolphin
superstructure. Insulation pads underneath the hook bases are not acceptable. This is due to
the very reason that these hook bases are susceptible to movement on the deck under load
over a period of time and may lead to cracking of such insulation pads.
d) Anchorage to Dolphin Structures

The quick release hook units shall be anchored into the concrete superstructures of the
dolphins by means of anchor bolts, which shall be part of the supply. The anchor bolts shall
be M56 X 1000L and hot-dip galvanized. Vendor shall also provide templates (one per hook
base type) for the correct positioning of holes for the anchor bolts.
A shear key hook base design and recessed installation is required to ensure better transfer
of mooring forces onto the jetty concrete structure. In this design, holding down bolts shall
resist uplift and tension and the base plate shear keys shall resist the applied shear forces
and torsional loading.
4.4.11 Operating Requirements of Powered Capstan

a) Capstan Capacity
Running pull (Line pull) is the load that the capstan can achieve when operating continuously
at the full speed and is considered the normal running pull capacity. The starting pull however
is the short term start up capacity that the capstan can sustain without overloading.
56
The minimum running line pull load of each capstan shall be 3 tonnes. Start up pull capacity is
twice the line pull. The nominal rope speed shall be 25 meters per minute offering better
operational efficiency during mooring operation.
b) Capstan Controls
The electrically-operated motor shall be equipped with a foot switch, Emergency Stop Switch
(E-Stop) and a direction selector switch. The capstan shall pull the eye of the mooring line
directly over the mooring hook.
The capstan shall be reversible type equipped with a brake designed to hold 150% of the
running pull. Capstan brakes are internally connected and automatically actuated when power
is removed.
4.4.12 Technical Requirements of Powered Capstan

a) Type of Capstan
The capstans shall be of vertical drum type, designed for efficient mooring practice, reducing
handling times and minimizing operator effort.
b) Design Criteria
The capstan motor shall be located within the body of the hook support structure to provide
increased protection from environmental and potential mechanical damage in service.
Exposed capstan motors are not acceptable for corrosion protection in a marine environment.
For ease of operation, the capstan height above jetty floor shall be less than 1450mm after
installation. The capstan head must have a ribbed design to assist traction between rope and
the drum. A fixed rope guide must also be provided to assist the operator to bring the mooring
line into the correct location over the hook.
A pressure sensor footswitch must be provided to enable hands free operation of the capstan,
giving the operator greater control of the lead line. The footswitches can be provided at a
reduced control voltage for added safety protection and must be provided with safety guards.
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c) Capstan Motor and Gearbox

The electric capstan must consist of a vertical mounted, in-line direct coupled geared squirrel-
cage motor assembly, with the capstan head keyed to the output shaft. The gearbox must be
oil-filled for life.
The motors for the freestanding capstans shall be rated at 15 kW (3 Tonnes Line Pull, 25m
per minute speed) and integral capstans shall be rated at 5.5kW (1 Tonne Line Pull, 25m per
minute speed). Both ratings must accept the site power supply of 3 Phase, 400 V AC, 50
Hertz. Power to each motor shall be supplied from a reversing combination starter. The
motors and combination starters shall be supplied as part of the capstan assemblies.
The freestanding capstans located on mooring dolphin are shared with multiple sets of QRH.
They are in a non-hazardous zone. The integral capstans are embedded in the QRH base
structure and these are in hazardous Zone 1.
The motors shall be TEFC (totally enclosed fan cooled) Control Devices. Within hazardous
areas, all contacts shall be located within an IP65 or greater rated, Ex’d or Exe enclosure.
The local combination starters shall be equipped with forward/reverse selector switches for
determining the direction of operation. Each combination starter shall be provided with an
emergency stop pushbutton on the starter door that is hardwired into the control circuitry for
immediate stoppage when pushed.
4.4.13 Technical Requirements of Electric Remote Release System
a) An electric remote release system is required in addition to the standard manual release
system. Local push button electric release shall be available at each hook unit.
b) ELECTRIC mode with actuators and controls in a hook base mounted enclosure only to
ensure a compact hook footprint. No electric actuator or electric release mechanism is to be
mounted on the face or top of the hook to prevent rope entanglement and accidental shearing
of the component.
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c) All jetty based equipment shall be rated for operation in a hazardous marine environment. All
key components of the electric remote release system must be housed and protected in an
explosion proof IP65 enclosure regardless of the components’ hazardous rating.
d) The system shall allow hooks to be released individually as well as simultaneously from a
remote console. The console is to be implemented as a software program with virtual buttons
and status indicators clearly displayed on the screen.
e) The virtual remote release console software shall be loaded on the desktop mounted
workstation computer with 19” LCD monitor located in the control room. This workstation shall
also provide normal operator interface and capable of displaying the integrated monitoring
data.
f) To safeguard against a “Release Hook” operation being triggered inadvertently by a fault in

the control system, a “Release Enable” interlock circuit must be connected to each slave
controller at the hook. Power to the release circuit shall only be enabled once the “Release
Enable” signal is activated.
g) For added safety and to ensure authorized release, a separate hardwired release enable
station with key lock facility is to be provided adjacent to the PC screen.
h) Remote release of hooks shall be by stainless steel cable connected to an electric

actuator. All key components of the electric remote release system must be protected within
an explosion proof IP65 enclosure mounted to the base structure.
i) The design must ensure that there are no actuator devices, proximity sensors / limit switches
within or on top of the hook assembly which might hinder the release operation or entangle
with the messenger rope or mooring rope. The actuating equipment shall be protected from
exposure to the harsh marine environment for a long-term maintenance free operation.
j) The remote release must be fail-safe i.e. a failure of either the remote release electronics or
any part of the remote release control system shall not cause an unintended release of hooks.
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k) The communication protocol shall be MODBUS RTU protocol on serial or Ethernet media.
4.4.14 Inspection Requirements for Hooks

The hook load testing shall be witnessed by an independent third party inspector (Lloyds,
ABS etc) and the certificate of such tests shall be furnished to Buyer for each Quick Release
Hook for the following:
a) Proof load test to (150%) of SWL
b) Release test at the SWL
All electrical equipment shall be pre-assembled, and electrically interconnected to the control
equipment inclusive of all cabling and glands, in order to perform an integrated performance
and operational testing to ensure intended control and performance characteristics are
obtained.
4.4.15 Installation and Commissioning

The installation of all mooring equipment and monitoring systems shall be carried out by the
Contractor in compliance with the vendor’s recommendations and project procedures. The
commissioning is to be carried out by the vendor’s representative at site. Vendor must provide
detailed installation instructions along with the supply of equipment.
4.4.16 Technical Documentation

a) Data Required
The vendor shall provide sufficient technical data to illustrate that quick release hooks and
capstans shall be able to withstand the applied design loads for buyer’s approval.
b) Drawings
The vendor shall submit detailed mechanical and electrical drawings for all items supplied
under this specification and information specifying the design requirements for related
equipment, cable or materials to be provided by others.
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c) Identification
The vendor shall note all documents with the specification number for identification.
4.4.17 Quality System Requirements

The vendor shall have an in-house Quality Assurance Program and must have current
certification to ISO 9001:2008 standards. Copy of certificate shall be included with the bid.
Upon completion of manufacturing, the vendor must carry-out a Factory Acceptance Test
(FAT) for the integrated system (of all sub-systems and instrumentation) at vendor’s factory.
Buyer may choose to witness this testing or appoint a third part inspector. Test reports must
be issued to the buyer prior to despatch or during FAT.
4.4.18 Submittals
a) Manuals
Submit maintenance and operation manuals.
b) Spare parts
Manufacturer’s recommended operational spare parts for two years. Also list the Start up &
commissioning spares and any special tools required.
c) Other item
i) General arrangement showing proposed system components and configuration
ii) Technical datasheets of the proposed sub systems.
iii) Track record of at least 20 international Oil & Gas projects with similar base scope in the past
20 years
iv) Vendor must propose an annual maintenance program for the offered equipment in line with
the recommendations of the recent SIGTTO/OCIMF publication “JETTY MAINTENANCE
AND INSPECTION GUIDE”.
4.5 Aluminium Gangway

Aluminium gangways shall provide a safe link between the ship and the operation Platform.
Gangways that are taken on board of the ship need to comply with ISO7061.
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Length of gangway must be adequate for access to VLCC and Aframax in different condition
such as fully laden, ballast, high water and low water.
Also gangway shall be in compliance with following:

a) Aluminium non-slip walking surface
b) Cross ridges for foot support
c) Clear width 0.60 meter between the rope-railings
d) 4 hoistings points to facilitate horizontal lifting by means of rigging.
e) Removable aluminium stanchions, complete with double rope-eye for rope-railing and
protection lines.
f) 2 nylon wheels for the quay-side and 2 railing hooks and 2 lashing eyes for the ship-side.
5 CORROSION PROTECTION
5.1 Painting
5.1.1 Scope
This section of the Specification covers surface preparation and application by Contractor of
paint coatings to steelwork and concrete works. Where conflict arises between requirements,
the stringent condition shall prevail. Generally, the paint systems shall be applied to piling, and
all structural steel work.
The work to be performed by Contractor includes preparation of surfaces prior to the paint
application. All stages shall be carried out by Contractor under shop conditions, and in
accordance with this Specification and the coating manufacturer's instructions. Whenever
conflict occurs between these requirements, the Contractor shall be responsible for resolving
such conflict.
The Contractor shall be responsible for ensuring that all steelwork has received the specified
treatment and that such treatment is in completely sound condition at the end of the Contract.
The Contractor shall check the paint thickness of all members and shall completely inspect all
items, making a final inspection at the conclusion of all the work of the Contract to ensure that
any damage caused by construction subsequent to erection has been rectified, in accordance
with the Specification.
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5.1.2 Materials
Prior to ordering materials, Contractor’s proposal shall include the manufacturer
recommendations relating to paint composition and application to achieve a design life of 25
years. The Contractor shall have a joint guarantee with the manufacturer that their painting
system will remain functionally adequate for their intended purpose for a period of ten (10)
years from the date of Taking-Over Certificate. The Contractor shall ensure that this
requirement is incorporated in orders placed by him and the deed of warranty for the painting
system all costs for replacement and transportation shall be included.
All approved coating materials and thinners shall be brought to the site of the coating
application in unopened, factory sealed, labelled containers, as supplied by the manufacturer.
Before commencing application of the coating, the Contractor shall supply to the Engineer the
manufacturer's certificates for each consignment of paint delivered to the site. These
certificates shall indicate the description of the material, vendor's reference number, batch
number, quantity in the batch and the date of manufacture.
The paint coating for quick release hooks shall be as described in these Specifications or as
nominated by the manufacturer and shall be absolutely adhered to. No other mixed coatings
shall be used.
5.1.3 Surface Preparation

Surface preparation shall be according to ISO 8501Ǧ 1, Standard Sa 2 1/2. Heavy deposits of
oil and grease shall be removed with suitable solvent before blast cleaning. All welds and
edges shall be ground to remove sharp projections and corners.
Coating shall be applied before any contamination or visible deterioration of the blast cleaned
surface has occurred, but no longer than three hours after cleaning. Where necessary, steel
shall be re-blasted to restore the specified class of surface preparation prior to coating
application.
The second and subsequent coats of paint coating shall be applied before the preceding coat
has fully cured. Where the steelwork to be recoated has fully cured or where the interval
between coats exceeds 48 hours, the surface to be coated shall be thoroughly and evenly
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roughened by abrasive blast cleaning or by other similar methods immediately prior to

recoating.
If, due to unforeseen or unusual circumstances the previous coat has been allowed to cure for
longer than the maximum time interval allowed, or has been subjected to intense sunlight
resulting in over-curing which produces a dull black surface, then the area may be recoated if
the affected area is first roughened by a light whip-blasting followed by a thorough swabbing
with chemical solvent recommended by the paint manufacturer.
A brown film on the surface of the coating will indicate water contamination in the process of
drying. To ensure satisfactory adhesion of the second coat, this brown film shall be removed
by a light whip-blasting and solvent washing. All coatings shall be mixed and applied in
accordance with the manufacturer's instruction.
All paint shall be applied to provide the specified minimum finished dry film thickness without
runs, sags or other blemishes and to ensure the proper curing, drying and hardening of the
coats. Where more than one coat are applied to a surface each coat shall be of a different
shade to its predecessor.
5.1.4 Coating Application

All coatings shall be applied under cover so that they are protected from exposure to rain, wind,
dew, etc. Work shall not be performed in the following circumstances:
a) If the surface is wet or likely to become wet after blasting or before or during application of prime
coating or top coating.
b) On surfaces where condensation is likely to form.
c) When the relative humidity of surrounding air is greater than 85%.
d) When the extreme of surface metal temperature exceed 40ºC.
Particular care shall be taken to ensure that spent abrasive material and other foreign matter
is not allowed to impinge on and adhere to freshly coated surfaces. The Contractor shall
ensure that all areas of paint affected by heat during welding are removed.
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5.1.5 Inspection
The Engineer shall have the right to inspect at all times any tools, instruments, materials,
staging or equipment used or to be used in the performance of the coating application. The
Contractor shall make all parts of the work accessible for these inspections.
The finished coating shall be continuous over the entire surface to be painted, and generally
be smooth and free of sharp protuberances. Sags, dimpling or curtaining on up to 3% of the
surface area of a member will be acceptable although sharp protuberances shall be removed.
Where this is required it shall be done with a sharp wood chisel laid flat against the surface
and the zones from which material is removed shall be lightly wire brushed, and recoated.
Inspection of the coating will be based on readings of an Elcometer or other magnetic

detector. If on any member, five (5) or more areas are found where the thickness is below that
specified, the member shall be completely recoated after a surface treatment to ensure
adequate bond.
The Contractor shall be responsible for the proper calibration and functioning of all testing and
inspection equipment at the time of inspection and shall ensure that this equipment is being
operated by skilled personnel.
At the decision of the Engineer the Contractor will be required to prepare small test plates
(600mm x 600mm) prior to commencement of coating using the proposed coating methods to
ensure that he can apply the recommended coating systems to the satisfaction of the
Engineer and the manufacturer.
5.1.6 Curing
Members shall not be handled or removed from the coating area until a sufficient period of
time, as recommended by the coating manufacturer, has elapsed to allow the coating to
become sufficiently hard as to avoid damage in handling. In any case, transport to site shall
not be allowed within seven days of painting.
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5.1.7 Parts in Contact

Where two mild steel bolted surfaces will be in permanent contact after assembly, each of them
shall receive, immediately before being assembled, and after being thoroughly scraped,
cleaned and dried, one heavy coat of coal tar epoxy coating and the surfaces shall be brought
together whilst the paint is still wet.
5.1.8 Handling of Painted Steelwork

Slings, ropes and chains employed for handling painted steelwork shall be rubber sheathed or
similarly covered to avoid damage to the paintwork. Steelwork shall not be stacked with
painted surfaces in direct contact.
5.1.9 Reinstatement of Damaged Surfaces

Pinholes, damaged areas and site welded areas which will not be subject to immersion before
the repaired coating has fully cured shall be reinstated in accordance with the following
procedure:
a) Clean the damaged area back to white metal by spot-blasting and feather back the adjacent
coating over 50mm.
b) Clean areas which have been subject to salt spray by washing thoroughly with fresh water after
sandblasting, allow drying and re-blasting to white metal.
c) Apply by brush at least two full coats of paint coating to achieve the required film thickness.
In the case of pinholes, damaged areas and the site welded areas which will be subject to
immersion before the repaired coating has fully cured, the procedure shall be as indicated in
c) above except that the repair material shall be as recommended by the manufacturer of the
originally applied coating. The testing of the reinstatement of the damaged surface unless
otherwise stated shall be in accordance to the vendor specifications subjected to Engineer’s
approval.
5.1.10 Areas not to be Painted

No paint will be required on surfaces that shall be galvanized and the following surfaces.
a) Internal surfaces of piles sealed at the top.
b) Internal surfaces of hollow steel members sealed at both ends.
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5.1.11 Protective Coating of Steel Sections

a) Protective Coating of Steel Pipe Piles
Steel pipe piles shall be coated on their exterior surfaced from the cut-off elevation to a depth
of not less than 1.0m below the seabed level.
The design and application of coating system shall comply with ISO 12944 Part 5, 2018. The
coating system shall be:
i) The coating system shall be 2 coats x 500 microns each glassflake reinforced epoxy or
glassflake reinforced unsaturated polyester coating in different colours with minimum total dry
film thickness of 1000 microns.
The Contractor shall be required to make good all defects in the coating system at any time
during the period of guarantee, all at his own expense.
b) Protective Coating of Other Steels

All other steel structures which are not specified as galvanized on the drawing or in the
Specification shall comply with ISO 12944 Part 5, 2018 and to be coated as follows:
i) Primer: 1 coat of 2 components zinc rich (minimum 80% zinc content) epoxy coating with
ASTM D520 type II Zinc dust at minimum 60 microns.
ii) 2nd coat: 1 coat of 2 components epoxy at minimum 200 microns.
iii) Topcoat: 1 coat of 2 components chemical curing aliphatic acrylic polyurethane coating at
minimum 50 microns
5.1.12 Painting to Concrete Surface Underneath and Sides of Dolphin Structures

All surfaces of precast and cast-in-situ concrete under and sides of dolphin deck shall be
protected against the effect of sea water.
All concrete shall be sufficiently cured for 28 days prior to surface preparation. The surface
preparation shall be carried out either by mechanical cleaning tools of wire brushing or rotary
brushing or by lights abrasive blasting or with high pressure water jetting to remove salt,
contamination and dirt.
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All mechanically cleaned surfaces shall be solvent-wiped to remove powdery concrete dust.
The surface treatment shall be applied by a three coat system of:
Surface Treatment Instructions
Apply one coat of two components epoxy sealer coating at minimum

Primer
50 microns
Apply one coat of 2 components epoxy coating at minimum 200

Intermediate coat
microns.
Apply one coat of two components chemical curing aliphatic acrylic

Top coat polyurethane at minimum 50 microns and of different colour than
intermediate coat
The finishing colour of paint shall be approved by the Engineer. All epoxy application shall be
carried out strictly in accordance with the manufacturer’s instructions. The procedures and
sequence of application of surface treatment shall be approved by the Engineer prior to
commencement of treatment works.
5.2 Cathodic Protection System (CP)

5.2.1 Scope
This section of the Specification sets out the minimum requirements to be taken into account
by Contractor for design, supply, installation and commissioning of a cathodic protection (CP)
system to prevent corrosion of all below sea level exposed steel surfaces. The Contractor
shall ensure that:
5.2.2 General
A sacrificial anode CP system shall be designed installed and commissioned fully in
accordance with BS 7361-1:1991 by an organization experience in this type of work. Full
details of the proposed system shall be supplied by the Contractor to the Engineer for his
approval.
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Information to be supplied shall include amongst others, such items as:

a) Basic design data and design statement;
b) Design and location of monitoring points;
c) Circuit diagram
i) Drawings and installation procedure
x Inspection procedures
x Commissioning procedures including guaranteed protection levels
d) Operating manual
e) Type(s) and manufacturer of anode(s) as well as replacement cost of one anode based on
current labour and material costs.
x Size, connection and calculated life of anodes
x Relevant governing standard.
5.2.3 Basis of Design of the System

The CP system shall have a minimum design life of 20 years. All steel piles to be cathodic
protected must be electrically isolated from the other parts of the structure.
The sizing of anode shall be done based on the schedule giving the theoretical pile quantities,
lengths and uncoated lengths, prior to construction with an extra 10% allowance. The piles
will be painted down to 1.0m below seabed level, but the cathodic protection design shall be
based on 50% breakdown of coating system considered immediately after installation.
Special emphasis shall be given to obtaining the optimum dimensions for the anodes for the
particular structure, utilizing standard anode types from approved manufacturers. Further it is
important that the multiple anode to anode interference (where applicable) has been
incorporated in the design calculations, to be reviewed by the Engineer.
The anodes shall be installed so as to be fully submerged at all times. Installation of anodes
will be carried out in one continuous operation at -1.0m CD and to be placed away from side
where there is possible damaged by small boats.
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5.2.4 The System

The system shall conform to the requirements of the appropriate statutory authorities. All costs
necessary to ensure such approval from the authorities shall be included by the Contractor in
his price.
5.2.5 Inspection and Testing

Anodes shall be inspected for assurance that dimensions and weight conform to the approved
design. The Contractor shall submit for approval by the Engineer the test procedure and test
method including inspection sequence. Inspections shall only be done by qualified personnel.
5.2.6 Commissioning
The Contractor shall:
a) Carry out a potential survey to verify that all piles are electrically connected in the system and
that the system provides adequate protection to the piles.
b) The potential at each test points shall be recorded against the reference half-cell monthly for a
period of at least four months.
c) Record all findings and include them in a commissioning report.
d) Issue the commissioning report to the appropriate statutory authorities for approval.
5.2.7 Guarantee
During the first two (2) years as from the date of Taking-Over Certificate, the Contractor shall
repair or replace and install at his own expense, all parts or sets of components of the cathodic
protection system which may have failed or caused improper operation of the global system.
This does not include damages caused by accidents or vandalism whatsoever.
The repairs and/or replacements indicated in the guarantee shall be executed in co-
ordination with the Engineer and shall be performed within thirty (30) calendar days as from
the notice by the Engineer of the component or system failure.
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5.3 Qualified Painting Inspector

The Contractor shall provide qualified Painting Inspector from an approved accredited Painting
Company to undertake full time supervision and certify all painting works. The Contractor to
submit details of painting Company to be engaged and curriculum vitae of Painting Inspector
for the approval of the Engineer. All painting works to comply with the Technical Specification
and Authority requirements accordingly.
6 STRUCTURAL STEEL
6.1 Scope
The work covered under this section of the Specification covers the supply of labour, a material,
connection design detailing, fabrication, delivery, and erection of structural steel items, and
includes storage, field welding, making steel to steel connections and miscellaneous
attachments. This specification shall apply to all steel structure components including walkway
steel structure.
6.2 General
Details, workmanship and general fabrication procedure shall be in accordance with BS 5950 or
superior International Standards.
6.3 Applicable Codes and Standards

Contractor shall ensure that all structural steel work shall conform to the latest edition of Codes
and standards mentioned below and the relevant referenced codes of practice therein.
Steel plate, sheet and strip – Carbon, carbon manganese

BS1449 : Sec1-1 : 1991
plate, sheet and strip, Sect 1.1, General Specification
Use of high strength friction bolts in structural steelwork. Metric

BS4604 : Part 1 : 1970
series. General grade.
Use of high strength friction bolts in structural steelwork. Metric

BS4604 : Part 2 : 1970
series. Higher grade.
Stairs, ladders and walkways – Code of practice for the design

BS5395 : Part 3 : 1985
of industrial type stairs, permanent ladders and walkways
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Structural use of steelwork in building – Code of practice for

BS5950 : Part 1 : 2000
design. Rolled and welded sections.
Structural use of steelwork in building – Specification for

BS5950 : Part 2 : 2001 materials, fabrication and erection. Rolled and welded
sections.
BS5950 : Part 5 : 1998
design of cold formed thin gauge sections.
BS5950 : Part 6 : 1995
design of light gauge profiled steel sheeting.
Structural use of steelwork in building – Specification for

BS5950 : Part 7 : 1992
materials and workmanship : cold formed thin gauge sections.

BS5950 : Part 8 : 2003
fire resistant design.

BS5950 : Part 9 : 1994
stressed design.
BSEN10088 Stainless steel
6.4 Materials
All steel material shall be grade S355. Manufacturer's certificates of all materials shall be issued
by Contractor to the Engineer in accordance with these specifications.
The Contractor shall ensure that all structural steel shall be new and material qualities,
dimensions and tolerances and suitable for marine environment.
Base plate anchors cast in concrete shall be hot-dip galvanized and have a tensile strength of
not less than 430 N/mm2 and a minimum guaranteed elongation of 17 percent. Dimension shall
comply with the requirements of BS 4190 or BS 1580 or BS 3643 or JIS B1180 and JIS B1181
as applicable.
Commercial bolts shall be Grade 4.6, mild steel washers and taper washers shall conform to
codes and standards specified. Commercial grade bolts shall only be used for minor
connections, purlins, girts, handrail and the like.
High strength structural bolts shall be Grade 8.8; minimum bolt size shall be M20, Hardened
steel round and square taper washers shall conform to codes and standards specified.
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All high strength structural bolts shall be hot dip galvanized. High strength structural bolts shall be
used in all connections, unless noted otherwise. Load indicating washers shall be used for all
tension and friction bolting categories. High strength tension grip bolts and washers shall comply
with BS 4395: Part 1 or JIS B1186 for torque shearing bolts.
Post-fixed anchors shall have European Technical Approval Guidelines (ETAG) certification and
be either hot-dip galvanized or stainless steel depending on the application. The installation of
post-fixed anchors shall be in accordance with the manufacturer's recommendations and
limitations and be approved by the Engineer.
Embedded shapes and plates and anchor bolt assemblies shall be hot dip galvanized after
fabrication.
6.5 Supply and Substitution

The Contractor shall be responsible for the ordering of all steel for the works based on assured
sources of supply. Members shall not be made of short lengths.
6.6 Shop and Working Drawings

The Contractor shall prepare and submit shop and working drawings to the Engineer for review
prior to manufacturing.
All shop drawings shall be ISO A-series and preferably shall be A1 size. The Contractor shall
submit two prints of completed and checked shop drawings to the Engineer prior to fabrication.
Shop drawings shall show clear and complete details of each assembly, component and
connection in the work, together with all information relative to their fabrication, surface treatment
and erection. The Contractor shall verify that all members can be erected properly.
6.7 Fabrication Work

The fabrication of steelwork items shown shall be carried out in accordance with the
requirements of codes and standards specified, together with any other requirements of this
specification.
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All members shall be fabricated true to shape and size, without distortion, complete with all
temporary brackets, straps, gussets, cleats, fixings and the like necessary for erection and
assembly of the steelwork. Unless otherwise approved by the Engineer all columns, beams,
truss members and bracing shall be of a single length of material. The design of splices, if
approved, shall be full penetration butt welds or bolted to achieve 100% member structural
capacity.
All steel sections shall be identifiable by colour or by marking throughout the fabrication process.
All fabrication processes where practicable, including welding, shall be carried out in the
workshop. Welding works shall not be executed at the site unless otherwise approved by
Engineer.
Structural steel hollow sections, which are to be welded, shall be profiled to fit the shape of the
members to which they are welded. All hollow section bolted connections shall be concentric and
shall be fully seal welded to prevent ingress of moisture. Plates of 3 mm minimum thickness shall
be used for this purpose, where the members to which they are welded do not seal the section.
Where galvanizing is specified the Contractor shall provide members with all holes necessary to
prevent deformation occurring during the galvanizing process. These holes shall be seal-welded
and touched up prior to delivery to site.
Holes for bolts shall be in accordance with codes and standards specified. Holes for anchor
bolts shall be not more than 6 mm larger in diameter than the bolts. Holes for baseplates or
bearing plates shall be drilled and not punched. Holes shall be clean cut without torn or ragged
edges, and free from burrs. Flame cutting of holes will not be permitted.
6.8 Workmanship
Contractor shall ensure that workmanship and finish shall comply with the relevant clauses in BS
5950. Where portions of the work are exposed to view, attention shall be given by Contractor to
the finish. Shearing, flame cutting and chipping shall be done carefully and accurately. Sharp
corners and edges, and edges that are marred, cut or roughened in handling or erection shall be
faired by grinding or other means.
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6.9 Clearances and Tolerances

The Contractor shall ensure that:
a) The tolerance on thickness of plates and flats shall be in accordance with BS5990;
b) Structural members consisting primarily of a single rolled section shall, after fabrication unless
otherwise specified, conform to the appropriate tolerances allowed by the BS5990;
c) Built up structural members, unless otherwise specified, shall conform to the tolerances
allowed for universal beams;
d) Completed members shall be free from twists, bends and open joints; and
e) The above tolerances shall not result in a cumulative error over the whole or any part of the
structure.
6.10 Details of Connections

The Contractor shall ensure that:
a) All welded connections shall conform to EN1090;
b) All steel bolts, where used, shall be galvanized by a centrifugal process with double
washers per bolted connection for coating protection. The only bolts excluded will be those
over stainless steel pipelines;
c) Bolts in bearing shall be of such lengths that no threaded portion shall be within the thickness
of the parts joined;
d) At least one washer shall be placed under the bolt head or nut, whichever is to be rotated.
Taper washers shall be used where the part under the bolt head or nut is not perpendicular to
the centreline of the bolt;
e) Only minor connections, like hand railing, may use Grade 4.6 or M16 size. All major bolted
connections shall use Grade 8.8 bolts; and
f) Where splicing of members is required, full strength butt welds shall be used. Welds shall be
ground flush.
6.11 Marking
The Contractor shall ensure:
a) Every separate member shall be plainly and permanently marked to show position and
direction as necessary for easy identification and correct placing;
b) Loose pieces for connections shall be attached to their respective members;
c) Bolts, where not in holes, shall be metal tagged, each type and size in a separate container;
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d) Connections which are to be made by high strength bolts shall be given a 75mm wide
distinctive flash of colour clear of holes for easy identification;
e) The extent and size of all fillet welds which are to be made in the field shall be clearly marked;
f) Where welds are to be made between dissimilar steels, they shall be given a distinctive flash
of colour; and
g) Unpainted steel for use in reinforced concrete shall be marked with tags.
6.12 Erection
The Contractor shall be responsible for planning erection procedures including the provision of all
necessary guying, temporary bracing and the like, so as to ensure the safety and trueness of the
structure under all conditions of wind and erection loads occurring during the construction period.
At all times, the field erection connections shall be sufficient to ensure that the structure is stable
and accurately held in its true position.
Erection tolerances shall conform to the requirements of codes and standards specified. All base
plates shall be positioned to the tolerance required and packed up to the correct level by means
of steel wedges or packers but shall not be grouted until the steelwork item has been plumbed
and checked for line and level and maintained in its final position.
Cementitious non-shrink or epoxy resin grout approved by the Engineer, shall be placed under all
base plates to form a solid bearing surface. Precautions shall be taken to avoid the formation of
air pockets using, if necessary air bleed holes or tubes. The edges shall be neatly bevelled off at
45 degrees on completion.
6.13 FRP Pultruded Grating

The grating for steel walkway shall be INTECH FRP Pultruded Grating at 50mm height with
additional FRP Chequered Plate finished at 5mm thickness. FRP (Fiberglass Reinforced Plastic)
in Isophthalic Resin, E Class Glass Roving with min > 55% glass content, Polyester surface veil
with min > 35 gm.
The quality standard shall comply with the American Bureau of Shipping (ABS), ASTM G154:
Fluorescent UV Light test, ASTM E84 Class 1: Flame Retardant test (FSI < 25), ASTM D570:
76
Sea Water immersion test (Max 0.6%) and Halogen free during combustion. The uniform load to
be carried requiring minimum 7.5 KN/Sq.M with deflection classification 1/200 span, Opening
Area 60%, loading bar pitch 38mm and cross rod pitch 152mm.
6.14 Welding
6.14.1 Scope
This section of the specification covers welding procedures, welding qualification and quality
standards of welding for the fabrication of steel piling and steel structures to be performed by
Contractor. All welding works shall be done at fabrication workshop. No on-site welding shall be
allowed unless approved by the Engineer.
6.14.2 Codes and Standards

a) BS EN ISO 2560 Welding Consumables – Covered Electrodes for Manual Metal Arc Welding
of Non-alloy and Fine Grain Steels – Classification ;
b) BS EN 1011 Welding - Recommendations for Welding of Metallic Materials ;
c) BS EN 1792 Welding - Multilingual List of Terms for Welding and Related Processes ;
d) BS EN 13622 Gas Welding Equipment – Terminology, Terms Used for Gas Welding
Equipment ;
e) BS EN ISO 4063 Welding and Allied Processes - Nomenclature of Processes and Reference
Numbers ;
f) BS EN 22553 Welded, Brazed and Soldered Joints - Symbolic Representation on Drawings ;
g) BS EN ISO 15614 Specification and Qualification of Welding Procedures for Metallic Materials
– Welding Procedure Test ;
h) BS EN 287 Qualification Test of Welders ;
i) BS 4872 Approval Testing of Welds When Welders’ Procedure Approval is not Required ;
j) BS EN ISO 14171 Welding Consumables - Solid Wire Electrodes, Tubular Cored Electrodes
and Electrode/Flux Combinations for Submerged Arc Welding of Non alloy and Fine Grain
Steels-Classification ;
k) BS EN ISO 14174 Welding Consumables - Fluxes for Submerged Arc Welding and Electroslag
Welding – Classification ; and
l) BS EN 10225 Weldable Structural Steels for Fixed Offshore Structures - Technical Delivery
Conditions.
77
6.14.3 Welding Procedures

A welding procedure is defined as the method and sequences to be adopted to achieve a
satisfactory welded joint when carried out by competent workmen under the expected conditions
of manufacture.
Before welding is begun, the Contractor shall carry out a procedure qualification test for each
weld on test specimens of the same dimensional cross-section and material as that to be used in
the structures. The test specimens shall be of sufficient size to establish satisfactory procedures
with the welding being carried out in positions as close as practicable to the actual positions used
in construction.
Procedure qualification tests shall be in accordance with BS EN ISO 15614. All procedure
qualification tests and test specimens shall be made available to the Engineer and no alterations
shall be made to approve procedures during the course of the work unless further procedure
qualification tests are carried out and the results supplied to the Engineer.
6.14.4 Qualified Welding Inspector

The Contractor shall provide qualified Welding Inspector from an approved accredited Welding
Company to undertake full time supervision and certify all welding works. The Contractor to
submit details of welding Company to be engaged and curriculum vitae of Welding Inspector
for the approval of the Engineer. All welding works to comply with the Technical Specification
and Authority requirements accordingly.
6.14.5 Welder Qualification

All welders shall undertake welder qualification tests to determine the welder's ability to produce
sound welds. The qualification test for manual, semi-automatic and automatic welders shall be
carried out by Contractor in accordance with the relevant clauses of the BS EN 287.
Only those welders who have carried out satisfactory qualification tests shall be used by
Contractor on the work and such welders shall perform only the particular types of weld for which
they have qualified.
78
6.14.6 Welding Preparation and Finish

Unless specified otherwise, all welding is to be strictly in accordance with the requirements of
the BS EN 1792 and BS EN 13622. All fabrication processes where practicable, including
welding, shall be carried out in the workshop unless otherwise approved by Engineer for welding
work must be executed at site.
All shop welding shall be carried out by the submerged arc process. All welding shall be carried
out in an order and manner designed to minimize distortion and contraction stresses and to the
satisfaction of the Engineer.
Plates and sections to be welded shall be free from paint, oil, scale rust, or any other substance
which may affect the quality of the welding. The work to be welded shall be correctly aligned and
located. The leading edges of any plates, sections, or members to be connected by welding shall
be closed by means of metal clamps or jigs.
Where the ends of any plates, shapes, or sections are prepared for groove welding by gas
cutting, all gas cut surfaces shall be ground to finish smooth and flat prior to any welding.
In all cases of groove welded joints, the weld shall be terminated at both ends of the joint by use
of extension bars or run-on and run-off plates at least 50mm long. Such bars and plates shall be
of the same thickness and material and profiled to the same form of preparation as the base
metal for the groove weld, and shall be attached by metal clamps. Attachment by tack welds will
not be allowed.
The weld shall extend at least 25mm onto the run-on and run-off plates. Run-on and run-off
plates are to be removed, upon completion and cooling of the weld and the ends of the weld
ground smooth and flush with the edges of the abutting parts.
All groove welded butt joints in web plates, flange plates or flange angles for plate girders, and
any joints, shall be ground smooth and flush with the base metal on all sides and shall be present
a neat appearance. All grinding shall be carried out in the longitudinal direction of the member
and the surfaces shall be left free from depressions.
All fillet and groove welds shall show good even contours of the specified shape. There must be
no break in the continuity of a weld as when proceeding with a new electrode. Undercutting will
not be allowed under any circumstances. All fillet welds shall be made continuous around all
sides of the connected parts unless specifically noted otherwise on the drawings.
79
6.14.7 Welding Processes

The following processes are permitted:
a) Shielded metal-arc
b) Automatic submerged-arc
Oxy-acetylene for carbon steel tubes of a nominal bore of 75mm or smaller. The maximum
individual layer thickness for submerged-arc welds shall not exceed:
a) 6mm for materials less than 32mm thick
b) 12.5mm for materials 32mm thick and greater.
6.14.8 Welding Electrodes

The welding electrodes shall comply with the requirements of BS EN ISO 2560, BS EN ISO
14171 and BS EN ISO 14174. The combination should be selected with regard to the particular
application.
The deposit analysis of welding consumables shall match that of the base materials. "Low
Hydrogen" welding consumables shall be used for all welds. The physical properties of deposited
weld metal shall be within the limits specified for the material being joined unless otherwise
approved for special applications.
Electrodes shall not be used if they become damp or damaged in any way, and shall not
normally be used later than 6 months after the date of manufacture. In particular electrodes
stored on the site shall be kept in a room or container, with a controlled humidity and temperature
suitable for the electrodes.
6.14.9 Slag
After each run of weld, the slag must be completely removed before any further run is added or
superimposed. All welds shall be cleaned of slag and wire brushed upon completion. Any slag
inclusions shall be cut out and the defective section re-welded.
80
6.14.10 Tack Welds

Tack welds where used shall be subject to the same quality and procedure (including preheat)
requirements as the final welds. Tack welds shall be cleaned of all slag and fused thoroughly
with the final weld.
Defective, cracked or broken tack welds shall be removed before final welding. In any case,
tacks welds shall not be used unless located in a position where a final structural weld is to be
made such as to incorporate the tack weld into the final weld.
6.14.11 Heat Treatment

Heat treatment of welds, where required, shall be done in accordance with the standard for the
particular application where such standard exists or shall be fully detailed by Contractor, taking
into account the effect on joint properties, where such standard does not exist.
6.14.12 Inspection of Welds

The frequency and type of testing shall be in accordance with these Specifications. Any weld
that fails to comply with the requirements laid down in the relevant standard, shall be rectified, or
shall be removed and replaced.
Repaired or replaced welds shall then be tested either by radiography or ultrasonically until such
time as they are in compliance with such requirements. The Contractor shall arrange for a
qualified welding inspector(s) or agency to carry out the inspection of all sites welding.
All factory or shop welding shall be tested by an agency or a laboratory experienced with such
testing. Such agency or laboratory shall be subject to approval by the Engineer.
For all welding, the Engineer will be supplied with a copy of all radiographs together with an
endorsed report covering such radiographs, and also an endorsed report, or equivalent, giving
results of all ultrasonic tests. All reports shall include a full statement of defects including the
location and magnitude of each such defect.
In addition, the Engineer will be provided with information by Contractor to correlate test reports
with the actual position of the welds in the structures. Identification marks shall be placed
81
adjacent to a weld but no mark shall be placed within 60mm of the centre line of the weld. Any
marking damaged or obliterated during subsequent repair work shall be re-stamped prior to
further testing. All markings shall be clearly visible after final assembly.
6.14.13 Mandatory Non-Destructive Examination of Welded Joints

The following regime of testing shall be followed by the Contractor:
Note:
Where steel plate thickness exceeds 35mm the Contractor, subject to the approval by the
Engineer may elect to substitute radiographic test (RT) for ultrasonic test (UT) inspection. NDE
shall take place after the final heat treatment and no sooner than 48 hours after welding.
Frequency of Examination for Welding
Frequency of Examination
Ref. Weld Type Exam. Type
(% of welds)
100% UT+200 mm RT at "T"

1 Longitudinal welds in piles UT+RT
Intersections with circumferential welds
20% (+100% for first 5 production

2 Circumferential welds in piles UT
splices per welder)
3 Full penetration welds UT 50% (100% for site welds)

Magnetic
4 Partial penetration welds 50% (100% for site welds)
Particle (MP)
5 Fillet welds MP 20%
All welds: visual inspection
Should in the opinion of the Engineer, the incident of defective welds be high, and then the
Engineer shall have the right to require an increase in the frequency of examination. Any
additional costs associated herewith shall be borne by the Contractor.
82
6.14.14 Weld Acceptance Criteria

Only welds complying with the Specification are acceptable. All other welds found to contain
defects shall be repaired or replaced to produce an acceptable quality level.
If difficulty is experienced in categorising defects revealed by radiography, ultrasonic testing shall

also be used to facilitate interpretation, or vice-versa.
The acceptance criteria for various type of test shall be as follow:

a) Inspection by visual mean, magnetic particle shall be according to BS EN ISO 17638 and BS
EN ISO 23278;
b) Penetrate examination shall be according to BS EN 57;
c) Radiographic examinations shall be according to BS EN 1435; and
d) Ultrasonic examination shall be assessed according to BS EN ISO 17640.
7 WORKING UNDER TIDAL / WATER CONDITION

The Contractor shall take in consideration the restrictive hours in respect of the tidal condition in
his tender.
The Contractor shall also make the allowance in his cost for the provision of temporary
structures for the successful completion of the work and provision of additional equipment for
the work under tidal / water condition.
No claim in terms of cost and/or time will be entertained in this respect.
83

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TECHNICAL SPECIFICATION

CIVIL AND STRUCTURAL

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

3 STEEL TUBULAR PILING WORKS........................................................................................ 35

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

3.5 DELIVERY ....................................................................................................................................................... 37

5 CORROSION PROTECTION ................................................................................................... 62

6 STRUCTURAL STEEL ............................................................................................................ 71

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

6.2 GENERAL ........................................................................................................................................................ 71

7 WORKING UNDER TIDAL / WATER CONDITION ................................................................ 83

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

1.1. Surveys - Datum

1.2. Bathymetric Survey

b) Multi Beam Echo Sounder (MBES) System

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

1.3. Marine Warranty Surveyor

1.4. Soil Investigation

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

c) Setting Out of Borehole

A summary of the soil investigation programme is given below:

Breasting dolphin Boreholes taken to bedrock or Classification test,

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

The content of the report shall include the followings:

1.5. Setting Out

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

1.6. As-Built Survey

2.3. Materials for Concrete Marine Construction

2.3.1 Type of Cement

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

Codes for Cements

Type Standard Other Requirements

b) Sulphate resisting Portland

c) Cement containing ground

- Portland blast furnace cement BS146

d) Combinations made in the concrete Combination

- Portland cement conforming to

- Portland cement conforming to

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

Nominal size (mm) Percent (%)

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

2.3.5. Corrosion Inhibiting Admixtures

x Project Details (Name, Location, Contractor, etc...)

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

2.4. Concrete Design Mix

Max. Minimum Minimum

C40/50 20 370 0.38 60

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

B.S. Nominal Size of Nominal Size of

37.5 95-100 100 - 0-30 85-100 100 - -

20 30-70 95-100 100 0-5 0-20 85-100 100 -

14.0 - - 90-100 - - - 85 -100 100

10.0 25-55 25-55 40-85 - 0-5 0-20 0-45 85-100

5.0 0-10 0 -10 0-10 - - 0-5 0-10 0-20

10.0 mm 100 100 100 100

TECHNICAL SPECIFICATION – CIVIL AND STRUCTURAL

2.4.2 Sampling and Testing of Aggregates