Bidding Documents

Construction of the New Fuel Unloading Facility

at the Free Port of Monrovia, Republic of Liberia
Contract No.: MPW-IIU/URIRP/FUF-LPRC/001/11

December 2011

Part 2
Section VI Employers Requirements
Table of Contents

Contents
1

INTRODUCTION

FUNCTIONAL REQUIREMENTS
2.1
General Criteria and Site Data
2.1.1
Design Life
2.1.2
Units
2.1.3
Standards and Codes of Practice
2.2
Site conditions and Environmental data
2.2.1
Materials and Workmanship
2.2.2
Durability
2.3
Marine structures
2.3.1
General Criteria for Marine Structures
2.3.1.1
Design Vessels
2.3.1.2
Seismic design
2.3.1.3
Analysis
2.3.1.4
Pile Design
2.3.1.5
Mooring Lay-out
2.3.2
Unloading platform
2.3.3
Access trestle
2.3.4
Breasting dolphins
2.3.4.1
Fendering
2.3.5
Mooring dolphins
2.3.6
Catwalks
2.3.7
Pump house
2.3.8
Miscellaneous Items
2.3.8.1
Services and utilities
2.3.8.2
Jetty Lighting
2.3.8.3
Aids to Navigation
2.3.8.4
Corrosion Protection
2.3.8.5
Hose Area and Manifolds
2.3.8.6
Reference coordinate for the position of the main jetty
2.3.9
Dredging works
2.3.10
On shore facilities
2.3.11
Existing facility
2.4
Mechanical and electrical Functional Requirements
2.4.1
General Requirements
2.4.1.1
Design life
2.4.1.2
Standards and Codes of Practice

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2.4.1.3
2.4.2
2.4.3
2.4.4
2.5
2.5.1

Performance testing and Equipment manuals

Trestle Pipe Rack
Platform Equipment
Fire Fighting
Corrosion Protection
Electrical Works

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GENERAL EMPLOYERS REQUIREMENTS

3.1
Project Execution
3.2
Quality Assurance
3.3
Environmental Compliance
3.4
Contractors Design and Documentation
3.4.1
Contractors Design Submissions
3.4.2
Issue of Design Submissions
3.4.3
Technical Specifications
3.4.4
Construction Drawings
3.4.5
As-built Drawings and Final Calculations
3.4.6
Operation and Maintenance Manuals
3.5
Progress Control
3.6
Health and Safety
3.6.1
Site Safety
3.6.2
Safety Plan
3.6.3
Training
3.6.4
Personal Protective Equipment
3.6.5
Life Lines, Motorized Rescue Boat, Etc.

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TECHNICAL SPECIFICATIONS
4.1
General specifications
4.1.1
Facilities for Personnel
4.1.2
Safety and security of the Site
4.1.3
Employers Regulations on Site
4.1.4
Use and Care of Roads
4.1.5
Disruption to Neighbouring Works
4.1.6
Setting Out
4.1.7
Facilities for Employers staff
4.1.8
Contractors Laboratory
4.1.9
Testing of Materials and Workmanship
4.1.10
Site Cleanliness
4.1.11
Access for Third Parties
4.1.12
Electricity, Water and other Services
4.1.13
Publicity and Public Relations
4.1.14
Port Operations and General Information
4.1.15
Tidal Levels
4.1.16
Site Access
4.1.17
Radio Communication
4.1.18
Restriction on Use of Public Roads
4.1.19
Traffic Safety Measures
4.1.20
Temporary Approaches & Diversion of Existing Rights of Way
4.1.21
Existing Services
4.1.22
Removal of Public Utility or Privately Owned Services, Etc
4.1.23
Scaffolding
4.1.24
Records

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4.1.25
4.1.26
4.1.27
4.1.28
4.1.29
4.1.30
4.1.31
4.1.32
4.1.33
4.1.34
4.1.35
4.1.36
4.1.37
4.1.38
4.1.39
4.1.40
4.1.41
4.1.42
4.1.43
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
4.2.12
4.2.13
4.2.14
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
4.3.11
4.3.12
4.3.13
4.3.14
4.3.15
4.3.16
4.3.17

Port Regulations
Lighting, Marking, Buoying and Watching
Navigation
Liability for Damage to Shipping
Floating Plant
Avoidance of Nuisance
Underwater Obstructions
Temporary Moorings
Port Charges
Radio Transmissions
Diving
Removal of Sunken Vessels and Offshore Plant
Debris in the Sea
Existing Ground Levels
Emergency Arrangements
Delivery, Handling and Storage of Materials
Construction Plant
Defective Work
Surveys
Dredging
General
Dredging Plant
Dredging in Any Materials
Tide Levels
Position Controls
Survey
Dredging Tolerances
Side Slopes
Disposal of Dredged Material
Siltation
Sweeping
Daily Records
Existing Operation
Method Statement
Piling Work
General
Materials
Handling and Storage of Piles
Fabrication and Splicing of Steel Piles
Pile Identification
Damage to Piles
Pile Design
Piling Method Statement
Installation of Tubular Steel Piles
Tolerances
Preparation of Pile Heads
Piling Programme
Records
Obstructions
Reinforced Concrete Riling
Pile Testing
Dynamic Pile Testing

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4.3.18
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
4.4.13
4.4.14
4.4.15
4.4.16
4.4.17
4.4.18
4.4.19
4.4.20
4.4.21
4.4.22
4.4.23
4.4.24
4.4.25
4.4.26
4.4.27
4.4.28
4.4.29
4.4.30
4.4.31
4.4.32
4.4.33
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
4.5.7
4.5.8
4.5.9
4.6
4.6.1
4.6.2
4.6.3
4.6.4
4.6.5
4.6.6

Pile Anchors
Concrete Works
General
Cement
Aggregates
Silica Fume for Concrete
Admixtures
Storage and Delivery of Aggregates
Washing of Aggregates
Water
Concrete
Trial Mix and Workability
Production and Delivery
Ready Mixed Concrete
Placing
Blinding layer
Curing
Concreting in Hot Weather
Testing
Formwork
Embedded Articles
Surface Finish
Reinforcement
Bending of Reinforcement
Welding of Reinforcement
Placing of Reinforcement
Cover to Reinforcement
Cutting Concrete
Faulty Works
Joints
Tolerances
Precast Concrete
Method Statement
Bedding of Precast Units
Waterproofing
Structural Steelwork
Steelwork and Connections - General
Materials
Documentation and Submissions
Handling, Storage and Transport
Fabrication of Steelwork
Erection of Structural Steelwork
Tolerances
Testing and Inspection of Steelwork
Miscellaneous steelworks
Corrosion Protection
Structural Steelwork
Schedule of Colour Finishes
Protective Treatments
Painting
Safety
Storage of Paint

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4.6.7
4.6.8
4.6.9
4.6.10
4.6.11
4.6.12
4.6.13
4.6.14
4.6.15
4.6.16
4.6.17
4.6.18
4.6.19
4.6.20
4.7
4.7.1
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
4.7.8
4.7.9
4.7.10
4.8
4.8.1
4.8.2
4.8.3
4.9
4.9.1
4.9.2
4.9.3
4.9.4
4.9.5
4.9.6

Sampling and Testing

Paint Trial
Prepared Surfaces
Preparation of Bare Metal Surfaces
Paint Preparation
Paint Application
Shop Painting
Storage of Steel and Fabricated Steelwork
Metal Coatings
Handling of Coated or Painted Steelwork
Repairs to Damaged Area
Bolted Connections
Welded Joints
Treatment of Completed Joints
Fixtures and Fittings
General
Miscellaneous Metalwork
Life-Saving Equipment
Metal Decking
Fendering
Quick Release Mooring Hooks
Bolted Connections
Tide Gauges
Navigation Lights
Depth Contour Buoys
Drainage and Services
Floor Drains Jetty
Cable Ducts
Ducts
Geotechnical Investigation
Boring activities
Boreholes
Marine Equipment
Laboratory Analyses
Deliverables
References

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DRAWINGS

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SUPPLEMENTARY INFORMATION

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ANNEX 1 ESTIMATED BILL OF QUANTITIES

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INTRODUCTION

Part 2 of the Bidding Documents set out the Employers Requirements. These requirements are
divided in the following items:
Chapter 2

Functional Requirements
This is a description of the works

Chapter 3

General Specifications
This includes requirements with respect to the project execution, quality assurance,
environmental protection, design and the submission of design information to the
Employer, progress control and health and safety

Chapter 4

Technical Specifications
This describes the material and workmanship specifications

Chapter 5

Drawings
The reference design drawings are included in this chapter, presenting the reference
design for bidding purposes

Chapter 6

Supplementary Information
Reference documents are included in this chapter

FUNCTIONAL REQUIREMENTS

This part of the Bidding Documents sets out the performance specifications and design criteria the
Contractor shall follow. This includes both the functional requirements for the civil and marine works,
and the requirements for the mechanical and electrical works.
The civil and marine works are described in chapter 2.3, followed by the mechanical and electrical
works in chapter 2.4.
The new fuel unloading facility (FUF) shall be designed for the import of gasoil, gasoline and Jet A1 /
Kerosene.
The overall scope of work includes the detailed design and construction of the following main
components of the new FUF:
The unloading platform
The access trestle
The breasting dolphins
The mooring dolphins
The catwalks
The pump house
Dredging works
Based on the functional requirements a reference design is prepared for the new fuel unloading
facility. The following drawings describe the reference design. These drawings are included in
Chapter 5 of this part of the Bidding Documents.
9V1468.03.001 General Layout Existing Situation
9V1468.03.002 Jetty Layout
9V1468.03.003 Loading Platform Layout and cross sections
9V1468.03.004 Access Trestle Layout and cross sections
9V1468.03.006 Pump House Platform Layout and cross sections
9V1468.03.007 Pump House Building Layout, cross sections and views
9V1468.03.008 Electrical Systems
9V1468.03.009 Flow Diagram
9V1468.03.010 Mooring Dolphins Layout and views

9V1468.03.011 Breasting Dolphins Layout and views

It must be noted that this reference design is for bidding purpose only. The Contractor may use this
design as reference for the preparation of his design. Ultimately, the Contractor will become fully
responsible for the input data used and for the design of the FUF.

2.1

General Criteria and Site Data

This chapter gives an overview of the general design criteria for the detailed design and construction
of the civil works of the new FUF. This includes:
Design life
Standards and Codes to be adopted
Site conditions and environmental data
2.1.1

Design Life

The design life is defined as the period for which structural elements, services, drainage systems,
etc. are to be used for their intended purposes with acceptable maintenance, but without major repair
and/or replacement being necessary.
At the end of the design life the structures shall comply with the design ultimate and serviceability
limit states. Due regard shall be given in design to any corrosion loss during the design life.
Design life for the Works is defined in the table below.
Element

Design Maintenance Routine Maintenance Unacceptable Repair

Life
Interval
by Employer
or Maintenance

Buildings,
including services
and utilities

50 years

5 years

Routine inspection of
services and utilities.
General repairs and recoating

Replacement and repair of

walls, roofs, floors and
foundations required for
structural integrity

Slopes and
revetments

50 years

15years

Routine inspection and

replacement of minor rock
damage

Steelwork

50 years

15 years

Re-coating of protective
treatment systems

Fencing, barriers
and gates
Marine structures
reinforced
concrete

50 years

15 years

50 years

50 years

Replacement of corroded
mesh & straining wires
None

Replacement or re-grading
of rock armour, involving
damage exceeding 5% of
revetment area. Repair of
slumping
Cutting out/replacement of
defective/corroded steel.
Welding of steel plates
onto existing steel
structures/elements
Replacement of posts &
foundations
Cutting out/replacement of
defective/spalled concrete
and corroded
reinforcement

Other concrete
work

50 years

25 years

Routine inspection of top

surface, visible and
accessible parts

Cutting out/replacement of
defective/spalled concrete
and corroded

Element

Design Maintenance Routine Maintenance Unacceptable Repair

Life
Interval
by Employer
or Maintenance
reinforcement
Cutting out/replacement of
defective/corroded steel.
Welding of steel plates
onto existing steel
structures/elements;
Replacement of cabling or
bonding.

Marine structures 50 years

steel piling;
cathodic protection

20 years

Re-coating of protective
treatment system;
Replacement of anodes,
power supplies

Other piling works/ 50 years

foundations

25 years

Routine inspection of
surface, visible and
accessible parts

Corrosion
10 years
protection (coating
of piles)
Pavements
50 years

5 years

Routine inspection of
Replacement of coating
coating and repairs after
damage
Repair of localised damage Any removal/ replacement
to correct out of tolerance
settlement

2.1.2

20 years

Cutting out/replacement of
concrete or steel elements

Units

Metric units shall be used, in accordance with the Systme International d'Units (SI).
2.1.3

Standards and Codes of Practice

Wherever reference is made in the Contract to specific standards and codes to be met by the goods
and materials to be furnished, and work performed or tested, the provisions of the latest current
edition or revision of the relevant standards and codes in effect shall apply, unless otherwise
expressly stated in the Contract. Where such standards and codes are national, or relate to a
particular country or region, other authoritative standards that ensure a substantially equal or higher
quality than the standards and codes specified shall be accepted subject to the Project Managers
prior review and written consent.
Differences between the standards specified and the proposed alternative standards shall be fully
described in writing by the Contractor and submitted to the Project Manager at least 28 days prior to
the date when the Contractor desires the Project Managers consent. In the event the Project
Manager determines that such proposed deviations do not ensure substantially equal or higher
quality the Contractor shall comply with the standards specified in the documents
The design shall comply with the latest versions of internationally recognised codes of practice such
as the Eurocodes (EN), the British Standards (BS) or the German Codes (DIN). Where the British
Standards referred to in these Bidding Documents are superseded by Eurocodes, the equivalent
Eurocodes (with British National Annexes) shall be used.
The Contractor shall confirm the codes and design standards proposed for the works prior to starting
the design. The codes and design standards shall be subject to the approval of the Employer.
It shall be the responsibility of the Contractor to ensure that the codes and design standards used
shall fulfil the mandatory minimum requirements of Liberian Codes of Practice.

10

A suggestion for codes to follow is given below.

Design of concrete, steel and foundations:
Eurocodes including but not limited to:
1990 Eurocode 0 Basis of design
1991 Eurocode 1 Actions on structures
1992 Eurocode 2 Design of concrete structures
1993 Eurocode 3 Design of steel structures
1997 Eurocode 7 Geotechnical design
1998 Eurocode 8 Design of structures for earthquake resistance
Reinforced Concrete Design:
Eurocode 2: Design of concrete structures
BS 8110: Structural use of concrete, Part 1
Steel Structures Design:
Eurocode 3: Design of steel structures
BS 5950: Structural use of steelwork in buildings.
Materials and Workmanship:
The design and construction of all buildings shall generally be in accordance with Part 2
Chapter 4 of these Bidding Documents unless otherwise approved by the Employer.
Foundations:
Eurocode 7: Geotechnical design
BS8004: 1986: Foundations.
Minimum factor of safety for foundations shall be 2.5.
Foundation design shall allow for the possible settlement of the existing fill and shall limit
settlement to prevent damage to the structure.
Marine Structures
BS6349: Maritime structures, Part 1 General Criteria
BS6349: Maritime structures, Part 2 Quay Walls, Jetties and Dolphins
BS6349: Maritime structures, Part 1 Fendering and Mooring
Seismic Loads:
Eurocode 8: Design of structures for earthquake resistance
Design of all buildings and foundations shall include seismic loadings.
The peak ground acceleration is 0.6m/s2, in accordance with the seismic hazard map.
(refer section 2.1.3 of this part, Site Data)
The seismic design of the jetty structure and its components shall be carried out using
performance-based design methods as described in the Seismic design guidelines for
port structures, PIANC Working Group 34, 2001 (WG34) and Performance-Based
Seismic Engineering of Buildings, Version 2000 Committee, SEAOC.

2.2

Site conditions and Environmental data

Relevant site data, including environmental conditions, is summarized in the following table.
Item
Reference Level
Coordinate System
Bathymetry and
Design levels

Specification
The Chart Datum (CD) is Mean Low Water Spring (MLWS)
UTM coordinates (WGS84) shall be used.
The current bottom level at the fender line of the existing
jetty is CD -10.0m and is sloping up towards the south
breakwater (first 50m 1v:10h and further 1v:70h).

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Item

Specification
A survey has been performed by the Royal Dutch Navy in
December 2009. A copy of the survey results is presented in
Chapter 6 for information purpose. This and any other
survey information (bathymetric, topographic etc) is provided
without warranty regarding accuracy. The Contractor is
required to check and confirm accuracy before commencing
the Works. The Contractor shall undertake further surveys
as he deems necessary.
The bathymetry is also shown on reference drawing
9V1468.03/001
Construction bottom level of the new FUF will be CD -11.0m.
Sloping up with 1v:5h till the existing bottom profile is
reached. The design bottom level will be CD -15.0m at the
fender line of the new FUF and sloping up with 1v:5h, till the
existing bottom profile is reached.

Soil Conditions

At the location of the new FUF the top layer consist of mud,
clay, silt and sand over the first two meters. In deeper layers
sand mostly prevails. In addition, there is a possibility of the
presence of bedrock below 30m depth.
Geotechnical investigations were carried out in 1978/79 by
Rhein Ruhr Ingenieur Gesellschaft Mbh. Details of this
investigation are included in Chapter 6. The Contractor shall
be responsible for the interpretation of this data and shall
confirm the soil conditions by performing additional soil
investigations before commencing the Works.
These additional geotechnical site investigations are
included in the scope of work in order to determine the local
soil conditions and design parameters for the foundations.
In his tender submission the Contractor shall provide details
of the testing that he intends to carry out. It is the
responsibility of the Contractor to provide a design which will
accommodate the ground conditions as encountered during
investigation and construction.

Earthquake

Monrovia is located on a transition of green and dark green

area on the GSHAP map of the UN for Africa, refer to the
seismic hazard map on the following page. For the design a
Peak Ground Acceleration (PGA) at bedrock level of 0.6m/s2
shall be used. Any reduced accelerations based on local
seismic hazard data may be used after approval by the
Employer.

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Item

Specification

Tidal levels

The following tidal levels apply:

- Highest High Water (HHW): CD +1.57m
- Mean Sea Level (MSL): CD +0.70m
- Mean Low Water Spring (MLWS): CD +0.00m
- Lowest Low Water (LLW): CD -0.10m

Long term sea level

rise

years
SLR Average
SLR Upper limit

Sea Level Rise (SLR):

5
10
25
0.02m
0.04m
0.09m
0.03m
0.05m
0.13m

1
0.00m
0.01m

50
0.18m
0.25m

100
0.35m
0.50m

Storm set up

A storm set up of 0.50m shall be taken into account in the

design

Wind

Limited information is available for wind speeds across the

project area. A maximum stay-at-berth wind speed of 17m/s
must be considered for the design. At higher wind speeds
the tankers will no longer be moored at the new FUF.

Waves

Wave conditions inside the port area:

Operational condition: Hs = 0.5m, Tp = 5s 10s
Extreme condition: Hs = 1.0m, Tp = 5s 10s

Currents

Current conditions inside the port:

0.1m/s

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The report mentioned for the soil investigations that was produced in 1978/79 by Rhein Ruhr
Ingenieur Gesellschaft GmbH, also contains information with respect to the tides, wind and waves.
Relevant extracts from the report are included in Chapter 6. Full details are available to view in the
Employers office. The Contractor will be responsible for the interpretation of this data and shall
confirm the information by performing additional (site) investigation.
2.2.1

Materials and Workmanship

Materials, equipment and workmanship including testing shall conform to the following:

The latest revision of the applicable standards

The minimum requirements stated in the Materials and Workmanship Specifications contained
within Part 2 Chapter 4 of the Bidding Documents;

In case of discrepancy the more onerous requirements shall govern.

2.2.2

Durability

All structures shall be designed to meet the durability requirements set forth in the Bidding
Documents and the Codes used.
The design of the concrete mix for all structures shall take account of the location of the Site and the
nature of the products to be handled over the jetty. The concrete mix shall include suitable additives,
such as silica fume, designed to reduce the porosity of the concrete.
All steelwork shall have a suitable corrosion protection system capable of achieving the required
design life. This shall consist of a coating, galvanising, a corrosion allowance on the steel thickness,
cathodic protection, or a combination of these.

2.3

Marine structures

2.3.1

General Criteria for Marine Structures

Within this section, the Functional Requirements for particular elements of the marine works are set
out based on the following subheadings as appropriate:

Work Scope

Function

Particular Requirements

All items within each section shall be taken into account both individually and in combination in order
to achieve the required finished product.
The detailed work scope and function for the individual elements are included in separate sections
below.

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The main structural elements are:

The unloading platform

The access trestle

The breasting dolphins

The mooring dolphins

The catwalks or access walkways

The pump house

Dredging works

The other elements include;

Pile design

Fendering

Mooring

The design criteria to be used for the structures are stated and the design requirements for particular
elements including are given.
2.3.1.1

Design Vessels

The new FUF shall be designed to accommodate tankers ranging between 10,000 DWT and 60,000
DWT. The design vessels presented in the following table are taken from PIANC Report nr. WG33,
Guidelines for the design of fender systems, 2002, Appendix C. table C1.
Dead Weight Tonnage
Displacement
Length Overall
Length Between
Perpendiculars
Breadth
Depth
Ballasted Draught*
Loaded Draught
Ballasted Freeboard*
Loaded Freeboard*
Wind Lateral Area
- Ballasted Condition
- Full Load Condition
Wind Front Area
- Ballasted Condition
- Full Load Condition

[te]
[te]
[m]
[m]

10,000
14,300
127.0
121.0

20,000
27,700
158.0
151.0

30,000
40,800
180.0
173.0

40,000
53,600
196.0
189.0

50,000
66,400
211.0
204.0

60,000
79,000
223.0
216.0

[m]
[m]
[m]
[m]
[m]
[m]

20.8
10.0
6.7
7.9
3.3
2.1

25.8
12.8
7.6
9.6
5.2
3.2

29.2
14.8
8.4
10.9
6.4
3.9

30.8
16.2
8.9
11.8
7.3
4.4

32.3
17.6
9.2
12.6
8.4
5.0

35.2
18.8
9.5
13.3
9.3
5.5

1,090
688

1,650
1,010

2,090
1,270

2,460
1,480

2,830
1,690

3,150
1,870

303
255

443
355

554
430

644
489

734
548

809
595

[m ]
2
[m ]
[m ]
2
[m ]

* Estimated values
- Loaded Freeboard = Depth Loaded Draught
- Ballasted Freeboard = Wind Lateral Area Full Load Condition / Wind Lateral Area Ballasted Condition * Loaded
Freeboard

15

- Ballasted Draught = Depth Ballasted Freeboard

2.3.1.2

Seismic design

In accordance with the definitions of the Level 1 and Level 2 seismic events given in WG34 (Pianc),
the over-riding requirements for the seismic design shall be:

Level 1 Serviceable

Level 2 Repairable

This is equivalent to performance grade A.

For the jetty structure, these terms can be further defined as follows:

Serviceable ship loading operations can recommence immediately after the seismic event while
minor repairs are carried out

Repairable the structure can be reasonably repaired and restored to operation in a reasonable
period of time, not exceeding 3 months.

After a Level 2 event, reasonable repairs could include:

Reinstatement of the berthing line by modification to the fenders to accommodate forward

movement of the structure

Modifications to the cope edge to restore the minimum hull clearance to vessels during berthing
and mooring

Repairs to expansion joints between sections of the jetty and between the jetty and adjacent
pavement

Repair of localised damage to structural elements to restore durability

Damage resulting in excessive forward movement of the structure, reduction in overall stability and
reduction in strength of primary load bearing elements shall not be permitted. Guidance on damage
criteria can be obtained from WG34.
The Contractor shall prepare and submit a fully comprehensive design submission demonstrating
that the specified performance requirements are satisfied by his design.
For the Level 2 event, the peak horizontal ground acceleration at rock head level shall be taken as
0.6g for a return period of 475 years, equivalent to a 10% probability of exceedance in 50 years.
For the Level 1 event, the peak horizontal ground acceleration at rock head level shall be taken as
0.3g for a return period of 72 years, equivalent to a 50% probability of exceedance in 50 years.
The peak horizontal and vertical ground acceleration shall be modified as required by the adopted
design standard. The design earthquakes shall consider the Site amplification effect.
2.3.1.3

Analysis

The following requirements make reference to Eurocode and Pianc guidelines. Should the Contractor
adopt alternative codes of practice for the design the design submissions shall contain a table

16

comparing the requirements of the adopted code of practice with the equivalent requirements in the
Eurocode and Pianc guidelines.
Static Condition
Load factors should generally be in accordance with Eurocode 1. Where load combinations are not
covered by Eurocode 1, for example for the marine structures, the factors from Table 2 of BS6349
Part 2 may be used, assuming normal loading conditions and incorporating both f and f3.
The self weight of the liquid bulk handling equipment including the pedestal mounted crane may be
considered as dead load, the dynamic loads from the equipment shall be considered as live load.
Seismic Condition
Same as static condition except:

Berthing shall not be considered

50% of imposed loads to be considered. The pedestal mounted crane loader shall be as static
case with zero wind and maximum operational load.

Design shall take account of -delta effects

The possibility of spalling of cover concrete under cyclic loading shall be considered.

The structure shall be designed for the design earthquake peak ground acceleration referred to in
section 2.2. This peak ground acceleration shall be assumed to relate to a Level 2 earthquake as
defined in the PIANC Seismic Design Guidelines for Port Structures publication. The structure
shall be designed to provide continued stability and strength during the design earthquake.
1.0 on loads with a material factor of 1.0.

The choice of analysis shall reflect the form of construction and design earthquake event and shall
follow the recommendations of Tables 5.3 and 5.4 of WG34. It is considered that quasi-static analysis
is not sufficient for demonstration of performance under the seismic event because movements are
not adequately addressed by this method. However, quasi-static analysis may be used to determine
strength requirements and overall stability. Analysis shall take account of the pedestal mounted
crane.
The analysis shall cover the following as a minimum:

Modelling of the jetty structure and miscellaneous facilities (pump house, etc)

Pedestal mounted crane interaction

Site amplification effects

Cracking of reinforced concrete (sensitivity analysis)

Sensitivity analysis to determine the effect of uncertainties in input motions, geotechnical

parameters, etc

Liquefaction assessment

Verification of software to demonstrate that the software can correctly carry out the required
analysis

17

For quasi-static analysis, the peak horizontal ground acceleration shall be increased by a subsoil
condition or soil foundation factor to account for the soil properties at the Site. This factor is codedependent but shall in all cases exceed 1.0.
Where the adopted code requires the use of an importance factor, this shall be taken as not less than
1.0.
In his design submission, the Contractor shall identify the possible modes of failure of the jetty
structure. The Contractor shall carry out and submit separate analyses to define the critical mode of
failure. The Contractor shall analyse the critical mode of failure using an appropriate level of analysis
as defined by WG34 to demonstrate that the performance requirements are met.
2.3.1.4

Pile Design

Static Condition
Piles working loads shall be based on the worst loading caused by one of the following load
combinations:

Dead Load + Max Live load

Dead Load + Berthing Load

Dead Load + Mooring Load

Dead Load + Pedestal mounted crane (in operation - wind) + UDL

Dead Load + Seismic Load

The minimum factors of safety for ultimate static capacities (ultimate static capacity working load)
shall be as follows:
Compression piles:
Overall safety factor 2.5
Tension piles:
Overall safety factor 2.5
Compression / Tension piles: Overall safety factor 3.0
Seismic Condition
Same as static condition except:

Berthing shall not be considered

50% of imposed loads to be considered with the exception of the pedestal mounted crane. The
pedestal mounted crane shall be as static case with zero wind and maximum operation load.

Because the soil information presently available is rather limited, the envisaged pile size and pile
length may be subject to change. Therefore additional items have been included in the Bill of
Quantities (BoQ) in Part 1 of the Bidding Documents for the material, transportation and installation
of different pile sizes.
2.3.1.5

Mooring Lay-out

The new FUF shall facilitate in unloading 10,000 DWT tankers up to 60,000 DWT tankers. Two
breasting and two mooring dolphins are required for a safe and efficient operation of the full range of
vessels.

18

The breasting dolphins are to be placed with a centre to centre distance of 70m at both sides of the
platform. The mooring dolphins are to be placed with a centre to centre distance of 200m, 100m at
both sides of the centre line of the platform, and 40m behind the berthing line.
This mooring layout is shown on reference drawing 9V1468.03/002 in Part 2 Chapter 5.
2.3.2

Unloading platform

Scope
The scope of works includes but is not limited to the design, supply, installation, construction,
monitoring, testing and quality assurance, commissioning and for the duration of the contract,
maintenance of the following. The reference design of the unloading platform is shown on drawing
9V1468.03/003.

Platform for unloading oil products, with a length of 20m (parallel to fender line) and width of 15m
(perpendicular to fender line), including facilities for unloading, a pedestal mounted crane, hose
area, auxiliary equipment, ladders, access to trestle and dolphins and jetty furniture.

Pedestal mounted crane

Gangway access

Cathodic protection system

Jetty deck drainage system (with collection in slop system)

All necessary ancillary works and services tied in with the utilities including drainage, power
supply (LV) distribution ductwork, and communication ductwork, manifolds and hose connections.

The unloading platform shall incorporate the following:

Piled foundations, support beams, deck structure, safety hand railing, services, and the like as
required.
Function
The unloading platform structure and associated fittings is required to:

provide unloading facilities for liquid bulk vessels carrying oil products in the range 10,000DWT to
60,000DWT.

support pedestal mounted crane.

provide a hose area for handling and connecting hoses to the product lines.

provide manifolds and pipe work for the connecting product lines on the trestle.

provide access to the vessels (using ships gangway)

provide access for victualling and stores to vessels (using the ships gangway)

provide access for emergency escape routes

be serviceable or repairable after the specified design seismic event.

support equipment required for the erection, commissioning and maintenance of the platform
furniture, equipment and services;

provide access to the breasting and mooring dolphins

19

incorporate provisions, pits and ducts for the following:

o

product lines from the trestle

electrical, instrumental and communication cabling

fire water supply and fire monitor

lighting

hose area

slop area

spill pump

provide for drainage of the jetty and collection of spill in a slop system

provide a cathodic protection system for immersed steelwork;

Particular Requirements Unloading Platform

Item

Requirements

Overall length of Platform

Structure
Width of Platform Structure
Cope level
Design seabed level

20m

Safety ladders

Surface Water Drainage

15m
+5.00m CD
-15.00m CD. In addition a scour allowance of 1m shall be
taken into account.
Ladders to be provided at either side of the platform.
Ladders shall extend 1m below MLWS and shall comply
with the requirements of ILO regulations, and
internationally recognised codes of practice.
Sufficient surface falls to ensure storm water is shed to
drainage collection points (the hose area or the slop
system). Ponding or standing water is not permitted.
Rainwater falling within the limits of the collection pit shall
be treated as slop water unless the pit is considered
clean due to either extensive cleaning or extended period
of disuse. Any rainwater falling outside the limits of the
collection pit may be drained to the sea.

Edge Protection

Hand railing shall be provided as edge protection to all

sides of the platform, except for the vessel side.
Design loading
Uniform distributed load: 10 kN/m2.
Pedestal mounted crane, including fire water monitor:
Capacity 15kN at 20m.
Horizontal loading: 10% x vertical load
The reference design of the unloading platform shows a suspended deck structure with steel tubular
piles and a concrete deck. It is envisaged that the deck is constructed with prefabricated concrete
beams, and an in situ reinforced concrete deck with precast concrete formwork.
The platform shall receive the product pipelines coming from the Trestle and reroute them such that
the end is placed above a slop pit of 4 meters wide and 16 meters long running lengthwise across the
platform. This pit is to be covered with a grating and the interior is to be slopped towards a sump. The
sump will house a pump to remove slop waters as they accumulate.

20

The incoming pipelines shall have a drain at their lowest point on the platform and the runoff from this
point will be pumped towards a slop tank on the platform. The slop waters recovered from the pit will
similarly be pumped towards this tank. The tank shall be equipped with a level indicator and low and
high level alarms. Once the tank has reached an adequate level its content will be pumped towards
the slop system of the terminal over a dedicated pipeline.
A set of 8hoses will be stored over the pit. The hoses will be approximately 20 meters in length and
be adequate to handle petrochemical products in a marine environment.
To connect the pipe endings to a tanker ship a crane will be placed on the platform. It is to be a
pedestal mounted crane capable of reaching a 20 meter envelope such that it can reach a ship
manifold in any predicted mooring position. It is to be capable of carrying a full 1.5 tonnes for the full
extent of its reach.
In addition to the product pipelines a Firewater pipeline will arrive at the platform. This pipeline will be
rerouted to provide firewater to a monitor mounted on the pedestal of the crane. Should for any
reason the remote control of the fire monitor fail, it will be controllable locally.
A nitrogen pipeline will arrive at the platform. This line will be prepared to serve any required task at
the platform such as the pigging of the pipelines.
A distribution cabinet at the platform shall provide power to all power drains on the platform and on
the dolphins. The cabinet will house a 400 to 115 VAC transformer. The platform will also house the
relevant control systems for the equipment on the platform with exception of the fire monitor.
Two lighting poles at the side most distant from the mooring vessel will illuminate the working area
with no less than 50 lux.
2.3.3

Access trestle

Scope
The scope of works includes, but is not limited to, the following:

Allow for safe access to the jetty structure from the access trestle. The works shall include all
associated structural aspects including supporting piles and foundations, walkway, pipe supports,
hand railing, etc.

Abutment at the interface with shoreline and the start of the piled trestle to support the on-shore
end of the trestle.

The structure shall incorporate the following:

Piled foundations, support beams, supporting structures for the walkway and the product pipelines
and utilities, hand railing, lighting and the like as required.
Function
The access trestle is required to:

provide access between the shore and the off-shore structures.

provide support for the product pipelines between the shore and the unloading platform.

21

provide access emergency escape route

provide protection of the walkway and product pipelines for waves

be serviceable or repairable after the specified design seismic event.

incorporate provisions, and ducts for the following:

o

2 water line

3 spill line

2 nitrogen line

12HFO line (spare)

12 Gasoil line

10 Gasoline line

8 Jet-A1/Kerosine line

12 Fire fighting line

Three cable trays (electrical, instrumental and one spare)

1m wide walkway

provide a cathodic protection system for immersed steelwork;

provide adequate lighting

Particular Requirements Access Trestle

Item

Requirements

Overall length of Trestle

Structure
Walkway

251m

Loading
Product pipelines

Width between hand railing 1.0m

Top level +5.45m CD
Uniform distributed load walkway: 5 kN/m2 (pedestrian
access only)
Horizontal load: 10% x vertical load
(water filled weight for testing):
12 gasoil:
151.7 kg/m
10 gasoline:
111.0 kg/m
8 Jet-A1/kerosene: 74.71 kg/m
12 Fire Fighting:
151.7 kg/m (between pump house
and the loading platform)
12 HFO:
151.7 kg/m (spare)
3 spill line:
13.43 kg/m
2 nitrogen line:
9.368 kg/m
2 fresh water line 9.368 kg/m
(non-potable)

It is envisaged that the walkway consists of a 50mm thick, 1.0m wide grating supported on UNP
profiles. At both sides of the walkway hand railing is foreseen. The reference design of the trestle is
shown on drawing 9V1468.03/004 in Part 2 Chapter 5.

22

The walkway and product pipelines shall be supported at a fixed spacing. This spacing is limited to
the maximum spacing of the pipe supports.
The trestle shall have longitudinal expansion joints and each section shall provide sufficient
longitudinal stability of the trestle structure.
The trestle is divided in two sections: section 1 is located between the access shore and the pump
house, section 2 between the pump house and the unloading platform. The fire water pipeline runs
connects the fire water intake at the pump house with the fire monitor on the loading platform.
All pipelines are to be welded for their complete length except where they tie in on the platform or in
the pump house.
A cable tray will house all power and signal cables for the full length of the trestle.
Lighting posts placed at regular intervals of approximately 30 meters will illuminate the walkways with
no less than 10 lux.
2.3.4

Breasting dolphins

Scope
The scope of works includes, but is not limited to, the following:

Two breasting dolphins capable of supporting the loads arising from the berthing and mooring of
vessels;

A fender connected to the dolphin facing;

A twin-hook Quick Release Hook (QRH) mounted on each dolphin of sufficient capacity to resist
the mooring loads from the design vessels with an adequate factor of safety but with a minimum
capacity of not less than 60 tonnes/hook, i.e. 120 tonnes per twin hook;

Remote and local release stations for the QRHs;

A capstan capable for providing a winding force of 1.5 tonne at a rate of not less than 30m per
minute.

The facility shall incorporate the following:

Piled foundations, reinforced concrete deck, fender with fender panel, quick release hook, safety
ladder, hand-railing, rope guards, life saving equipment, lighting, low voltage power, communication
equipment, and the like as required.
Function
The breasting dolphins are required to:

Provide for the safe and adequate berthing and mooring of the design vessels;

Support the Quick Release Hooks

Provide for the safe and adequate working area for the mooring crews

Provide access from the unloading platform

incorporate provisions, pits and ducts for the following:

23

lighting, low voltage power supplies.

be serviceable after the specified design seismic event.

The interfaces between the structures shall be designed to accommodate movements arising from
environmental (including seismic), and mooring loads.
Particular requirements Breasting Dolphins
ITEM

REQUIREMENTS

No of breasting dolphins
Fenders

2
One cone type fender for each dolphin. The use of other
fender types is subject to approval by the Employer. A
steel fender panel, with UMHW-PE facing, shall be
mounted on the fender.
1 x Twin QRH per dolphin, with integrated capstan
60 Tonnes
0o to 90o
0o to 45o above horizontal
5.0 kN/m2
One per dolphin. Ladders shall extend 1m below MLSW
and shall comply with the requirements of ILO
regulations, and internationally recognised codes of
practice.
To be provided over the length of deck not covered by the
horizontal operating range of the hooks less 1.0m at each
end and at ladder positions.
To be provided over the length of deck covered by the
horizontal operating range of the hooks plus 1.0m at each
end.
365
Required for safe access
8m x 8.5m
+4.00m CD
-15.00m CD. In addition a scour allowance of 1m shall be
taken into account.
-15.00m CD
LV electricity, communications, lighting.
1.1 x Reaction force fender
Line loads: minimum 2 x 600 kN = 1,200 kN
Lean-on: 50% x 1.1 x Reaction force fender

Quick Release Hook (QRH)

Minimum hook capacity
Operating range Horizontal
Operating range Vertical
Design deck load
Safety Ladders

Handrails
Rope guard
Days in service/ annum
Lighting
Minimum deck area
Deck level
Design seabed level
Design seabed level
Services/ utilities
Berthing loads
Mooring loads

One lighting pole at the side most distant from the mooring vessel shall illuminate the working area of
each dolphin with no less than 10 lux.
2.3.4.1

Fendering

Scope
The scope of works for the fender system includes, but is not limited to, the following:
The provision, testing and installation of a fixed fendering system comprising elastomeric rubber
cone fenders with low friction frontal panels and galvanised restraining chains

24

the design of the fendering system

the fender system shall be compatible with the provision of a 10-year warranty for the entire
system.

Function
The fendering system and associated works are required to provide a safe and effective fendering
system.
Particular requirements; fendering
ITEM
Berthing mode
Maximum eccentricity
Maximum vessel berthing
angles
Bow flare angle
Bow radii
Bulbous bows

REQUIREMENTS
Side berthing (dolphin berthing), parallel berthing to be
considered
Third point vessel impact
10o for vessels up to 50,000t loaded displacement
6o for vessels over 50,000t loaded displacement
15
Fender performance to take account of bow radii
Fender design to take account of bulbous bows

25

ITEM

REQUIREMENTS

Energy absorption

For vessels < 30.000DWT, 175% of berthing energy from

normal impacts, within rated deflection
For vessels 30.000DWT, 150% of berthing energy from
normal impacts, within rated deflection
Approach velocity
To be appropriate for the location of the jetty and the
vessel size.
Softness coefficient
to be appropriate to the type of jetty construction.
Berth configuration coefficient to be appropriate to the type of jetty construction.
Rated energy and deflections The rated fender energies and deflections shall be based
on the test speed recommended in PIANC Bulletin No 45
(1984): Annex 4.1.
Reduction in rated fender
rated energy and deflections values shall be reduced,
energy
where necessary, using manufacturers factors, to take
account of temperature, berthing and flare angles
Distance between cope edge To be the minimum dimension which will allow 400mm
and berthing line
clear between the vessel hull and the cope with the fender
fully compressed. The fender size and spacing selected to
satisfy this criterion.
Maximum permitted
60% of height of fender unit
compression of fender units
under abnormal berthing
Fender panel facing
UHMW PE low friction, minimum 40mm thick, yellow.
Coefficient of friction UHMW- Not less than 0.2
PE to steel (dry)
Chains between jetty and
Required
fender (to prevent rope
snagging)
Restraint chains
Required
Factor of safety on restraint Factor of safety of 3.0. A weak link in the form of a
chains and fixings
shackle, shall be provided in chains to avoid damage to
any fixings cast into the jetty structure.
Allowable hull pressures
20 tonnes/m2 maximum
Fender panel
The steel fender panel shall be designed to accommodate
a horizontal line load equal to the abnormal fender reaction
at any point.
Approach velocities to be based on unfavourable berthing conditions as defined in PIANC Guidelines
The fender calculations are to be carried out in accordance with the requirements of BS6349 Part 4.
All fenders shall be pre-compressed prior to installation. In addition, fendering shall be tested in
accordance with the recommendations of PIANC/INA Guidelines for the Design of Fender Systems:
2002.
For the calculation of the berthing energy a misalignment of 10m shall be taken into account to allow
vessels berthing eccentric to the spotting line of the new FUF.
The following fender reaction forces shall be taken into account in the structural design of the
dolphin:
Horizontal fender reactions (perpendicular to jetty)

Horizontal fender shear forces (parallel to jetty) based on a co-efficient of friction not less than 0.3

26

Vertical fender shear forces (vertical to jetty) based on a co-efficient of friction not less than 0.3

The design fender shear forces shall be considered co-incident with the design fender reaction
forces. The design shall take into account variation of fender performance with temperature.
Rigid structures are envisaged for the two breasting dolphins, constructed of a concrete deck and
raked tubular steel piles. A reference design is show on drawing 9V1468.03/011 in Part 2 Chapter 5.
2.3.5

Mooring dolphins

Scope
The scope of works includes, but is not limited to, the following:

Two mooring dolphins capable of supporting the loads arising from the mooring equipment to be
mounted on the dolphins;

A triple-hook Quick Release Hook (QRH) mounted on each dolphin of sufficient capacity to resist
the mooring loads from the design vessels with an adequate factor of safety but with a minimum
capacity of not less than 60 tonnes/hook, i.e. 180 tonnes per triple hook;

Remote and local release stations for the QRHs;

A capstan capable for providing a winding force of 1.5 tonne at a rate of not less than 30m per
minute.

The facility shall incorporate the following:

Piled foundations, reinforced concrete deck, quick release hook, safety ladder, hand-railing, rope
guards, life saving equipment, lighting, low voltage power, communication equipment, and the like as
required.
Function
The mooring dolphins are required to:

Provide for the safe and adequate mooring of the design vessels;

Support the Quick Release Hooks

Provide for the safe and adequate working area for the mooring crews

Provide access from the unloading platform and the breasting dolphins

incorporate provisions, pits and ducts for the following:

o

lighting, low voltage power supplies.

be serviceable after the specified design seismic event.

The interfaces between the structures shall be designed to accommodate movements arising from
environmental (including seismic), and mooring loads.
Particular requirements Mooring Dolphins
ITEM

REQUIREMENTS

No of mooring dolphins

2
27

ITEM

REQUIREMENTS

Quick Release Hook (QRH)

Minimum hook capacity
Operating range Horizontal
Operating range Vertical
Design deck load
Safety Ladders

1 x Triple QRH per dolphin

60 Tonnes
0o to 90o
0o to 45o above horizontal
5.0 kN/m2
1 per dolphin. Ladders shall extend 1m below MLSW and
shall comply with the requirements of ILO regulations,
and internationally recognised codes of practice.
To be provided over the length of deck not covered by the
horizontal operating range of the hooks less 1.0m at each
end and at ladder positions.
To be provided over the length of deck covered by the
horizontal operating range of the hooks plus 1.0m at each
end.
365
Required for safe access
6m x 6m
+4.00m CD
LV electricity, communications, lighting.
Line loads: minimum 3 x 600 kN = 1,800 kN

Handrails
Rope guard
Days in service/ annum
Lighting
Minimum deck area
Deck level
Services/ utilities
Mooring loads

Similar to the breasting dolphins rigid structures are envisaged for the two mooring dolphins,
consisting of a reinforced concrete deck, and raked tubular steel piles. The reference design of the
mooring dolphins is shown on drawing 9V1468.03/010 in Part 2 Chapter 5 of the Bidding Documents.

Each mooring dolphin is equipped with:

a triple 60 tonne QRH unit with integrated capstan, to handle the spring lines of the vessels;

corner protection, to prevent chamfering of the mooring lines over the concrete deck;

a safety ladder is placed along the dolphin. The ladder is at both sides protected with vertical
fendering. Both the ladder and the fendering shall extend to CD -1.0m;

1.0m high railing, without the area where the mooring lines are able to run.

One lighting pole at the side most distant from the mooring vessel shall illuminate the working area of
each dolphin with no less than 10 lux.
2.3.6

Catwalks

Scope
The scope of works includes, but is not limited to, the following:
Access walkways to provide safe personnel access between the unloading platform structure and the
breasting and mooring dolphins. The level of the walkway shall be level with the upper surface of the
platform and the dolphins. Because of the difference in top level of the platform and the breasting
dolphins, the catwalks between the unloading platform and the breasting dolphins will be at a
gradient.
The access walkways shall incorporate the following:

28

Open grid steel flooring, kick plates, heavy duty hand-railing, support bearings, lighting, and the like
as required.
Function
The catwalks and associated works are required to:

provide for safe access to and from the dolphins for personnel;

provide emergency escape routes (from the dolphins to the shore);

meet the requirements for design life and corrosion protection;

incorporate provisions for the following:

o

lighting, low voltage power supplies, communications;

meet the specified performance requirements during and after a seismic event.

The design shall comply with the deformation and vibration requirements of the applicable standards.
Particular requirements Catwalks
ITEM

REQUIREMENTS

Design load
Design wind load
Minimum width
Days in service/ annum
Services/ utilities

5.0 kN/m2
1 in 100 year wind condition
1.0m
365
LV electricity, communications, lighting.

Construction shall be a structural steelwork frame with open grid flooring and hand railing. The
steelwork, open grid flooring and hand railing shall have a suitable corrosion protection system
capable of achieving the required design life. The structural steelwork frame may be used as the
supporting structure. Alternatively, a tubular steel beam may be used as shown in the reference
design on drawing 9V1468.03/003 in Part 2 Chapter 5.
2.3.7

Pump house

Scope
The scope of works includes, but is not limited to, the following:

A covered pump house for the intake of fire water, including the foundation;

An electric pump and back-up diesel powered pump

A foam tank and foam injection pump

Jockey pump and pipe work related to the fire water intake;

An electrical and instrumentation cabinet;

Access to and from the trestle walkway.

Function
The pump house and associated works are required to:

Provide for safe and adequate intake of fire water from the port basin;
29

Provide for a safe and sheltered environment for maintenance work of the pumps and other
equipment;

Provide for storage of mechanical, electrical and general spare parts for the pumps and other
equipment;

Protect the pumps from external weather influences;

Support all equipment associated with the fire water intake;

Provide sufficient access and windows.

Incorporate provisions, pits and ducts for the following:

lighting, low voltage power supplies;

communication cabling

Be serviceable after the specified design seismic event;

Particular requirements Pump House

The workshops and the substation room shall be designed in accordance with the mechanical and
electrical requirements. These are described in Chapter 5. The layout of the building shall provide
sufficient room for the required equipment.
ITEM

REQUIREMENTS

Dimensions L X B X H
Minimum clear headroom
Top level floor
Loading

6x7m
3m
+5.45m CD
17.5kN/m2 (uniform distributed load, includes
equipment loading)
Horizontal load: 10% x vertical load
Protected from external weather influences
365
LV electricity, fresh water, telephone/network

Climate internal
Days in service/ annum
Services/ utilities

The building shall be of steel-framed construction or other acceptable design approved by the
Employer. Where necessary for fire protection (in accordance with local building guidelines /
regulations), the steelwork shall be cased in concrete or otherwise protected. All window frames and
doors shall be clear anodised aluminium. Windows shall have fenestration as appropriate. Cladding
shall be coloured profiled metal sheeting. Concrete floor shall be treated with hardener or granolithic
finish. Layout and reference design of the workshop is shown on Drawing 9V1468.03/006 and 007.
The reference design of the platform for the pump house consists of a reinforced concrete floor, with
prefabricated elements and an in situ concrete layer on top. Concrete beams and vertical steel
tubular piles are envisaged to support the platform.
For the building a steel frame of HE and UNP sections is envisaged to support the walls and roof.
The top part of the roof is elevated for good ventilation, but shall provide good shelter during the rain
season. Windows are located at two sides of the building In the East wall, a 1m wide door mounted,
for easy access to the pump house from the walkway on the trestle.
The pump house shall have one electric firewater pump capably of delivering 450m/h of water to the
monitor on the jetty at no less than 6 bar. A backup diesel powered pump will also be present and
have a capacity no less than its electric counterpart. Both pumps shall have vertical collection pipes
extend into the waters below the pump house. These pipes will be of sufficient length to be able to
30

collect water at the lowest predicted low water level. The pipes will be capped with strainers to
prevent the entry of debris. A jockey pump will use fresh water supplied by the terminal to keep the
system under pressure while not in use.
A foam tank will supply foam concentrate to the water flow by means of a pump. The tank is to
contain sufficient foam to maintain a full capacity supply during no less than 30 minutes.
The pump house will also contain personal protective equipment and two 75kg wheeled dry powder
extinguishers suitable for class A, B & C fires and be compatible with the foam system. Four 9kg
portable extinguishers of equal characteristics will either be stored in the pump house or available at
the platform or along the trestle.
A cabinet at the pump house shall hold the distribution cabinet to supply power to the pump house
itself and the walkways (and connected equipment) that extend from it. This cabinet will contain a
400 to 115 VAC transformer. The cabinet will also contain the relevant control systems for all
equipment in the pump house and the monitor on the platform.
The pump house should be equipped with adequate ventilation and climate control necessary for
safe operation. It shall also house all equipment necessary for automatic and manual control and for
periodic testing of all fire fighting equipment.

2.3.8

Miscellaneous Items

2.3.8.1

Services and utilities

Provision shall be made for the following services on both the unloading platform and the trestle:

LV electricity supply

HV electricity supply

Fresh water supply

Fire-fighting water supply (from the pump house to the unloading platform)

IT/communication cables

With the exception of fire-fighting water supply, services which run on the unloading platform shall be
contained within ducts cast into the structure. Fire-fighting water supply pipes may be supported on
the external faces of the structures providing they do not obstruct or encroach on working areas. Fire
fighting facilities shall be in accordance with local fire fighting regulations and fire fighting standards
from the international shipping industry.
The anticipated requirements for ducting within the approach bridges, Main jetty and Landside jetty
are as follows:
HV electricity supply

Minimum inside diameter: 150mm

Minimum bend radius: 1700mm

LV electricity supply

Minimum inside diameter: 150mm

31

Fresh water supply

IT cabling

Suitable to accommodate pipe diameter of: 50.8mm

Minimum inside diameter: 100mm

During installation, temporary open ends of pipes and ducts shall be plugged/ sealed to prevent entry
of material into the pipe/duct. All ducts shall incorporate draw strings.
The Contractor shall prepare and submit for the approval of the Project manager sufficient details of
the services to show how they shall be installed.
All services shall be confirmed to the Contractor by the Start Date.
2.3.8.2

Jetty Lighting

Supply, installation and commissioning of lighting are included within the scope of this Contract. The
lighting towers shall be of the type where the crown is lowered vertically for maintenance purposes.
The following lighting tower heights are envisaged:

Unloading platform (2)

Trestle
Dolphins (1for each dolphin)

10m high, min 50 lux

5m high, min 10 lux, spacing 30m
5m high, min 50 lux

Reference design drawing 9V1468.03/008 shows a layout with the envisaged location of light poles,
and power points.
2.3.8.3

Aids to Navigation

Aids to navigation shall be provided on the dolphins and corners of the unloading platform as per
international standards and guidelines.
2.3.8.4

Corrosion Protection

The marine steel piles shall be protected from corrosion by means of a cathodic protection system.
When in addition a coating is applied, this shall protect the intertidal zone from soffit of concrete up to
2m below low water.
2.3.8.5

Hose Area and Manifolds

All product pipelines coming from the trestle will be rerouted on the unloading platform such that the
end is placed above a slop pit / hose area running lengthwise across the platform. This pit is to be
covered with a grating and the interior is to be slopped towards a sump. The sump will house a pump
to remove slop waters as they accumulate. The top level of the grating does not need to be flush with
the deck level of the platform, as long as safety precautions are taken for access to the hose area.
The incoming pipelines shall have a drain at their lowest point on the platform and the runoff from this
point will be pumped towards a slop tank on the platform. The slop waters recovered from the pit will
similarly be pumped towards this tank.
A set of 8hoses will be stored over the pit. The hoses will be approximately 20 meters in length and
be adequate to handle petrochemical products in a marine environment.

32

2.3.8.6

Reference coordinate for the position of the main jetty

Layout drawing 9V1468.03/002 shows the coordinates of the outline of the berth pocket in northing
and easting. These coordinates define the position of the jetty.
2.3.9

Dredging works

A berth pocket has to be dredged in front of the unloading platform; the pocket will be perpendicular
to the fender line. The sides are sloping up with 5v:1h, till they reach the existing bottom profile.
Details are shown on reference drawing 9V1468.03/002.
2.3.10

On shore facilities

No onshore facilities are included in the scope of work. The tie in point is located at the start of the
trestle, the abutment. The contractor shall be responsible for verifying if there is an need for upgrade/
rehabilitation of the On shore facilities to adapt to the specifications of the new FUF (e.g. pipeline
pressures, pumping rates, safety inter-faces for shut-downs, corrosion protections systems, control
systems, etc).
2.3.11

Existing facility

The existing facility will be operational during the construction of the new unloading facility. The
Contractor shall take these operations into account in his construction methodology and planning of
the works.
If the operations need to be stopped temporary, approval shall be obtained from the Project Manager
beforehand.

2.4

Mechanical and electrical Functional Requirements

The Scope of Works provides for the design, supply, delivery, handling, installation, commissioning,
testing and setting to work of the product pipelines, fire fighting system, fire pump house, diesel
driven fire pumps, valves, pipe work, fittings, control systems and all such related works as outlined
in the Bidding Documents, together with any minor building works required inside or outside the fire
fighting pump house and on the jetty as set out or implied in the Bidding Documents and the
accompanying drawings.
The scope of work for the Mechanical and Electrical Works of the new FUF includes, but is not
limited to, the following elements:

Trestle pipe rack with product and utility lines;

Platform equipment;

Fire fighting system to supply water and foam to combat, and prevent the spread of, fires on the
unloading platform, sea surface and vessel, including associate infrastructure and equipment;

Spillage collection and drainage systems including associate utilities and equipment;

Supply of electricity to the equipment and lighting of the facility.

33

The general and particular requirements will be further elaborated in this chapter.
Reference design drawing 9V1468.03/009 shows the flow diagram for the product lines and also
shows the details of the slop system at the unloading platform.
As part of the overall work scope, the Contractor shall liaise with the following organisations where
local regulations are important for the design and construction of the Works:

National Port Authority of Liberia (NPA)

Liberia Petroleum Refining Company (LPRC)

Local Fire Brigade

Environmental Protection Agency of Liberia

2.4.1

General Requirements

2.4.1.1

Design life

The design life for the mechanical and electrical equipment shall be 20 years.
At the end of the design life period the asset will continue to be serviceable. It includes the
presumption of adequate regular inspections and maintenance, but no major repairs or rebuilding,
will take place. The design shall fully take into account this requirement for durability.
2.4.1.2

Standards and Codes of Practice

The design shall comply with the latest versions of internationally recognised codes of practice such
as the Eurocodes (EN), the British Standards (BS) or the German Codes (DIN).
The Contractor shall confirm the codes and design standards proposed for the works prior to starting
the design. The codes and design standards shall be subject to the approval of the Project Manager.
The following codes and standards are suggested for the mechanical and electrical works:

ASTM or API standard

American National Standard Institute (ANSI)

American Society of Mechanical Engineers (ASME)

British Standards

Engineering Equipment and Material Users Association (EEMUA)

International Electrical Commission (IEC)

ILO Publication Safety and Health in Ports

IP codes (Energy Institute)

International Standards Organisation (ISO)

Joint Inspection Group for Jet Fuel A1 (JIG)

National Fire Protection Association (NFPA)

34

Oil Companies International Marine Forum (OCIMF)

2.4.1.3

Performance testing and Equipment manuals

A complete set of operation and maintenance manuals for each item of equipment shall be supplied
by the Contractor.
Provision shall be made by the Contractor for carrying out all the required tests on the
equipment/pump set complete with all necessary instrumentation for the implementation of these
tests. If any faults are discovered during testing the Contractor shall rectify them and retest at the
Contractors cost.
Quality certificates of materials used in the construction of the equipment, including chemical
analysis/mechanical properties shall be supplied together with shop proving test results/power/flow
curves, etc., of the diesel driver, pump, gearbox and electric motor and pump and control
instrumentation.
The pumps and engines shall be works tested as matched pairs, as they will be installed on site. Full
operational performance tests shall be concluded in the works (type testing, rotational tests and the
like are not acceptable).
2.4.2

Trestle Pipe Rack

The access trestle shall support the following product pipelines:

One 8 carbon steel pipeline for Kerosene and Jet A-1;

One 10 carbon steel pipeline for Gasoline;

One 12 carbon steel pipeline for Diesel.

All pipelines, hoses and associate equipment shall comply with its intended use, with proper
considerations for the context of the facility, and all relevant standards and regulations. The
installation shall be pressure tested before entering into operation.
The Jet-A1 pipeline system shall be in accordance with JIG regulations and be conform to all
required regulations for the handling of aviation fuel.
Provisions shall be taken for the possible addition of an electrically traced 12 pipeline for unloading
of HFO.
The following utility pipelines shall be installed:

One 3 carbon steel pipeline for spillage;

One 2 carbon steel pipeline for nitrogen;

One 2 carbon steel pipeline for fresh water (non-potable).

One 12 carbon steel pipelines for fire water from the pump house to the platform only.

All pipe lines shall be made of carbon steel. Pipes, fitting material and welds shall be in accordance
with ASME standards. A corrosion allowance of 1.5mm shall be used for the pipe work.

35

The hydrostatic test pressure shall not be less than the greater of the two following values (EN
13480-5:2002):
1 - Ptest = 1.25 x PS x ftest / f
2 - Ptest = 1.43 x PS
The test temperature shall be between +5 oC and +50 oC, and the test medium shall be potable
water.

2.4.3

Platform Equipment

The jetty platform shall be equipped with a pedestal mounted crane including but not limited to:

Pedestal mounted crane

Pedestal with access ladders and platform

Hydraulic Instruments and hydraulic control system

Electrical Instruments and electric control system

Radiographic remote control unit

All equipment shall be suitable for hazardous area Atex Zone 1 EExd IIB T3
For spill prevention a collection pit shall be included:

The pit must be placed in such a manner that the connection point between pipeline and hose
falls well within its limits.

The dimensions are to be sufficient to store all hoses when not in use without excessive stress on
any hose.

The pit is to be covered with a mesh grating so as to permit the unobstructed flow of liquids and
prevent injury.

The interior of the pit will be sloped as to collect all liquid at one point via gravity flow.

From this low point a pump of sufficient capacity will pump the slop liquid to the slop tank on the
platform.

Furthermore a slop tank is required:

The slop tank collects slops from the collection pit and from the drainage point on all product
lines.

The slop tank is to be equipped with a level indicator and High Level and Low Level alarms. A
pump will empty the slop tank by pumping its content to a slop system at the terminal.

Any rainwater falling within the limits of the collection pit will be treated as slop water unless the pit is
considered clean due to either extensive cleaning or extended period of disuse. Any rainwater falling
outside the limits of the collection pit is permitted to flow into the sea.

36

The Contractor shall employ any necessary additional precautions to minimise spillages.
Flexible hoses of 8 for each product with sufficient length shall be attached to the fixed pipes of the
manifold at the platform and the vessel (approximately 20 meters total length).
Between the hoses and the pipelines, check valves shall be placed to prevent draining of the pipes in
case of an emergency disconnection or rupture of the hoses during unloading operations.
The unloading platform shall be equipped with a crane to assist in attaching the hoses to ship
manifolds in case ships are not equipped with cranes or the ship cranes are for any reason not in
operation.
The crane will be locally controlled and will be either electrically or hydraulically operated. It must be
able to reach the full length of the hose storage area and to every possible manifold location, given
ship sizes and dolphin location, while carrying the maximum expected load.
The crane is also expected to serve as support for the fire monitor and its associate equipment.

2.4.4

Fire Fighting

The following fire fighting equipment is required at the unloading facility:

One 12 carbon steel pipelines for fire water from the pump house to the Fire monitor

One 2 fresh water (non-potable) pipeline from the shore to the jockey pump

Sea Water Fire Pump house

Electrical Fire pump

o

Duty pump capable of delivering 450 m/h at no less than 6 bar at the monitor

Electrical Jockey pump

Diesel-powered Fire pump

o

Backup pump capable of at least equal performance of the Electrical pump

During regular stand by time only the jockey pump will activate to keep the system under
pressure. In case of a fire the electrical pump is assigned to be the duty pump. Should
the electric pump for any reason fail to start, or fail to supply adequate water flow, then
the diesel powered pump will be activated. Both electrical and diesel fire pumps must be
capable of individually supplying the full required load of the fire fighting system and be in
accordance with all other requirements by NFPA. The diesel pump is to come equipped
with a fuel tank of sufficient capacity to maintain operations for the longest expected fire
fighting scenario

Fire monitor
o

The water pressure at the monitor is to be no less than 6 bar

Placed on the pedestal of the crane

Capable of launching foam at the platform, ship and sea surface

The fire monitor is to be controlled from the pump house

37

Foam system
o

A flow measuring instrument must be placed in the pump house to confirm the flow of
450 m/h.
Foam tank with sufficient foam concentrate for no less than 30 minutes continuous
application

Dry Powder Extinguishers

o

Four 9 kg portable

Two 75 kg wheeled

The powder will be suitable for class A, B & C fires and be compatible with the foam
system employed.

Personal Protective Equipment is to be supplied and stored at the pump house to protect people
involved in a fire fighting effort

Additional passive fire fighting methods such as, but not limited to, protective coating, should also be
considered for each component potentially at risk.
Sufficient fire detection sensors and fire alarm provisions shall be foreseen in accordance with
OCIMF regulations.
The Contractor shall liaise with the Port Authority, Local Fire Brigade and port operators to finalize
the port fire fighting strategy, to identify fire scenarios and to confirm the fire protection system shall
meet the requirements of the strategy. The strategy shall not be reliant on the provision of a fire
fighting vehicle.

2.5

Corrosion Protection

Similar to all structural items, all mechanical and electrical items in the facility are to have adequate
corrosion protection in accordance with EN 12944.

Structural steel, pipe supports, stairs, supporting, grating, platforms and handrails shall be hot dip
galvanized. The zinc layer shall not only achieve the required thickness, but also be smooth and
free of irregularities like droplets, sharp edges, burrs, over thick areas, pinholes and lacking
adhesion between zinc and steel;

Piping to be installed in the field shall be:

o

Prepared and painted after installation;

Prepared and primed before installation when blast cleaning is required, followed by
final painting after installation;

Shop primed surfaces shall be touched up as soon as possible after erection. Final painting shall
follow immediately after mechanical completion, or after successfully completed pressure testing;

Grit blasting on site is not allowed;

Surfaces that will be inaccessible after assembly shall receive the complete painting system
before assembling. Contact surfaces of bolted connections are to be primed only.

Platforms, gangways and stair beams shall receive the complete painting system before the gratings
or stair treads are mounted.

38

2.5.1

Electrical Works

Scope of work:
All required electrical equipment for a safe and functional operation of the jetty equipment

Supply, installation and termination of all power- and signal cables for process equipment
(pumps, valves etcetera), utilities (lighting, ventilation, etcetera) and instrumentation & control
equipment

Emergency stop circuit

Provision of all cable support systems and fixings

Provision of earthing, bonding and lightning protection to the facilities

Provision of exterior lighting installations throughout the marine works

Provision of interior lighting for the pump house

Provision of lighted navigation aids at extremities of the marine structures

Excluded are the power generation and power supply to berthed vessels
The following general requirements apply for the electrical design:

Spare capacity of electrical distribution equipment, cabinets and the main supply cable shall be at
least 20%;

All electrical distribution equipment and switching equipment shall be installed in free-standing
cabinets with lockable doors;

The protection level of electrical cabinets and distribution boards with doors open shall be at least
IP21;

All cable trays and supports, mounted outside shall be stainless steel;

All cables shall be fire retardant and halogen free;

All equipment shall be suitable for the explosion zone it is to be placed in;

Over voltage protection shall be applied;

Distribution boards placed at the pump house and on the platform shall house additional 400 to
115 VAC transformers;

All equipment shall have a local maintenance switch.

The cabling shall be designed and installed in accordance with the following requirements:

Voltage between 380 and 415VAC, 50/60Hz (herein to be referred to as 400VAC) shall feed the
main distribution board. To this board all 400 VAC consumers and 400 VAC supplies shall be
connected. A multifunctional energy meter (V, I, f, cos phi, kW, kWH) shall be installed;

In a separate cabinet or a separated part of the distribution board, the distribution of 110 VAC
and 120 VAC, 50/60Hz (herein referred to as 115VAC) and corresponding distribution rail shall
be installed;

39

Both 400VAC and 115VAC cables to be available at the tie-in point. From there the cables
extend to the distribution points on the jetty;

400/115V electrical distribution cables shall be laid in cable trays along the jetty. The cables will
generally comply with all relevant requirements of IEC;

Where cables are to be installed in a designated potentially explosive atmosphere they shall be
of the correct type suitable for use in a potentially explosive atmosphere.

Cable trays shall be installed in accordance with the manufacturers recommendations. Cable trays
shall have adequate mechanical strength for the load to be carried and shall have provision for the
addition of a minimum of 25% of the initial installed cable and/or load. The deflection shall not exceed
that recommended by the manufacturer. The installation shall cater for the expansion and contraction
that will occur. All cable tray runs shall be continuous and constructed of bends, tees and other
accessories that are purpose made by the manufacturer of the cable tray.
The lighting design shall be in accordance with the following requirements:

The lighting along the jetty and at the jetty head shall comply with the requirements of the Safety
and Health in Ports, published by the International Labour Office (ILO), with a minimum of 10 lux
luminance along the walkways and not less than 50 lux luminance on all working areas;

The lighting supporting structures shall be positioned on the jetty so as to not impede any traffic
movement along the jetty and/or operational staff. They shall be placed at intervals of
approximately 30 meters along the walkways

The lighting shall be switched ON/OFF on basis of timer and light sensor or manually;

The minimum free space between the footpath and the luminaries shall be 3 meters of the raising
and lower type, where the luminaire(s) mounted at the head of the column can be lowered to the
jetty deck level for maintenance, lamps changes and/or cleaning;

In the control cabinet all circuits shall be installed, required for:

Automatic operation;

Manual operation;

Safety (emergency stop).

Following automatic circuits shall be provided as a minimum:

Automatic starting of fire fighting pumps (water and foam) at adjustable pressure levels, when the
fire fighting will be used;

Automatic starting of slop- and spill pumps on level of the tanks / collectors;

Automatic switching lighting on both timer and darkness;

Following manual intervention controls shall be available on the front of the control cabinet:

Automatic 0 Manual switches for all equipment;

Corresponding indicators for ON OFF- Failure

40

Earthing, Bonding , Lightning protection

The Contractor shall design, supply and install an integrated system of earthing, bonding and
lightning protection facilities, hand railing, pipe work, and pipe work support systems. The
installations shall be provided with all earthing, bonding, protective conductors, etc. required for
compliance with the specified Design Standards.
The Contractor shall design, provide and install a lightning protection installation to enhance the
safety of the jetty structure and product pipeline services, its facilities and personnel. The installation
shall incorporate all requirements and recommendations of IEC standards The Contractor shall,
wherever practicable, take advantage of the metallic structure to provide a self protecting structure to
ensure the provision of the lowest possible impedance in the connection to earth and ensure that all
metallic element of the structure are maintained at the same potential.

GENERAL EMPLOYERS REQUIREMENTS

This chapter of the Employers Requirements set out the general requirements the Contractor shall
follow in respect to:
1.
2.
3.
4.
5.
6.

Project Execution
Quality Assurance
Environmental Protection
Design and the Submission of design information to the Employer
Progress Control
Health and Safety

Both the General Employers Requirements and the Technical Specifications are

3.1

Project Execution

The Contractor shall prepare a Project Execution Plan (PEP) which extensively describes the
chronology, methodology and time span of the Project.
Interfaces with other Works to be executed interrelated shall be clearly identified. Possible project
risks shall be identified and accordingly risk management plans shell be developed.
The Contractor shall present maximum flexibility to adapt the Works to be executed with respect to
day-to-day operations.

3.2

Quality Assurance

The Contractor shall operate a Quality Assurance system according to ISO 9001.
The Contractor shall nominate a senior member of his personnel to act as his Project Quality
Manager. The Project Quality Manager shall maintain all Quality Documentation and be available at
all times to deal with enquiries from the Employer or from the Project manager regarding the
Contractors Quality Management System.

41

The Contractor shall ensure that the approved Quality Plan for the project is subject to a full internal
audit at least two times during the course of the project. The timing of such audits shall be clearly
indicated on the programme of the Works. The Project Manager shall be supplied with a copy of each
audit report.
The Project Manager shall be entitled to audit the Contractors Quality Management System at any
time subject only to giving the Contractors Project Quality Manager 24 hours notice of his intention.
When the Contractor has employed a firm of Consulting Engineers to carry out the design of the
works he shall ensure that his agreement with this firm contains a provision for the Project Manager
to similarly audit their Quality Management System at any time.
3.3
Environmental Compliance
The Contractor must identify and comply with restrictions, international and local legislation regarding
the environment and marine conservation requirements.
During construction the Contractor shall prepare and submit the following documents to the
Employer:

Outline of the Project including construction and operations activities and a Construction
Method Statement (CMS);

Outline of an Environmental Management Plan (EMP) for construction (CEMP) and operation
(OEMP).

Master Construction Programme

Baseline Environmental Study;

Detailed Description of the Project including construction and operations activities and a
Construction Method Statement (CMS);

Detailed Environmental Management Plan (EMP) for construction (CEMP) and operation
(OEMP).

Construction Quality Plan.

During Construction the Contractor shall carry out environmental monitoring. The results of the
monitoring program shall be submitted to the Employer.
The documents required for environmental clearance shall be reviewed by the Employer.

3.4

Contractors Design and Documentation

The design of the Works is the responsibility of the Contractor and shall satisfy the Employers
Requirements contained within This Document. The Contractor shall give full consideration in the
design to minimise the operating and maintenance costs, to minimise spillage and to minimise the
extent/frequency of maintenance and its disruptive effect to operations.
All Contractors Documents are to be submitted to the Employer. Unless otherwise stated, each
submission shall be for the purpose of information only.
Contractors Documents that are required to be submitted to the Employer will be submitted to the
Employer in hardcopy (three copies) and a digital file, unless otherwise specified.
The language of all documents shall be English and all units shall be applied in accordance with the
metric system.

42

3.4.1

Contractors Design Submissions

Design submissions shall be prepared for the various elements of the project before finalising the
detail of the construction drawings and commencement of the physical work.
The design submissions shall cover, but not be limited to, the following project elements:

Dredging;
Approach Trestle structure (including: pedestrian walk way, abutments, bearings, pipe rack
etc.);
Jetty structures (including fenders and mooring systems, pedestal mounted crane) for safe
mooring of the vessels and scour protection;
Liquid bulk handling system: pipe lines and pipe rig, pumps, marine loading equipment;
Fire Fighting system
Utilities systems (potable water, nitrogen, drainage),
Power supply and electrical system;
Control and Automation system;

The design submissions shall include as a minimum the following:

Design basis statement covering all assumptions, codes and standards used and
demonstrating how the design complies with the Employers Requirements;
Checked Calculations;
Preliminary engineering design drawings including dimensions and setting out of structures;
Method statement.

The design submissions will form part of the Contractors Documents and shall be reviewed by the
Project Manager. Each submission shall be a complete package, fully indexed and referenced.
3.4.2

Issue of Design Submissions

At the start of the Contract, the Contractor shall prepare a design submission programme to identify
the scope of each design package and its submission date. This programme shall allow a period of
21 days for the assessment of each design package. If it becomes necessary to revise the design
submission programme the revised programme shall be submitted 2 weeks before any further design
package is submitted.
The number and scope of the packages shall be subject to the approval of the Project Manager.
The Contractor shall also produce, maintain, update and issue at appropriate intervals in accordance
with his Quality Assurance system a register of all drawings in circulation and their status. Any
superseded drawings shall be clearly marked S/S and removed from circulation.
3.4.3

Technical Specifications

The Contractor shall prepare a complete set of Technical Specifications for the execution of the
Works in line with or in addition to Technical Specifications contained within the Employers
requirements.
The Technical Specifications shall form part of the Contractors Documents and shall be reviewed by
the Project Manager.

43

3.4.4

Construction Drawings

Once the Project Managers no objection to the design reports and design drawings has been
obtained, the Contractor shall produce the construction drawings which shall sufficiently define the
design to provide the basis for the preparation of fabrication drawings and construction of the Works
listed in this document and any other matters necessary for the completion of the Works.
The Contractor shall be responsible for ensuring that the construction drawings are in accordance
with the approved design drawings and technical specifications. The drawings and details shall
comply with recognised international drawing standards.
The Construction Drawings form part of the Contactors Documents.
3.4.5

As-built Drawings and Final Calculations

One set of all drawings shall be kept on Site and shall be marked up by the Contractor to show
variations in the works.
They shall be used to maintain a record of the dimensions and other particulars of the works as they
are actually constructed, as and when these particulars differ from what is shown on the For
Construction Drawings prepared by the Contractor.
These records shall be available at all reasonable times on the Site for inspection and use by the
Employer and by any other person authorised in writing by the Employer.
Prior to requesting a Certificate of Completion for the whole of the works, the Contractor shall provide
the Project Manager with three full sets of drawings, Final Calculations and other details and
information fully marked-up, revised and updated to indicate the final "As-built" construction details.
These shall be provided as a single package fully co-ordinated and cross-referenced.
Upon approval of this single package of information the Contractor shall provide the following:

three sets of bound prints of the As-built Drawings, reduced to A2 size;

three electronic copies of the As-built Drawings written to CD or DVD (three sets of CDs or
DVDs) in
o AutoCAD 2004 format; and
o Compressed *.TIF format.

Tree bound copies of the Final Calculations;

Three electronic copies of the Final Calculations written to CD or DVD (three sets of CDs or
DVDs).
The As-built Drawings shall be suitable for reduction and inclusion in the operating and maintenance
manuals.
The Final Calculations shall be set out in sections to suit the particular discipline, be fully crossreferenced to the drawings and incorporate all the supplementing technical information to
substantiate the design. The calculation document (bound hard copy and electronic version) shall
incorporate the validation certificates, design certificates and check certificates as appropriate. The
document shall be fully indexed and include a commentary for ease of reference. Subject to the
Project Managers approval an electronic system of submitting and approving drawings may be
considered.

44

The Contractor shall submit, in addition to the requirements of this Clause, copies of all his
documents, schedules and submittals in electronic form, as well as hard copies. The computer
software packages for these submissions shall be to the approval of the Project Manager.
The As-built Drawings and Final Calculations form part of the Contractors Documents.
3.4.6

Operation and Maintenance Manuals

The Contractor shall supply an Operation and Maintenance Manual for the Works, covering all
installed equipment and setting out of maintenance activities required.
The Operations and Maintenance Manuals shall be prepared and submitted for each system and
shall be supplemented with Vendors instructions and data covering the operation and maintenance
of individual items and equipment.
Each system shall be described in brief, including the operating parameters, interfaces with other
systems, major equipment and their physical and operating and maintenance characteristics.
The Operation and Maintenance Manuals form part of the Contractors Documents.

3.5

Progress Control

A programme shall be prepared by the Contractor using Microsoft Project software, version 2007 or
later. The programme shall clearly indicate the critical path.
The work headings to be shown in the programme shall be the main elements of the Work and the
structure shall be aligned with the work breakdown structure established and agreed with the Project
Manager.
Each work heading shall be split into detailed activities. Work to be undertaken by statutory
undertakers and other third parties shall be shown as separate activities. The duration of activities to
be undertaken by the Contractor shall be broken down into periods of one (1) week.
The programme shall clearly show the inter-relationship between approvals, design, procurement,
fabrication, delivery, construction, rehabilitation, testing and commissioning of each work heading.
Long lead-in items and their lead-in times shall also be identified.
Times allowed for review by the Project Manager and for Third Party Approvals shall be shown in the
programme.
Float times within the programme shall be clearly shown.
Each activity shall be uniquely referenced. Bar charts, logic diagrams / tables and any other
necessary tabular and graphical reports shall be submitted to show the following information for each
activity on the network:

Reference
Description
Duration
Relationship with other activities
Early and Late Start and Finish Dates
Resources or Unit Production Time
45

The Contractor shall assess and report progress on each activity and all other input data not more
than 2 days after the scheduled time for an update. Changes in the network logic may only be made
after consultation with the Project Manager.
Where slippage has occurred, the Contractor shall give explanations together with his proposals for
recovery of critical activities.
The Programme shall form part of the Contactors Documents and shall be submitted to the Project
Manager for review in accordance with the Conditions of Contract.

3.6

Health and Safety

The Contractor shall prepare a Construction Health and Safety Plan to fully consider the hazards and
risks that may arise during construction, operation and maintenance of the Site, and design shall be
carried out accordingly to avoid risks to health and safety as far as is reasonably practicable.
3.6.1 Site Safety
The Contractor shall be solely responsible for all aspects of Site safety within the project area. A
proper standard of safety supervision and care shall be exercised by the Contractor during the
construction and rehabilitation works.
The Contractor and Subcontractors shall attend monthly Site Safety Meetings. The Employer or the
Project manager shall attend these meetings, which shall be chaired by the Contractor or his
designated representative. The Contractor and all Sub-contractors shall be represented at senior
management level together with their nominated Site Safety Officers.
3.6.2

Safety Plan

Prior to the start of construction, the Contractor shall prepare a Construction Phase Health and
Safety Plan covering all aspects of the Works. This plan shall form part of the Contractors
Documents and shall be submitted to the Project Manager for his consent prior to the start of
construction. The plan shall include co-ordinated emergency evacuation procedures for both land
and marine based activities. It shall be co-ordinated with Other Contractors and operators working
on Site or on adjacent sites, and the Project Manager. The Contractor shall identify, as part of the
plan, all potential risks and hazards, and his proposed procedure for dealing with them should they
arise during construction. The plan shall be reviewed and developed / updated as necessary during
the construction phase.
3.6.3

Training

The Contractor shall ensure that all personnel employed on or about the Works regularly receive
appropriate training by way of tool-box meetings and the like, such that they understand the risks
involved in the works being undertaken, the safe use of tools and equipment, and the relevance of
personal protective equipment (PPE).
3.6.4

Personal Protective Equipment

The minimum personal protective equipment (PPE) to be worn by any Contractors Personnel on the
Site includes:
Hard hat
Fall protection equipment (Harnesses)

46

Reflective vest (except when operating rotating tools)

Safety boots/shoes;
Life jackets when working over or near water.
Additional PPE, such as hearing, eye protection and gloves, shall be worn as required by the
operations being undertaken and ascertained by risk assessment.
3.6.5

Life Lines, Motorized Rescue Boat, Etc.

Contractor shall provide life lines and life buoys at all times in easily accessible positions together
with a motorized safety boat for rescue work prepared and ready with a skilled crew of a minimum of
two persons available for instant use.
Whenever any floating craft is in use as a safety boat such use shall be exclusive and the craft shall
not be used for or in connection with any other purpose.

TECHNICAL SPECIFICATIONS
This specification is to be read in conjunction with the relevant Functional Requirements and General
Employers Requirements respectively and the more onerous requirements shall apply.

4.1

General specifications

4.1.1

Facilities for Personnel

The Contractor will be held responsible for all his personnel, including the personnel of his subcontractors and suppliers required facilities.
The Employer will indicate a suitable location for the Contractor to set-up his offices, workshops,
canteen and wash/locker room and other facilities required for the execution of the Works. Such
location will be at the premises of the Employer in the vicinity of or at the Site. No Site
accommodation is allowed.
The Contractor is responsible for his own HSE & QA/QC plans during design and construction.
However, during Rehabilitation Works the Contractor shall adhere to the Employers HSE plans.
4.1.2

Safety and security of the Site

The Employers premises are completely surrounded by fencing (except for the water front) and
guarded full time by watchmen.
The Contractor shall provide, maintain and adjust fencing, lighting, guarding and watching until
completion and Taking over.
The area within the Site fence (for a particular Section) will be a restricted area. In case the
Contractor has to perform works outside this restricted area he shall obtain the necessary work
permits (general work permit, hot works, electrical works, etc.) from the Employer.

47

4.1.3

Employers Regulations on Site

The Site is located next to and on the Employer's Terminals. Besides the safety rules and regulations
prescribed by Law, the Contractor shall keep strictly to the following rules and regulations:

General rules for contractors;

General safety regulations for contractors.

A copy of the above mentioned rules and regulations will be made available to the Contractor before
the Date of Commencement.
4.1.4

Use and Care of Roads

The Contractor shall take care to avoid damages to existing roads and shall repair any damages to
roads caused by his activities at no cost to the Employer.
The Contractor shall carry out a pre- and post survey of applicable roads in the presence of the
representatives of the relevant Authorities to document the state of these roads.
4.1.5

Disruption to Neighbouring Works

The Contractor shall liaise with the Project Manager and Other Contractors to minimise disruption to
all works, including those of the neighbouring site and port operations and to co-ordinate and cooperate to ensure health and safety on the Site.
4.1.6

Setting Out

The Contractor shall verify and agree the co-ordinates of existing benchmarks.
The Contractor shall provide additional setting-out points, lines or levels of reference he requires for
the execution and completion of the Works and the remedying of any defects therein.
The Contractor shall establish a permanent benchmark on the Site and arrange for the benchmark to
be independently verified by an approved authority or survey company. The Contractor shall protect
and maintain all permanent benchmarks until the end of the Defects Liability Period.
4.1.7

Facilities for Employers staff

The Contractor shall provide and maintain for the period of the Contract, and shall remove on
completion of the contract, the following accommodation and facilities for use by the Employers staff.
Site office, minimum size 3m x 4m, with windows and air conditioning containing:

Desk (with drawers)

Table
2 chairs
4-draw filing cabinet
4 shelf book-case
Tea/coffee making facilities
Telephone
Computer
Stationery and office equipment
Surveying equipment

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1 set of waterproof clothing

Meeting room, minimum size 3m x 4m, with windows and air conditioning containing:
Table
chairs
4.1.8
The contractor shall provide cleaning and maintenance of these facilities throughout the contract.
The contractor shall provide two (2) 4x4 cars (Toyota Landcuiser type or alike) including the
insurance and the running cost.
4.1.9

Contractors Laboratory

General
In order to carry out the specified tests the Contractor shall arrange a Site laboratory or employ a
laboratory to carry out the tests needed to control the works. The Project Manager shall be given
reasonable opportunity to witness all testing.
Schedule of Tests
Contractor shall provide a schedule of Tests and details of laboratory and equipment to Project
Manager for review and approval prior to starting any testing.
Attending of tests
The contractor shall invite the Project Manager and employer to witness the laboratory and insitu
tests.
4.1.10

Testing of Materials and Workmanship

General
The Contractor shall for the purpose of checking the compliance of materials and workmanship with
the requirements of the Technical Specifications carry out tests at the frequencies stated in the
approved QA Manual, the codes, the Design Report and the Technical Specifications.
The Test reports are part of the Contractors Documents.
Schedule of Tests
Contractor shall provide a schedule of Tests and details of laboratory and equipment to Project
Manager for review and approval prior to starting any testing.
Attending of tests
The contractor shall invite the Project Manager and employer to witness the laboratory and insitu
tests. The result of such tests shall be submitted to the Project Manager at the times specifically
stated or if none is stated as soon as possible.
4.1.11

Site Cleanliness

The Contractor shall at all times be responsible for the proper upkeep and maintenance of the Site
and the Works. The Site shall be kept clean and tidy at all times.
The activities on the Site shall not be permitted to create excessive noise, dust, water pollution, etc.

49

In addition the Contractor shall arrange for the collection of rubbish by the provision of suitably
located and regularly cleared bins.
On completion, all temporary fences and structures shall be removed; the Site area cleaned, tidied
up and left to the satisfaction of the Project Manager.
4.1.12

Access for Third Parties

The Contractor shall ensure that he maintains safe and unobstructed access for third parties as
specified and agreed between the Contractor and the Employer.
4.1.13

Electricity, Water and other Services

The Contractor shall be responsible for the provision of all power, water and other services he may
require.
The Contractor shall be responsible for making his own arrangement for electrical power supply for
the purpose of construction and erection works (i.e. to provide, operate, and maintain electrical
generator(s)).
The Contractor shall be responsible for making his own arrangement for suitable and adequate
supply of water for the purpose of executing construction and erection works.
The Contractor shall make on Site his own arrangements for telephone and potable water supply and
discharge of foul water. No polluted water shall be disposed to the sea. The Contractor shall comply
with the requirements of the Authorities having jurisdiction over such supplies and installations.
4.1.14

Publicity and Public Relations

Within one week of commencing work on Site, the Contractor shall supply and erect a notice board,
showing name and logo of the Employer, the Project Manager, the name of the Project, the name
and logo of the Main Contractor and of the Sub Contractors on Site, and after-hours telephone
numbers.
The layout and location of the notice board shall be agreed between the Project Manager and the
Contractor.
4.1.15

Port Operations and General Information

Contractor shall note that other port terminals and approaches thereto will be in full operation during
the progress of the Contract and the Work must be programmed and executed in such a manner as
not to cause inconvenience or interference to port operations and users.
In particular, Contractor shall ensure that his activities are conducted not to interfere at all with
shipping and navigation or any vehicular traffic, including loading/unloading operations.
Contractor shall be responsible for consulting regularly through Project Manager with the port
authorities to confirm that his method of working is such as not to impede in any way the operation of
the Port and for modifying his method of working if Port operations are adversely affected by his
activities. On the instruction of Project Manager, Contractor shall promptly remove any vehicle,
vessel or other equipment within his control that may be causing obstruction to the use of the existing
facilities by others. Contractor shall allow in his programme for any interruption or effect on his
working due to vessels berthing and un-berthing at the Port or other shipping movements in the area.

50

Contractor shall obtain all necessary permits required by different authorities, prior to commencing
work on Site.
4.1.16

Tidal Levels

Contractor should make himself fully aware of times, ranges and depths of tides and make due
allowance in his manner and mode of working.
4.1.17

Site Access

By Road
If it is unavoidable that Contractor has to drive tracked vehicles along existing roads or tracks, he
shall take all necessary precautions to prevent damage thereto. Such precautions shall not, however,
relieve Contractor of his responsibility for reinstating any damage caused to the roads or tracks to the
satisfaction of Project Manager. All parking of Contractors vehicles and those of his employees and
people under his direct control shall be confined within his working areas. Contractor shall inform his
sub-contractors of these restrictions and ensure that they comply with them.
By Sea
Where Contractor brings working equipment or Materials to the Site by sea, he shall be responsible
for obtaining the consent of, and making all necessary arrangements with and paying any charges
due to the appropriate authority.
Contractor shall be responsible for complying with any conditions that may be imposed regarding the
use of the berthing facilities, executing all temporary works necessary for his utilization of the
facilities, removing such temporary works on completion or when no longer required and reinstating
any works disturbed.
Subject to the approval by the Project Manager is Contractor to bring plant and/or materials onto the
Site by sea.
Contractor shall be responsible for complying with any conditions that may be imposed regarding the
use of the waterfront facility, executing all temporary works necessary for his utilization of the
waterfront facility, removing such temporary works on completion or when no longer required and
reinstating any works and/or ground disturbed.
The Contractor shall give The Ports Authority and the Employer and any other relevant statutory
authority prior notice of the commencement of marine operations and shall keep them informed of the
transfer of operations from one area to another. The progress of the work, the movements of the
contractor's floating plant and vessels and the location of temporary works, moorings and buoys shall
be arranged so as to cause a minimum of interference with the normal shipping traffic in the area.
The Contractor's operations shall not interfere with work being carried out by other contractors except
when in the opinion of the Project Manager such interference is unavoidable.
Emergency Access
In addition to all floating craft, safety boats etc. Contractor shall maintain, for the duration of the
Contract, sufficient motor boats to be able to rapidly evacuate all members of Contractors and
Employers staff employed on construction of the jetty, in the event of an emergency.
The motor boats shall be suitable for the local conditions and in good condition.

51

The motor boats shall be located adjacent to working areas whenever work is being undertaken on
the jetty, to permit rapid evacuation.
All members of staff employed on the jetty shall be fully conversant in the operation of the motor
boats and be instructed as to the location of the boats at the beginning of every shift.
4.1.18

Radio Communication

Contractor shall be responsible for all necessary communications with the Port Authorities.
Notwithstanding these requirements, all radio equipment shall be operated on a private frequency
which shall not interfere with any other local transmission or other equipment of any type. Contractor
shall ensure that his transmissions and equipment comply with the requirements of the appropriate
Statutory Authorities.
All floating plant or other vessels navigating within the Port Area must carry a V.H.F. radio capable of
working on Marine Channels as required by Port Authorities.
4.1.19

Restriction on Use of Public Roads

Contractor shall not make use of roads for depositing or storing plant, materials, tools or implements.
Equipment, materials, tools implements and temporary works shall be placed in such a way as to
cause minimum interference with the use of any right of way by Project Manager or other parties.
4.1.20

Traffic Safety Measures

Contractor shall maintain all traffic safety measures in good working order and condition at all times
and shall reposition, cover or remove them as necessitated by the progress of the Works.
4.1.21

Temporary Approaches & Diversion of Existing Rights of Way

Contractor shall form all temporary roads, crossovers, footpaths, tracks, hard standings, etc. within
Employer Site and shall provide temporary protected footpaths outside the boundary if required to
protect Third Party properties.
Where, in the opinion of Project Manager, it is necessary to provide safe and expeditious access to
different parts of the Plant, Contractor shall provide suitable temporary approaches, bridges,
gangways and roads. All such approaches bridges, gangways and roads shall be maintained in
service until it is agreed with Project Manager that this use is no longer required.
Contractor shall provide and maintain temporary diversion ways wherever the Work will interfere with
existing public or private vehicular or pedestrian rights of way. Such diversion ways must be
constructed in advance of any interference with the existing rights of way and shall be of a standard
suitable in all respects for the class or classes of vehicles or pedestrians requiring using them.
Contractor shall remove temporary diversion ways when no longer required and shall reinstate any
disturbed ground or works.
4.1.22

Existing Services

Contractor shall make his own investigations to establish the exact location of existing services which
may affect or be affected by the construction of the Work. In addition Contractor shall, before using

52

mechanical plant in the vicinity of existing services, carry out full and adequate preliminary
investigations by means of hand-dug trial holes and the like, to verify the location of existing services.
All drains, pipes and cables, whether above or below ground, that are encountered during the course
of the work shall be left in position and be carefully supported and guarded from damage by
Contractor to the satisfaction of all owners and proper authorities so that such drains, pipes and
cables may continue in use until the completion of the Work or until no longer required.
Contractor shall exercise the greatest care during the construction of the Works to avoid damage to
or interference with any existing services and shall be responsible for any such damage caused by
him or his agents directly or arising indirectly from anything done or omitted to be done. Contractor
shall carry out all temporary works necessary to adequately support and protect any existing
services.
Any damage to mains or services shall be notified immediately to Project Manager.
4.1.23

Removal of Public Utility or Privately Owned Services, Etc

If any Public Utility or privately owned services or other obstructions are required to be removed
during the construction of the Work, Contractor shall draw this to the attention of Project Manager
and if required to do so Contractor shall arrange with Service Authorities to divert, protect or take
whatever action is required.
4.1.24

Scaffolding

Where necessary Contractor shall provide, erect, maintain, dismantle and clear away on completion
proper and adequate scaffolding. Contractor shall be entirely responsible for all safety precautions in
connection with the scaffolding and for its entire sufficiency for the work.
4.1.25

Records

Contractor shall ensure that his own copies of all records for matters relating to the Contract are kept
available on Site for inspection by Employer.
A detailed description and quantified breakdown of all imported material, including sourcing
certification and other supporting documentation as specified within this Specification shall be
maintained by Contractor.
4.1.26

Port Regulations

Contractor shall at all times observe the regulations of the port authorities regarding navigation and
safety and shall obey all local instructions.
All floating plant operated by Contractor shall display at all times such lights and/or shapes as are
laid down in the International Regulations for Preventing Collisions at Sea relating to such craft or
its nature of work and shall keep a listening watch on an appropriate radio frequency channel so that
when necessary he can be made aware of traffic movements in the vicinity.
4.1.27

Lighting, Marking, Buoying and Watching

Contractor shall be responsible for complying In every way with the requirements of any statutory or
other authority having jurisdiction so to require in respect of marking, lighting and watching the Work
or any structure vessels or offshore plant which may be used in connection with the Work and for the

53

issue of local notices to mariners.

Contractor shall be responsible for ensuring that all moorings have lights and marker buoys which
conform to International Association of Lighthouse Authority Regulations.
Contractor shall ensure that all his vessels and offshore plant carry at all times the correct lighting,
markers, signals, radar reflectors, etc., as required by the said authorities commensurate with the
nature of the work in which they are engaged.
Contractor shall provide all buoys and other markers required for the proper indication of submerged
work and moorings for his vessels and offshore plant. He shall also provide every description of
watching, lighting and maintenance required in connection with the foregoing and he shall also
provide and maintain any guards, fencing required for the protection of the Plant, or for the safety and
convenience of the public or others.
Contractor shall maintain all such lights, markers, buoys, guards, fencing and lighting in sound
condition until either the Work is completed or Project Manager decides that such services are no
longer required.
All vessels and offshore plant working or moored shall be attended at all times. If such attendance is
not possible they must be moved to an approved mooring location.
All lights required by Contractor shall be so placed or screened so as not to interfere with or be
mistaken for any navigation lights or with or for any signal lights.
Should Contractor in any way obstruct or affect lights, signals, buoys or navigational aids then he
shall at his own expense pay all costs whatsoever for the resetting and reinstating or providing
alternatives for the aforesaid to the satisfaction of the said authorities.
Contractor shall provide all vessels and offshore plant with approved fog warning devices which shall
be operated in accordance with the requirements of the said authorities.
4.1.28

Navigation

Contractor shall be responsible for complying in every way with the requirements of any statutory or
other authority having jurisdiction with respect to the navigation and movement of his vessels and
offshore plant in and around the area of the Works.
4.1.29

Liability for Damage to Shipping

Contractor shall be held responsible for any damage or injury to shipping or craft of whatever
description which may occur during the execution of the Contract through any act or omission or
default of Contractor or of any person in his employ or for whom he is responsible.
4.1.30

Floating Plant

Whenever floating plant is employed by Contractor for the purpose of the Work, such plant shall be
maintained in a satisfactory and seaworthy condition, shall have adequate attendance by competent
seamen at all times, shall be fully provided with sound and satisfactory ropes, lines and moorings and
shall be fully equipped with lights.
At all times Contractor shall be wholly responsible for the protection and safety of all floating craft
engaged by him.
If in the opinion of a person having authority at the port management any craft is unsafe to be used to
transport staff, for diving operations or as a safety boat, he may order the craft to be withdrawn and
54

replaced by another which, in his opinion is in all respects suitable for the work.
The costs involved in such replacement shall be borne entirely by Contractor.
All craft must be fitted with V.H.F. radio provided with channels in accordance with the requirements
of the Port Authorities and any statutory or other authority having jurisdiction with respect to the
navigation and movement of his vessels and offshore plant, which must be operational at all times
whilst the craft is under way.
4.1.31

Avoidance of Nuisance

Contractor shall ensure at all times that spillage does not occur of concrete, oils or other deleterious
material into any new or existing drainage, duct system or water course.
Nevertheless, should any drainage or duct system or water course be fouled by such materials
Contractor shall clean the drainage or duct system or water course at his own expense, to the
satisfaction of Project Manager.
Contractor shall ensure that there is no spillage of oil or other contaminant into the sea. Before
commencing any work which could involve spillage into the sea, Contractor shall consult Project
Manager and provide such effective anti-pollution measures as may be required to prevent such
spillage. In the event of any such spillage it must be immediately reported to the Port Authorities.
4.1.32

Underwater Obstructions

Contractor shall mark all temporary underwater obstructions with buoys and lights and do all things
necessary for the safety of navigation while the obstruction remains and shall remove any such
obstruction at the earliest possible time.
4.1.33

Temporary Moorings

Contractor shall not lay down or provide moorings for his vessels and offshore plant apart from
temporary moorings in such position and laid or provided in such a manner and such conditions as
may be permitted by Project Manager. Contractor shall not lay down or provide moorings at any
locations where they may present a hazard to any shipping using the Port. Contractor shall submit to
Project Manager for review detailed sketches showing the dispersal of his proposed moorings within
the Port.
4.1.34

Port Charges

Contractor shall pay all dock charges, wharfage, and anchorage charges, charges on vessels and
offshore plant, charges on goods, conservancy charges and other charges in respect of the
conveyance to Employer Site of all materials and plant required for use in or in connection with the
Work.
4.1.35

Radio Transmissions

The use of radio communication equipment on the Site by Contractor shall be subject to prior review
by Project Manager.
Contractor shall provide on his floating plant a VHF radio receiver/transmitter with authorised
channels for the purpose of maintaining contact with the Port Authority concerning shipping
movements. Notwithstanding these requirements, all radio equipment shall be operated on a private

55

frequency which shall not interfere with any other local transmission or other equipment of any type.
Contractor shall ensure that his transmissions and equipment comply with the requirements of the
appropriate Statutory Authorities.
When required by Project Manager, Contractor shall provide a suitable two-way radio complete with
all necessary licenses, to enable Project manager to contact Contractors vessels from shore.
4.1.36

Diving

No diving operations within the Port Limits shall take place without the prior authorization of all
authorities having jurisdiction over the area concerned.
Contractor shall be responsible for obtaining all necessary approvals from all statutory or other
authorities prior to undertaking diving operations.
4.1.37

Removal of Sunken Vessels and Offshore Plant

Contractor shall forthwith and with dispatch raise and remove any vessel or offshore plant belonging
to him or to any Subcontractor or to any person employed by him which may be sunk or stranded or
gone adrift in the course of the Work or otherwise deal with the same as Project Manager may direct
until the same shall be raised, removed or recovered.
Contractor shall buoy and light and do such things for the safety of navigation as may be required by
Project Manager or any statutory or other authority having jurisdiction.
The fact that the vessel and offshore plant sunk, stranded or gone adrift is insured or has been
declared an actual or constructive loss shall not absolve Contractor from his obligations under this
clause.
Contractor shall give both Project Manager and the said authorities immediate notice of the
occurrence of any such sinking, stranding or going adrift as is referred to in this clause.
4.1.38

Debris in the Sea

Contractor shall, at his own expense, remove from the sea, the sea bed and foreshore any floating or
submerged debris caused by the construction of the Work. He shall not discharge into the water area
any oil, solid, noxious or floating material and all water discharged into the sea shall be reasonably
free from impurities.
On completion of the Works Contractor shall guarantee that the area around the jetty is clear of all
debris, etc., which may in any way cause damage to vessels using the jetty.
4.1.39

Existing Ground Levels

Contractor shall, before commencing work, check, verify and satisfy himself as to the existing levels
of Employer Site and existing structures and agree them with Project Manager. Before any
excavation or breaking out, Contractor shall define reference lines for setting out the Plant.
4.1.40

Emergency Arrangements

The Contractor shall maintain arrangements whereby he can quickly call out labour outside normal
working hours to carry out work needed for an emergency associated with the Work or an emergency
at the site. Project Manager shall be provided at all times with a list of addresses and telephone

56

numbers of the Contractors staff who are currently responsible for organizing emergency work.
Contractor shall acquaint himself and his employees with any relevant local arrangements which are
in existence for dealing with emergencies at the Port.
4.1.41

Delivery, Handling and Storage of Materials

All Materials that are liable to damage shall be delivered in the original package, containers, etc.
bearing the name of the manufacturer and the brand.
Materials shall be carefully loaded, transported unloaded and stored in the approved manner,
protected from damage and exposure to weather or dampness during transit and after delivery to the
Site. Damaged materials or manufactured items damaged during and after fixing in position shall be
removed and repaired or replaced by and at Contractors expense.
Two copies of a certificate verifying that the materials meet the specified requirements shall be
provided by Contractor to Project Manager with each main delivery of prime materials, e.g.
aggregates or cement or as required by Employer, together with the results of any tests that are
required by the Specification and the relevant Standards.
4.1.42

Construction Plant

All constructional plant used on the performance of the Works shall be of such type, size and of such
method or working as is acceptable to Project Manager. If for any reason whatsoever Project
Manager shall be of the opinion that any excavator, mechanical digger, crane, concrete mixer,
vibrator, or that any such machine or appliance employed or proposed to be employed by the
Contractor for the purpose of the Works shall not be used, or that any such machine or appliance as
aforesaid is unsuitable for use on the Works or any part of them, then such equipment shall be
immediately withdrawn from use.
In particular the Project Manager may prohibit or suspend the use of machinery which in the
Employers opinion is likely to remove more material than is necessary, damage or render unstable
any structure, or any other property or works of any kind. Similarly the Project Manager may prohibit
the use of machinery causing a nuisance by noise or otherwise. Any change of the method of
performing the work as a consequence of such order shall be at the cost of Contractor who shall
have no cause for claim against the Project Manager on account of having to carry out the work by
another method or for the idleness or removal of any constructional plant.
4.1.43

Defective Work

Where any of the finished work, or the Materials or workmanship in any part of the FUF, does not
comply with all the relevant requirements of this Specification, that part of the FUF shall be classed
as defective work. All work classed as defective work shall be removed and replaced so as to be
acceptable to Employer.
The extent of the work to be removed and the methods to be used in the removal of this work shall
be in accordance with Project Managers directions.
In all cases, cutting out of defective concrete work shall be carried back to form satisfactory
construction joints before the replacement of defective work and any other work thereby affected is
commenced.

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4.1.44

Surveys

Initial Survey
Before any temporary or permanent works are carried out, the Contractor shall carry out a number of
initial surveys of the Site. The scope of the surveys shall include but not be limited to the following
items:
a)
Geotechnical Soil Investigation
A soil investigation shall be carried out by the Contractor, in accordance with clause 4.10 of this
section of the Bidding Documents. The required scope of work of the investigations shall be
determined by the Contractor.
b)
Bathymetrical and Topographical Survey
A positional and level survey of the onshore Site as well as the offshore site. The survey shall define
the positions and levels of all items to be effected by the works or for reference. All measurements
shall be to an accuracy of + 5mm. The levels shall be taken at intervals not exceeding 1m. The
levels shall be to an accuracy of + 2mm.
The bathymetrical survey shall include a level survey of the dredge location as well as the disposal
location.
c)
Diving Survey
A visual diving survey shall be carried out to confirm the existence, size and location of any existing
obstructions on the seabed.
Three copies of all survey plots and the visual records shall be given to the Project Manager. The
location and level surveys shall be plotted to a suitable scale to each single A0 sheet.
Final Survey
Upon completion of the construction works a number of final surveys shall be undertaken.
d)
Bathymetrical and level Survey
A final positional and level survey on the site (including the Jetty and bathymetric survey) shall be
carried out by the Contractor on completion of the works. The bathymetrical survey shall include the
dredged berthing pocket.
e)
Diving Survey
A final visual diving survey shall also be carried out to confirm that the seabed in the vicinity of the
berths is free of obstructions on the seabed.

4.2
4.2.1

Dredging
General

All dredging works shall comply with BS 6349 Part 5 1991, except as amended herein.
Before any dredging plant is brought to the Site the Contractor shall agree with the Project Manager
the method and detailed program for carrying out dredging work, including full particulars of all
dredging and other plant, craft and equipment which he proposes to use.
The method and sequence of dredging shall be such as to ensure that no damage is caused to
existing Port facilities and that the tolerances given herein can be achieved.
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Contractor shall take every precaution to minimize the possible negative effects on the environment
due to the dispersion and deposition of silt in the waters in and around the area of his dredging
operations and he shall provide detailed proposals in this respect for review by Project Manager.
Contractor shall ensure that his dredging operations do not in any way interfere with or endanger
shipping or navigation and shall at all times take full account of all relevant requirements of this
Specification.
Methods to be employed in all dredging operations shall be issued for review by Project Manager in
advance of any work commencing. Within 28 days after the acceptance of his tender, Contractor
shall submit to Project Manager for review a detailed method statement for undertaking the dredging
work. The method statement shall confirm and expand upon the information previously provided with
Contractors tender and shall include the following:
i)
ii)
iii)
iv)

Details of proposals for conveying dredged material to the disposal site.

Details of all plant and equipment to be employed on the dredging works.
Detailed program.
Any other details required by the Employer.

4.2.2

Dredging Plant

Contractor shall provide and maintain in good order all plant and equipment required for the
successful execution of the Work.
Dredging shall be carried out using suitable floating or shore-based plant, or a combination thereof.
Due regard shall be paid to limitation on access to the areas for dredging and the required
tolerances. Details of the types and outputs of dredging plant to be employed shall be provided for
the Project Manager which shall confirm and expand upon information supplied with Contractors bid.
4.2.3

Dredging in Any Materials

Dredging shall be carried out in any type of material which may be encountered, which shall include
natural bed materials, rock in varying states of weathering, including fresh rock and materials or
items of a manufactured nature such as chains, wires, cables, ropes, anchors, pipes, castings,
steelwork, concrete, timber, tires or similar.
Contractor shall be responsible for the clearance and disposal off Site of any manufactured or
fabricated items that are encountered in the dredging areas.
Where major items of wreckage are encountered, before the required dredged profile has been
achieved, Contractor shall immediately inform the Project Manager and await instructions before
proceeding with the removal of same.
4.2.4

Tide Levels

Contractor shall establish, for the duration of the Contract, a tide gauge of approved pattern at an
agreed location. The gauge shall be accurately leveled and related to Port Datum and periodically
checked for level monthly during the duration of the Works.
4.2.5

Position Controls

The methods by which the horizontal dredging limits are to be established shall be presented to
Project Manager for review.
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Contractor shall provide and maintain on board all dredging plant adequate position fixing systems,
together with competent operators to ensure that the position of dredging plant can be accurately
located to within 0.5m and recovered whilst dredging is being undertaken.
4.2.6

Survey

During the course of the dredging, Contractor shall carry out interim surveys as Project Manager may
require for the purpose of checking the dredged depths, which have been achieved as the work
progresses and to provide a basis for evaluating interim payments.
Project Manager may require Contractor to extend the surveys to cover other areas in order to
determine whether material is being deposited within these areas as a result of the dredging
operations or for any other purpose in connection with the Work.
When the dredging has been completed, the dredged areas shall be surveyed by Contractor jointly
with Project Manager to ensure that the dredging has been carried out to the required levels and
profiles.
For the purpose of carrying out pre-dredge, interim and post-dredge level surveys, Contractor shall
provide a motor boat, fully manned with experienced staff and equipped with echo sounding
apparatus, available for use at any time throughout the duration of the Contract.
The levels of the seabed shall be recorded by means of echo sounding equipment with an accuracy
of not less than 0.lm, which shall record output onto a paper tape. The paper printout shall have
minimum scale of 1 in 100 from which the water depths can be scaled. Equipment used for
determining the locations of the sounding positions shall be capable of fixing positions to an accuracy
of 1 .5m in plan.
Contractor shall allow for all surveys to be witnessed by Project Manager and provide suitable
facilities accordingly. Contractor shall notify Project Manager of his intention to survey at least 24
hours prior to the survey.
Contractor shall prepare record drawings of the pre-dredge and post-dredged surveys carried out for
review by Project Manager and shall provide copies of each agreed drawing to Project Manager.
4.2.7

Dredging Tolerances

No part of the finished dredging work shall, on completion, be higher than the specified dredged level
or profiles.
Within 30m of any existing structure or proposed new structure the maximum permitted over dredge,
below the required dredged levels, shall be 300mm.
If required by Employer, Contractor shall make good, at his own cost, any over- excavated areas with
such material and in such a manner as Project Manager shall direct.
4.2.8

Side Slopes

Side slopes shall be formed to profiles designed by Contractor. Contractor shall demonstrate to the
satisfaction of Project Manager that the slopes to be provided in the various material types shall be
stable.

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No portion of the finished work shall be higher than the approved lines and levels unless directed by
Project Manager.
Over dredging will not be permitted within 30m of any structure for the purposes of forming of side
slopes by over dredging or slope instability. Such slopes shall be accurately formed to the required
profiles.
4.2.9

Disposal of Dredged Material

The Contractor shall make his own arrangements for the disposal of surplus or unsuitable material off
Site. He shall be responsible for all liaisons and for obtaining any appropriate licenses, copies of
which shall be provided for Project Manager prior to the commencement of dredging.
All non-contaminated dredge material shall be disposed of in a designated sea disposal site at a
distance of 3.5 nautical miles (nm) West South West of the heads of the breakwaters.
Prior to signing of the Contract the Employer will advise the selected Tenderer the exact details of the
sea disposal site. The dumping site has to be surveyed to ensure that disposal would not do any
harm to that location; the sediment to be disposed off has to be tested to ensure that its pollution
content is within the legal limits.
To verify that dredge material is disposed of at the designated sea disposal area, all vessels
involved in the dumping operation shall be equipped with a track plotter integrated with a
computer/DGPS receiver. The route of each trip of the vessel(s) shall be plotted. The track plots shall
be submitted to the Engineer on a daily basis and not later than 24 hours after the respective trip has
been completed. Failure to submit track plots shall result in a deduction from the contract value of
USD 5,000 per trip.
The Contractor shall carry out a pre-dredging and post-dredging survey and present these results to
the Engineer for approval. All hoppers or barges used for the transport of dredged materials shall
only be used with good door or aperture seals, such that when the hopper is filled with water to a
level of 1.0 m above the outside sea level the retained water level is maintained, or at least does not
fall at a rate greater than 300 mm per hour. The Engineer may at any time require that the
effectiveness of hopper seals be proved by means of the test described. The use of automatic or
manual "light mixture overboard" shall not be operated when the density of the pump mixture is in
excess of 1050 kilograms per cubic meter. Trailing suction hopper dredgers will overflow their
hoppers only to the extent that economic loads are achieved and the Contractor will undertake to
give their utmost co-operation to the Engineer to minimize deleterious influences caused by overflow
and any migration of fines beyond the dredging area.
4.2.10 Siltation
Contractor shall dredge and dispose at his own cost any material which, during the period between
the dates of commencement and completion of all dredging operations, accumulates above the
specified dredged levels within the area to be dredged.
4.2.11 Sweeping
On completion of dredging Contractor shall undertake a physical sweep of all dredged areas to
ensure that the seabed is level and free from projections above the respective specified minimum
levels. Contractor shall remove any such projections and sweep the area again to check that their
removal is complete.

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4.2.12 Daily Records

Contractor shall keep daily records of the dredging work. The records shall include the following
information:a) Type of material(s) dredged
b) Areas of materials dredged
c) Estimated volume dredged
d) Weather and sea conditions
e) Tide plot
f) Times, duration and causes of all stoppages
4.2.13 Existing Operation
Contractors attention is drawn to the restrictions on his operations due to Port operations, vessel
movements and construction works by others within the Port. No demurrage will be paid for any
effects on dredging operations due to shipping movements or construction works by others within the
Port. Demurrage will only be paid should Contractor be prevented from working by order of
Employer.
4.2.14 Method Statement
Not less than 14 days before commencement of any rock pretreatment or dredging work Contractor
shall provide a full and detailed Method Statement for the dredging and pre-treatment works to
Project Manager for review. The Method Statement shall cover all aspects of dredging works
including the following:
a. Type and capacity of dredgers and barges.
b. Methods of anchorage and positioning of dredger.
c. Sequence and programming of dredging.
d. Method of position control, surveys and soundings to be used.
e. Methods of dredging adjacent to existing or new structures.
f. Measures to be adopted to avoid interference with port operations and ferry movements.
g. Measures to be taken to control dispersion and deposition of silt and to absolutely minimize
adverse environmental effects.
h. Methods of disposal of dredged material.
i. Methods of control and placement of dredged material placed as fill (if any).
j. Methods of investigations to determine extent of material requiring pre-treatment.
k. Pre-treatment methods, sequencing and programming.
l. Procedures for handling and storage of explosives.
m. Methods of ensuring vibration limits are not exceeded and monitoring procedures to be adopted.
n. Methods of achieving stable dredged slopes.

4.3

Piling Work

Spirally welded tubular steel piles may be used as an alternative to longitudinally welded tubular steel
piles (described and specified below) provided satisfactory documentation (material, welding,
fabrication etc.) and references can be provided by Contractor.
4.3.1

General

This Section describes the minimum piling requirements for supply, delivery and construction of piling
works associated with the construction of the Jetty.

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Piling work shall conform in all respects with the principles contained in BS 8004 - Foundations.
Contractor shall submit to Project Manager for review detailed proposals, including the sequence of
piling and type of plant which he intends to employ prior to commencement of any piling work.
Contractor shall ensure that the method and sequence of piling operations does not in any way
interfere with or endanger shipping or navigation.
All piles shall be longitudinally seam welded tubular steel piles with concrete plugs at the top and
bottom.
The Contractor shall provide the necessary piling plant required to install the piles to achieve the
required programme, pile penetrations and bearing capacities.
In the event that the piles cannot be driven to their design penetration the Contractor shall notify his
Designer and propose a solution to achieve the required penetration.
The Contractor shall give due and reasonable notice of his intention to drive piles so that the Project
Manager may make arrangements for inspection if he so requires.
The pile shall be cleaned out to toe level. The piles shall be anchored using approved means, as
required by Contractors design. Contractor shall take full responsibility for determining the length of
casing after the pile test described in this Specification.
Contractor shall be responsible for ascertaining the available capacity of partly completed piles and
for demonstrating to the satisfaction of the Project Manager, if so required, that adequate capacities
are available at each stage to facilitate the construction of the works in the temporary condition
without overstressing the pile casings or sockets.
In addition to submitting the records required by this Section Contractor shall report immediately to
the Project Manager any circumstances which indicate that the ground conditions differ from those
expected by Contractor from the site investigation to be undertaken so as to affect materially the
bearing capacity of the pile.
Where piles have not been positioned or driven within the limits described in the Contract, no method
of forcible correction shall be permitted. Project Manager may require piles so positioned to be
withdrawn and re-driven or take such other action as considered necessary.
4.3.2

Materials

Tubular steel piles shall have dimensions and steel grades as shown on the Drawings, fabricated
from steel conforming to BS EN 10025 or equivalent.
Materials to be used for the Contract shall be new, or unused in good condition as new.
Longitudinal seam welds shall be carried out by automatic welding by a metal arc process in
accordance with BS 5135 with full penetration butt welds.
The external dimensions at any section measured by using a tape on the circumference shall not
differ from the theoretical dimensions by more than -1% to +1%. The manufacturing tolerance shall
be such that the actual weight of any section does not differ from the theoretical weight by more than
-2.5% to +5%.

63

Contractor shall record and retain certified copies of test sheets covering each consignment of piles
received by Contractor stating the process of manufacture and giving the results of each of the
mechanical tests applied and of the chemical analysis.
Where original test certificates are not available or cannot be directly identified with unused second
hand material Contractor shall arrange for mechanical and chemical tests to be carried out in
accordance with BS 7668, BS EN 10113-1, BS EN 10155, BS EN 10210-1 upon a minimum of 3 No.
samples cut from each size of tubes from each source, prior to delivery of the tubes. Where the
results from such tests are inconsistent or otherwise unsatisfactory Project Manager may require
additional tests to be carried out, or an alternative supply of tubes to be identified.
Contractor shall note that paint and other surface treatment to unused second-hand materials is to be
fully removed and the ends of tubes shall be prepared as necessary for welding.
4.3.3

Handling and Storage of Piles

Contractor shall, before taking possession of the piles, submit to Project Manager for review detailed
proposals for storing handling and transporting the piles. He shall also submit details of any
temporary fixtures to the piles he wishes to use to facilitate handling.
All operations such as handling, transporting and pitching shall be carried out in a manner which shall
avoid damage to the piles.
4.3.4

Fabrication and Splicing of Steel Piles

General
Tubular steel piles shall be fabricated for installation in one piece by Contractor, by welded splices
using full penetration butt joints.
Where pile splices are to be made in situ, when it is necessary to lengthen piles after installation,
these shall also be full penetration butt joints.
Longitudinal seam welds of lengths of piles forming a completed pile shall be even staggered at joints
whenever possible and always by not less than 100mm.
Welding
All welding shall be by the metal-arc process in accordance with BS 5135 using consumables /
processes producing a diffusible hydrogen content greater than that specified in BS 5135, Table 1,
Scale C, i.e. less than l0ml of hydrogen per 100g of weld metal deposited.
Electrodes for welding shall be compatible with the grade of steel to be welded and shall produce a
weld equivalent in strength to the parent metal of the tubular steel casing. PQR test shall be done to
confirm the compatibility of the welding electrodes and the steel grade.
The chemical composition and mechanical properties of welding consumables shall be compatible
with the grade of steel to be welded and shall produce a joint equivalent in strength to the parent
metal.
Stick electrodes for the manual metal arc welding of mild and medium tensile steel shall comply with
the requirements of BS EN 499.
Electrode wires for the metal inert gas or metal active gas arc welding of carbon steel and medium
tensile steel shall comply with the relevant requirements of BS 2901.

64

Electrode wires and fluxes for the submerged arc welding of carbon steel and medium tensile steel
shall comply with relevant requirements of BS EN 756.
Full details of the welding procedure proposed by Contractor, in each case accompanied by
diagrams showing the build-up of all welds, together with the details of the manufacture,
classification, code (as defined in BS EN 499) and size of electrodes, including details of any
preheating required, shall be submitted to the Project Manager for review and no changes in
procedure shall be made without Employers prior agreement.
Surfaces to be welded shall be dry, free from rust, loose scale, grease and paint. Temporary tack
welds shall be subject to the same quality requirements as the final welds. They shall be thoroughly
cleaned and fused with the final weld.
Particular care shall be taken to ensure the smoothness of finished welds, which shall be smooth and
flush with the adjoining surfaces of the parent metal, and all irregularities, undercutting and porosity
shall be eliminated to ensure good corrosion resistance.
Welding sequences shall be such that distortion is reduced to a minimum, and local distortion is
rendered negligible in the finished work. Contractor shall be responsible for the consequence of any
distortion that may occur.
All welds shall be finished to produce a smooth weld profile and full throat thickness having been
deposited in accordance with an approved welding procedure, with inter-run cleaning carried out
between each weld pass to remove all slag and any other non-metallic deposits.
Welding consumables shall be handled in accordance with the manufacturers recommendations with
instructions for the storage, baking and re-drying of fluxes and/or electrodes strictly adhered to.
Where required, electrodes shall be re-dried to restore them to a satisfactory condition.
All welds shall be finished full and made with the correct number of runs, the welds being kept free
from slag and other inclusions, all adhering slag being carefully removed from the exposed faces
immediately after each run.
When carrying out welding operations on installed piles Contractor shall ensure that the earth return
to the welding site is attached to the pile. Indirect earth returns will not be permitted.
Weld Testing and Approval
Approval testing of welding procedures and operators shall be in accordance with BS EN 288:3.
Welders shall be qualified in accordance with BS EN 287:1 and copies of approval test certificates
shall be made available for review by Project Manager.
The acceptance of welded work shall depend upon correct dimensions, alignment and absence of
distortion in the finished work, satisfactory results from the examination and testing (where required
by Project Manager) of the joints, the soundness of the welds and general good workmanship.
Completed welding shall be subjected to 100% volumetric examination together with surface flaw
detection in accordance with BS EN 1435, BS 3923 and BS 6072 as appropriate.
The acceptance criteria for butt welds shall be to BS 5135 Table 18, Quality Category B for
circumferential butt welds for bearing piles designed primarily to resist axial loads and Category A for

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piles designed to resist lateral loads. For fillet welds the acceptance criteria shall be BS 5135, Table
19, Quality Category A.
If Contractor proposes to use ultrasonic testing in lieu of radiographic testing he shall provide full
details of proposed testing procedures to Project Manager for review. All testing operatives carrying
out ultrasonic weld testing shall be approved for the relevant connection type and copies of their
qualification certificates shall be made available for review by Project Manager.
All butt welds shall have full penetration throughout their length to develop the full strength of the
tube. Tests on butt welds shall otherwise be carried out on 25% of shop welds and all site welds.
100% testing using ultrasonic, radiographic and magnetic particle methods shall be carried out
200mm in each direction on the transition between welded circumferential and longitudinal butt joints.
Tests on fillet welds shall be carried out on 10% of shop welds and all site welds.
Before the commencement of production welding, butt weld test plates shall be fabricated for each
plate connection type and shall be subjected to non-destructive and mechanical tests by an
accredited laboratory.
All testing and interpretation work shall be carried out by an accredited testing laboratory nominated
by Contractor and accepted by Project Manager. Three copies of examination results shall be
submitted to Project Manager as soon as they are available and in any case before the pile is
installed.
4.3.5

Pile Identification

Each fabricated pile shall be clearly marked in white paint with its number and overall length. In
addition each pile shall be marked at intervals of 250mm along the top 3m of its length before being
installed.
4.3.6

Damage to Piles

Contractor shall ensure that damage does not occur to piles at any time. The sequence and timing of
driving of piles shall be such as to ensure that completed piles are not damaged as a result of driving
of adjacent piles.
Piles which have in the opinion of Project Manager been damaged in handling or during installation
may be rejected. Rejected piles shall be removed from the Site and replaced at Contractors
expense.
4.3.7

Pile Design

The piles shall have working load capacities appropriate to their design. Contractor shall be
responsible for determining the depths to which all the piles shall be advanced and/or the related
driving criteria to achieve the required load carrying capacities. He shall be responsible for
demonstrating the adequacy of the depth assessment prior to installing piles and for confirming that
the completed piles have achieved the specified load carrying capacity and to conduct the load piles
test prior to commencing its driving activities in order to confirm the piling design.
Contractor shall submit details and calculations of his determination of the depth of piles a minimum
of 28 days prior to commencement of pile installation and shall allow a period of 14 days for review
by Project Manager. Piles shall have a safety factor as detailed in of 2.5 against failure under vertical
load for piles with only compression or tension loads and 3.0 against failure for piles with both

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compression and tension loading, failure being defined as a settlement of the pile toe whilst under
load of greater than 15mm (to be confirmed after soil investigation).
4.3.8

Piling Method Statement

Not less than 28 days before commencement of piling works Contractor shall provide a full and
detailed Method Statement to Project Manager for review for the fabrication and installation of each
type of piling required for the various structures. The Method Statement shall confirm and expand
upon information previously supplied and shall include:
a) Type and Details of permanent piles including materials, internal diameter and wall thickness.
b) Details of the method of fabricating and details of method of installation of permanent piles and
service piles including all temporary works and details of method by which required verticality or rake
will be achieved.
c) Details of the methods to facilitate the installation of the pile to top of competent bedrock including
methods of advancing a pile in the event that obstructions are encountered during piling; to be
compatible with item e) below.
d) Details of method of pre-boring, grubbing out, chiselling or other such technique to permit the
installation of pile casings to the minimum design penetrations required.
e) Details of proposals for the use of any reinforcing to pile toe and/or head which together with c)
and d) above will ensure that a pile achieves the minimum design penetration.
f) Details of method for demonstrating that the casing has reached competent bedrock and the
criterion for determining the toe level of individual piles.
g) Details of the method of forming rock sockets beneath pile toes into bedrock and for maintaining
the temporary stability of the bore prior to placement of the concrete (if applicable).
h) Details of method of fixing reinforcement.
I) Details of method of placing concrete.
j) Details of the method of applying any surface treatment to the piles and details of the method of
repair of such treatment.
k) Details and numbers of plant and personnel to be used for pile installation.
I) Detailed construction programme showing the sequence of and periods for pile construction.
m) Disposition of piling plant during piling operations.
n) Details of proposals for storage, handling and transporting the piles.
o) Method of extending a pile.
p) Pile driving acceptance criteria and the basis of assessment.
q) Installation of temporary bracing between the driven piles.

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r) Drilling requirement inside the piles till the end of the sockets and cleaning of the piles and the
sockets.
s) Pile cap requirements.
t) Disposal of the waste material.
u) Any other details required by Employer.
Contractor shall be responsible for determining the installation requirements at each pile location and
the need to employ additional measures including pre-boring or pre-chiselling in order to advance the
piles to the required penetration and resistance without causing damage to the piles.
4.3.9

Installation of Tubular Steel Piles

All plant and equipment to be used for the installation of piles may be subject to review by Project
Manager and all work shall be carried out in compliance with BS 8004 - Foundations.
At all stages during installation and until incorporation in the superstructure the piles shall be
adequately supported and restrained by means of leaders, trestles, temporary supports or other
guide arrangement as required to maintain position and alignment and to prevent buckling. These
arrangements shall be such that damage to the piles is avoided.
Contractor shall ensure that piles are temporarily braced or stayed immediately after driving to
prevent loosening of the piles in the ground and to ensure that no damage resulting form oscillation,
vibration or movement of any free-standing pile length can occur.
Contractor shall satisfy Project Manager regarding the suitability, efficiency and energy of the driving
equipment.
The equipment shall be sufficiently robust, heavy and powerful to drive the piles as specified without
damaging them and the size and type of equipment shall be changed as necessary when driving a
pile. As necessary, suitable driving caps, helmets, dollies and anvil blocks shall be provided which
shall be the correct size to suit the section of pile to be driven and to avoid distorting or damaging the
pile.
Each pile shall be driven continuously until the approved set and depth has been reached, except
that driving may be suspended where this is necessary to permit any pre-boring or pre-chiselling to
facilitate the further advancing of the pile.
Where tubular steel piles are lengthened after driving, the pile shall be cut down to sound material
and the joint prepared and the splices shall be made with butt joints as specified.
A detailed record of the driving resistance over the full driven length of each pile shall be taken.
A follower (long dolly) shall not be used unless approved, in which case Project Manager will require
the set to be revised to take into account the reduction in effectiveness of the hammer blow.
Contractor shall inform Project Manager without delay if an unexpected change in driving
characteristics is noted.

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To ensure complete water-tightness of driven tubular steel piles, no holes, openings or the like shall
be formed in the piles.
Contractor shall give adequate notice and provide all facilities to enable Project Manager to check
driving resistances, if necessary.
Re-drive checks, if required, shall be carried out to an approved procedure.
The final set to each pile shall be recorded as the penetration in millimetres per 10 blows.
When a final set is being established the following requirements shall be met.
a) The exposed part of the pile shall be in good condition without damage or distortion.
b) The dolly and packing, if any, shall be in sound condition.
c) The hammer blow shall be in line with the pile in sound condition.
d) The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at
right angles to the pile and hammer axis.
e) The temporary compression of the pile shall be recorded if required.
When required, levels and measures shall be taken to determine the movement of the ground or any
pile resulting from the driving process.
When a pile has risen as a result of adjacent piles being driven, Contractor shall submit to Project
Manager proposals for correcting this and the avoidance of it in subsequent work.
4.3.10 Tolerances
The maximum permitted deviation of the position of any pile centre at cut-off level from the centre
point shown on the setting out drawing shall be 70mm in any direction. The verticality of the piles
shall be correct within a slope of 1 in 75.
The piling rig shall be set and maintained to attain the required rake. The maximum permitted
deviation of the finished pile from the specified rake is 1 in 25.
Where piles have not been positioned or driven within the limits specified, no forcible method of
possible correction shall be permitted. Project Manager may require piles so positioned to be
withdrawn and re-driven, all at Contractors own expense, or take such other action as Project
Manager considers may be necessary.
To ensure complete water-tightness of driven tubular steel piles, no holes, openings or the like shall
be formed in the piles.
Re-drive checks, if required, shall be carried out to an approved procedure.
A detailed record of driving resistance over the full length of each pile shall be taken.
4.3.11 Preparation of Pile Heads
Following completion of driving, the pile shall be cut to the required level and, if necessary, to provide
a clean square true and level head for the seating of the superstructure.

69

Contractor shall take all due care to prevent the redundant sections of pile being damaged whilst
being removed. All cut-off sections of pile shall be stored on Site for the duration of the piling works
and Contractor shall keep a detailed list of these which shall be submitted to Project Manager as and
when required.
Contractor shall not weld or fix any temporary attachment to the piles without prior agreement with
Project Manager. Any such attachment shall be fixed in accordance with this Specification and shall,
unless agreed otherwise with Project Manager, be removed on completion of the Work and the piles
made good.
4.3.12 Piling Programme
Contractor shall inform Project Manager each day of the programme for piling for the following day
and shall give adequate notice of his intention to work outside normal hours.
4.3.13 Records
Contractor shall keep records as indicated below of the installation of each pile and shall submit two
signed copies of these records to Project Manager not later than noon of the next working day after
the pile was installed. The signed records will form a record of the work.
Any unexpected driving or boring conditions reported in accordance with the
Specification shall be noted in the records.
Pile Record Data:
a) Contract
b) Pile Reference Number (Location)
c) Pile type
d) Nominal cross-section dimensions or diameter
e) Length of preformed pile
f) Date and time of driving or re-driving or boring
g) Ground or bed level at commencement of installation of pile
h) Working level
i) Toe level
j) Type of drilling equipment and method of pre-boring equipment.
k) Type, weight, drop and mechanical condition of hammer and equivalent information for other
equipment.
I) Number and type of packings used and type and condition of dolly used during driving the pile.
m) Record of driving resistance over the full length of pile including the final set of pile or pile tube in
mm per 10 blows or number of blows per 25mm of penetration.
n) If required brief description of materials encountered in pre-boring and socketing including
consistency, colour, structure, type, penetration rate and depth of change of each stratum.
o) If required, the sets taken at intervals during the last 3m of driving.
p) If required, temporary compression of ground and pile from time of a marked increase in driving
resistance until pile reaches its final level.
q) All information regarding obstructions, delays and other interruptions to the sequence of work.
r) Date of concreting.
s) Concrete mix.
t) Volume of concrete placed in pile.
u) Length and details of reinforcement.
v) Length of the socket and the concrete socket, (levels of the concrete to be indicated.

70

4.3.14 Obstructions
If an obstruction to normal driving is encountered, driving shall cease and Contractor shall employ the
measurers previously proposed to Project Manager for review.
Notwithstanding any such review, Contractor shall be entirely responsible for ensuring that the piles
will be repositioned in such a way as to ensure that the required bearing capacity is assured.
4.3.15 Reinforced Concrete Riling
General
Piles shall not be concreted until all piles within a radius of 5 meters from both the head and toe of
the pile to be concreted have been driven.
Piles are to be kept thoroughly clean of all foreign matter whilst driving. Pile casings shall be cut to
level prior to placing concrete and prior to the positioning of reinforcement. The piles shall be
reinforced as shown on drawings and filled with concrete as specified.
Reinforcement to Piles and Sockets
Joints in reinforcement shall be such that the full strength of the bar is effective across the joint and
shall be made so that there is no relative displacement of the reinforcement during the construction of
the pile. Approved spacers shall be provided on reinforcing cages to ensure that the minimum
required concrete cover to reinforcement will be achieved. Welding of steel reinforce is not accepted,
mechanical couplers shall be used for the steel bar joints.
Reinforcement shall be left projecting from the top of the pile as appropriate to the design.
Placing of Concrete infill to Piles and Sockets
Prior to placing of concrete within sockets Contractor shall ensure that all loose and disturbed
material is removed from the sockets.
The method of placing and workability of the concrete shall be such that a continuous monolithic
concrete shaft of the full cross-section is formed.
Concrete infill to piles shall be placed without such interruption as would allow the previously placed
batch to have hardened.
Contractor shall if required by Project Manager, undertake full scale trials to demonstrate the
suitability of the proposed concrete mix and placement methods to form satisfactory pile infill.
Contractor shall take all precautions in the design of the mix and placing of the concrete to avoid
arching of the concrete in a casing. No spoil, liquid or other foreign matter shall be allowed to
contaminate the concrete.
Internal vibrators shall not be used to compact Concrete unless Contractor is satisfied that they will
not cause segregation or arching of the concrete.
4.3.16 Pile Testing
General
Testing of piles shall be carried out in accordance with BS 8004. Contractor shall submit to Project
Manager for review full details of testing equipment, temporary works and the testing procedure he
proposes to adopt.
71

Contractor shall carry out Maintained Load Tests to one and a half times the vertical working load of
piles.
As a minimum the Contractor shall carry out one static load test in addition to dynamic pile testing.
Safety Precautions
When preparing for, conducting and dismantling a pile test Contractor shall carry out the
requirements of the various acts, orders, regulations and other statutory instruments that are
applicable to the Work for the provision and maintenance of safe working conditions and shall in
addition make such other provision as may be necessary to safeguard against any hazards that are
involved in the testing or preparations for testing.
Where kentledge is used Contractor shall construct the foundations for the kentledge and any
cribwork, beams or other supporting structure in such a manner that there will not be differential
settlement bending or deflection of an amount that constitutes a hazard to safety or impairs the
efficiency of the operation The kentledge shall be adequately bonded, tied or otherwise held together
to prevent it falling apart, or becoming unstable because of deflection of the supports
The weight of kentledge shall be greater than the maximum test load and if the weight estimated from
the density and volume of the constituent materials an adequate factor of safety against error shall be
allowed.
Where tension piles or ground anchors are used Contractor shall ensure that the load is correctly
transmitted to all the tie rods or bolts. Extension of rods by welding shall not be permitted unless it is
known that the steel will not be reduced in strength by welding. Bond stresses of rods in tension shall
not exceed normal permissible bond stresses for the type of steel and grade of concrete used.
In all cases Contractor shall ensure that when the hydraulic jack and load measuring device are
mounted on the pile head the whole System will be stable up to the maximum load to be applied.
Means shall be provided to enable dial gauges to be read from a Position clear of the kentledge stack
or test frame in conditions where failure in any part of the system due to overloading buckling, loss of
hydraulic pressure and so on might constitute a hazard to personnel
The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under
hydraulic pressure shall be capable of withstanding a test pressure of 1.5 times the maximum
working pressure without leaking.
The maximum test load or test pressure expressed as a reading on the gauge in use shall be
displayed and all operators shall be made aware of this limit.
Preparation of a Working Pile to be tested
The pile shaft shall be extended where necessary above the cut-off level of working piles so that
gauges and other apparatus to be used in the testing process will not be damaged by water or falling
debris.
Where the pile shaft is extended above the cut-off level of a working pile in a soil which would
influence the load bearing capacity of the pile, a sleeve shall be installed and kept in place during
testing to eliminate friction which would not arise in the working pile. Alternatively, if the friction above
the designed cut-off level can be calculated with reasonable accuracy, a sleeve need not be used,
but the calculated friction must be taken into account in assessing the load being applied to the pile.

72

The pile head or cap shall be formed to give a plane surface which is normal to the axis of the pile,
sufficiently large to accommodate the loading and settlement measuring equipment and adequately
reinforced or protected to prevent damage from the concentrated application of load from the loading
equipment.
The pile cap shall be concentric with the pile; the joint between the cap and the pile shall have a
strength equivalent to that of the pile.
Sufficient clear space shall be made under any part of the cap projecting beyond the section of the
pile so that, at the maximum expected settlement, load is not transmitted to the ground except
through the pile.
Reaction Systems
Compression tests shall be carried out using kentledge tension piles or specifically Constructed
anchorages.
Where kentledge is to be used, it shall be supported on cribwork disposed around the pile head so
that its centre of gravity is on the axis of the pile.
The bearing pressure under supporting cribs shall be such as to ensure stability of the kentledge
stack. Kentledge shall not be carried directly on the pile head.
Where kentledge is used for loading vertical piles in compression, the distance from the edge of the
pile to the nearest part of the crib supporting the kentledge stack in contact with the ground shall be
not less than 1.3m.
The centre to centre spacing of vertical reaction piles from a test working pile shall be not less than
three times the diameter of the test pile or the reaction piles or 2m, whichever is the greatest.
Where rock anchors are used to provide a test reaction for loading, no part of the section of the
anchor transferring load to the ground shall be closer to the test pile or working pile than three times
the diameter of the test pile.
The sizes, lengths and number of the piles shall be adequate to transmit the maximum test load to
the ground in a safe manner without excessive movement or influence on the test pile.
The method employed in the installation of any reaction piles, shall be such as to prevent damage to
any working pile.
The loading arrangement used shall be designed to transfer safely to the pile the maximum load
required in testing. Full details shall be submitted to Project Manager prior to any work related to the
testing process being carried out on the Site.
Loading Equipment
The equipment used for applying load shall consist of one or more hydraulic rams or jacks. The total
capacity of the jacks shall be at least equal to the required maximum load. The jack or jacks shall be
arranged in conjunction with the reaction system to deliver an axial load to the pile. The complete
system shall be capable of transferring the maximum load required for the test.
The load shall be measured by a load measuring device and by a calibrated pressure gauge included
in the hydraulic System. Readings of both the load measuring device and the pressure gauge shall
be recorded. In interpreting the test data the values given by the load measuring device shall
normally be used the pressure gauge readings are required as a check for gross error.

73

The load measuring device may consist of a proving ring, load measuring column, pressure cell or
other appropriate system. A spherical seating shall be used in conjunction with any devices that are
sensitive to eccentric loading; care must be taken to avoid any risk of buckling. Load measuring
devices and jacks shall be short in axial length in order to achieve the best possible stability:
Contractor shall pay attention to details in order to ensure that axial loading is maintained.
The load measuring device shall be calibrated before and after each series of tests whenever
adjustments are made to the device or at intervals appropriate to the type of equipment. The
pressure gauge and hydraulic jack shall be calibrated together.
Certificates of calibration shall be supplied to Project Manager.
The loading equipment shall be capable of adjustment throughout the test to obtain a smooth
increase of load or to maintain each load constant at the required stages of a maintained loading test.
The maintained load test movement of the pile head shall be measured by one of the following
methods:
1) Levelling Method
An optical or any other levelling method by reference to an external datum may be used.
Where a level and staff are used, the level and scale of the staff shall be chosen to enable
readings to be made to within an accuracy of O.5mm. A scale attached to the pile or pile cap
may be used instead of a levelling staff.
At least two datum points shall be established on permanent objects or other well-founded
structures or deep datum points shall be installed. Each datum point shall be situated so that
only one setting up of the level is needed.
No datum point shall be affected by the test loading or the Operations on Employers Site.
Where another method of levelling is proposed this shall be submitted for prior review by
Project Manager.
2) Independent Reference Frame
An independent reference frame may be set up to permit measurement of the movement of
the pile. The supports for the frame shall be founded in such a manner and at such a
distance from the test pile, kentledge support cribs, reaction piles, anchorages and rafts that
movements of the ground in the vicinity of the equipment do not cause movement of the
reference frame during the test which will affect the required accuracy of the test.
Check observations of any movements of the reference frame shall be made and a check
shall be made of the movement of the pile head relative to an external datum during the
progress of the test. In no case shall the supports be less than three test pile diameters or
2m, whichever is the greater, from the centre of the test pile.
The measurement of pile movement shall be made by two dial gauges rigidly mounted on the
reference frame that bear on surfaces normal to the pile axis fixed to the pile cap or head.
Alternatively the gauges may be fixed to the pile and bear on surfaces on the reference frame. The
dial gauges shall be placed in diametrically opposed positions and be equidistant from the pile axis.
The dial gauges shall enable readings to be made to within an accuracy of 0.1mm.

74

The reference frame shall be protected from sun and wind.

Contractor may submit any other method for measuring the movement of pile heads for review by
Project Manager.
Protection of Testing Equipment
Throughout the test period all equipment for measuring load and movement shall be protected from
the weather.
Construction equipment and persons who are not involved in the testing process shall be kept at a
sufficient distance from the test to avoid disturbance to the measurement apparatus.
Maintained Load Test Procedure
Contractor shall give Project Manager at least 24 hours notice of the commencement of the test.
During the progress of a test, the testing equipment and all records of the test shall be available for
inspection by Project Manager.
The maximum load which shall be applied shall be not less than 1.5 times the working load on a
working pile. The loading and unloading shall be carried out in stages as shown in
Table 4-1 below.
Following each application of an increment of load, the load shall be held for not less than the period
shown in the
Table 4-1 or until the rate of settlement is less than 0.25mm/hr and slowing down. The rate of
settlement shall be calculated from the slope of the curve obtained by plotting values of settlement
versus time and drawing a smooth curve through the points.
Each stage of unloading shall proceed after the expiry of the period shown in
Table 4-1.
For any period when the load is constant, time and settlement shall be recorded immediately on
reaching the load and at approximately 15 minute intervals for 1 hour, at 30 minute intervals between
1 hour and 4 hours, and at 1 hour intervals between 4 hours and 12 hours after the application of the
increment of load.
Table 4-1: Test Loading Cycle to Working Piles

75

Load, percentage of

Minimum time of

working load

working load

25

1 hour

50

1 hour

75

1 hour

100

1 hour

75

10 mins.

50

10 mins.

25

10 mins.

1 hour

100

6 hours

125

1 hour

150

6 hours

125

10 mins.

100

10 mins.

75

10 mins.

50

10 mins.

25

10 mins.

1 hour

The criteria for acceptance of working piles shall be a defined limit for settlement of the pile toe whilst
under test load or a reduced limit after removal of the load to be defined by Contractor from his
designs and submitted for review by Project Manager. Settlement of the pile toe is defined as the
total elastic and plastic deformation of the ground which is assumed to be the gross settlement
measured less the elastic pile compression calculated for an appropriate proportion of the total pile
length.
Details of Tests to be Submitted
In addition to pile information specified in Clause 4.3.5, Contractor shall submit the following
additional information:
Pile Test Data:
a) Position relative to adjacent piles.
b) Ground level at pile position.
c) Head level at which test load is applied.
d) Details of pile cap including date and time of casting.
e) Condition of pile head after driving.
f) Weight of kentledge, tension pile of ground anchor details.
g) Plan of test arrangement showing position and distance of kentledge supports rafts, or tension
piles and reference frame to test piles.
h) Jack type and capacity.
i) Method of load measurement.
j) Method of penetration measurement.
k) Test results in tabular and graphical form with load/settlement and time/settlement curves.
I) Effect, if any, on adjacent structures, ground heave, etc.
Completion of a Test
On completion of a test all equipment and measuring devices shall be dismantled checked and either
stored so that they are available for use in further tests or removed from Employers Site.

76

Kentledge and its supporting structure shall be removed from the test pile and stored so that they are
available for use in further tests or removed from Employers Site as directed by Project Manager.
On completion of a test on a working pile, the test cap shall be stripped and left in a state ready for
incorporation in the Plant and the resulting material disposed of off the Site. Temporary piles and
ground anchors shall be removed and cut off as specified.
4.3.17 Dynamic Pile Testing
Contractor shall submit to Project Manager for review details of equipment to be used, the method of
fixing and location of equipment and the method of analysis of test results not less than 7 days prior
to the proposed commencement of testing Strain transducers and accelerometers shall be located
within two pile diameters of the top of the pile.
Heads of piles to be tested shall where necessary be cleaned, trimmed and strengthened to safely
withstand and dissipate the impact stresses. The hammer which shall be of sufficient size to deliver
the force necessary to induce the required test load without causing damage to the pile shall impact
on a flat surface at right angles to the axis of the pile.
Dynamic pile testing on tubular steel piles shall be carried out at times to be agreed with Project
Manager which shall in no event be less than 24 hours after the completion of driving the respective
pile.
The testing and the interpretation of the test results shall be carried out by persons experienced in
this particular method of testing. Initial test results shall be submitted to Project Manager within 2
days of the completion of a test and shall include the maximum values of the following criteria:
a) Force applied to the pile head.
b) Pile head velocity.
c) Energy transmitted to the pile.
In addition to pile information, specified in Clause 4.3.5, Contractor shall include the following
additional information in his report on dynamic pile testing:
a) Length of pile from instrument to toe of pile.
b) Load achieved for selected test blow in terms of equivalent static load.
c) Pile head movement at:
i) Equivalent design verification load
ii) Equivalent design verification load +50% specified working load iii) maximum test load
d) Permanent movement of pile head after each blow.
e) Temporary compression
4.3.18 Pile Anchors
Pre-stressed anchors for bearing piles shall not be used in the Works.
Passive anchors may be used but Contractor shall first submit full details to Project Manager for
review and acceptance.
Anchors shall comply with the requirements of BS 8081.

77

4.4

Concrete Works

4.4.1

General

Contractor shall submit to Project Manager for review all details of all materials which he proposes to
use in the concrete including the names of manufacturers or suppliers and sources of supply.
Materials or sources of materials shall not subsequently be changed unless it can be demonstrated
that such change will not be to the detriment of the properties of the concrete.
Certificates for tests referred to in this Specification shall be provided by Contractor to Project
Manager.
Materials shall not be used in the permanent Work until trial mixes have been concluded.
Contractor shall provide all necessary samples of materials for the testing of concrete and its
constituent parts and carry out all the necessary testing as described in this Specification applicable
British Standards and Codes of Practice and other procedures to suit local laws and standards.
Testing shall be carried out by an independent testing laboratory. A laboratory shall be established
on Employer's Site to undertake as many of the Specified tests as is practicable.
4.4.2

Cement

Cement shall be:

-

Pozzolanic cement ENV 197-1 CEM Il/A-P 42.5

Cement shall conform to the requirements of ENV 197-1 Cement - Composition, Specification and
Conformity Criteria - Part 1: Common Cements.
The cement shall be tested in accordance with ENV 197-1.
The source of supply of cement shall be subject to Project Managers acceptance and Contractor
shall furnish the manufacturers test certificates and proof that the required Standard Specification
has been complied with, together with a note of the date of manufacture, certified by an independent
agency. Supplies of cement shall be obtained from one specific source unless otherwise accepted by
Project Manager.
All cement shall be fresh and shall be delivered either in unbroken water resistant bags containing
approximately 25kg cement, or bulk containers specifically designed for the purpose, bearing the
manufacturers name and the date of manufacture.
Cement shall be stored off the ground in a suitable dry shed or in a self-clearing silo and shall be
protected against deterioration. Consignments of cement shall be used in order of delivery. During
transport and storage cement shall be fully protected from all weather elements.
Cement which has deteriorated in any way shall not be used.
Any cement which has been stored on Employers Site for more than one month shall be re-tested for
moisture content, soundness and setting time before being used in any part of the Plant.
Any cement which fails to pass the test shall not be used.

78

4.4.3

Aggregates

General
Aggregates shall be from a source accepted by Project Manager.
Aggregates shall be hard, durable and clean and shall not be chemically reactive. They shall not
contain any deleterious material in sufficient quantity to adversely affect the strength at any age or
the durability of the concrete or to cause corrosion of reinforcement.
The grading and shape of aggregates shall be such that a concrete can be produced with the
specified proportions and consistency and which will readily work into position without segregation
and without the use of excessive water and which can readily be compacted into a dense impervious
mass.
All aggregates shall have a specific gravity not less than 2.6.
Aggregates shall in general comply with the requirements of BS882. All-in aggregate shall not be
used.
No aggregates shall be delivered to the Site without satisfactory initial sampling and testing. The
sample of fine aggregate shall be 25kg in weight and that of the coarse aggregate shall be 50kg in
weight.
Contractors attention is drawn to the need to maintain a consistent aggregate quality and he will be
expected to undertake adequate testing to ensure that the quality does not vary significantly.
The following tests as described in BS 812 shall be carried out as appropriate on both fine and
coarse aggregates:
- Determination of Particle Size and Shape - Sieve Analysis
- Determination of Flakiness Index and Elongation Index
- Determination of Ten Percent Fines Value
The flakiness index and elongation index when determined in accordance with BS 812 Part 105 for
each of the predominant size fractions in each single sized coarse aggregate shall not exceed 20%
and 25% by weight respectively. Fine aggregate shall not contain appreciable amounts of flaky
and/or elongated material.
When tested in accordance with BS 812: Part 4 the total acid-soluble chloride salt content for the
aggregates shall not exceed the following figures:
- Fine Aggregate -0.06% by weight
- Coarse Aggregate -0.03% by weight
The acid soluble sulphate salt content for the aggregates, when tested in accordance with BS 812:
Part 118 shall not exceed 0.25% by weight for both fine and coarse aggregates.
Notwithstanding the above figures every effort shall be made to obtain aggregates with as low a
chloride and sulphate content as possible.
The shell content (as calcium carbonate) as a percentage by weight of dry single size aggregates
shall not exceed 20% for 5mm to 10mm and 8% over 10mm.

79

All aggregates which are to be used shall have negligible alkaline reactivity. The water absorption of
both fine and coarse aggregates, determined in accordance with BS 812, shall not exceed 2.0%.
Fine Aggregate
The fine aggregate shall be from an approved source and shall be sharp and free from clay, organic
matter and other impurities. The gradation of fine aggregate shall be in accordance with grading C M
or F of BS 882 Table 5 and the percentage by weight passing the sieve No. 50 shall not exceed 30%.
The percentage passing the sieve No. 200 shall not exceed 3% and the sand equivalent shall be not
less than 50%.
The clay, silt and fine dust content shall not exceed the appropriate percentage stated in BS 882:
Table 6 by volume when using the field setting test given in BS 812 or such other equivalent test.
When fine aggregate is subjected to five cycles of the sodium sulphate soundness test carried out in
accordance with BS 812, Part 121, and the loss shall not exceed 10% by weight.
The amount of hollow shells, which are likely to form voids, present in material retained on a BS No.
7 sieve determined by direct visual separation, shall not exceed 2% by weight of the entire sample.
Coarse Aggregate
When the coarse aggregate is obtained by combining aggregates of different screen sizes the
respective quantities of the various sizes of coarse aggregates shall be premixed by the supplier at
the pit and loaded into vehicles from one hopper for transportation to the batching plant and stored
separately until weighed for batching.
Under no circumstances shall the mixing of different sizes of coarse aggregates be done by loading
the vehicles at the pit with calculated amounts of each respective size from individual hoppers.
The coarse aggregate shall be from an approved source, shall be clean, free from shell, sand, clay,
mica shale, quarry refuse, dust, organic matter and other impurities. The stone shall not be thin or
flaky.
The amount of material passing a BS No. 200 (75 micron) sieve in each size of the single-sized
course aggregate, determined in accordance with BS 812 (Decantation Method) shall not exceed 1
% by weight.
The Aggregate Impact Value, determined in accordance with BS 812 and using standard 14mm to
10mm test sizes, shall not exceed 30 except where specified minimum compressive strength or
characteristic strength of the concrete is 50
N/mm2 or higher in which case the AIV shall not exceed 25.
The 10% fines value tested in accordance with BS81 2 Part 111 in 90% of the test samples shall be
100kN with an absolute minimum of 80kN.
The shrinkage of the coarse aggregates tested in accordance with BS 812, Part 120 shall not exceed
0.075%.
4.4.4

Silica Fume for Concrete

Silica fume shall be used in all structural concrete. Silica fume shall comply with the latest
international Standard - Silica Fume for Concrete.

80

The silica fume shall be supplied and used in strict accordance with manufacturers instructions.
Contractor shall supply the following details of the silica fume to Project Manager:
a) Manufacturer, supplier and brand.
b) Chemical composition.
c) A design of the mix where the use of silica fume and possible admixtures are considered.
d) Samples for testing in sufficient time to enable assessment without delaying Contractors
programme.
e) Records of previous usage in similar environments, particularly hot climates.
f) Manufacturers' storage and use requirements.
g) Any precautions necessary for health and safety when handling.
Chemical composition of silica fume
- S1O2 85% mm.
- LOI (Loss on Ignition) 2.5% max.
Fineness shall be minimum 12 000m2/kg and the maximum density of densified silica fume shall be
650kg/rn3.
If densified silica fume is used, special precautions shall be taken to ensure the dispersion of the
silica fume in the mix.
4.4.5

Admixtures

Admixtures shall be permitted if Contractor demonstrates to the satisfaction of Project Manager that
they do not lead to a reduction in strength, durability, additional shrinkage or bleeding or any other
undesirable effects.
If the use of the admixtures is permitted they shall be used strictly in accordance with the
manufacturers instructions and any method statement accepted by Project Manager after site trails
have been carried out.
If concrete is made using a water reducing set retarding admixture it shall conform to the
requirements of BS 5075 or ASTM C494, Type D. Formulations shall be available to provide varied
setting times relating to conditions of climate and Contractors Site requirements at a constant
dosage rate as recommended by the manufacturer.
Admixtures containing calcium chloride or chloride salt shall not be used under any circumstances.
They shall not contain chloride ions in excess of 2% by weight of the admixture or 0.03% by weight of
the cement content of the concrete mix.
Admixtures shall comply with one of the following British Standards as appropriate:
- BS 1014, BS 4887 or BS 5075.
Where it is proposed to use more than one admixture Contractor shall obtain from the manufacturer a
written confirmation that the combination of admixtures will have no harmful effects either short or
long term upon the concrete.
Concrete to be placed underwater shall be mixed with a suitable admixture which produces concrete
that is free flowing without segregation when placed underwater and self-levelling and selfcompacting provided by approved supplier. Contractor shall carry out underwater trials to
demonstrate that his proposed admixture is capable of producing concrete with the required
properties.

81

All concrete shall be produced with the use of super plasticizer.

4.4.6

Storage and Delivery of Aggregates

Coarse and fine aggregates shall be delivered to Employers Site or to the mixing plant by means
that prevent contamination due to environmental effects, if necessary in covered containers, and
shall be stored separately. Care shall be exercised in the handling and storage of the aggregates to
prevent the segregation of the various particles and to prevent contamination from deleterious
materials.
Stockpiles shall be formed in bins or bags of suitable concrete foundations and to falls to allow
drainage and shall be sheltered from the sun and wind blown dust. All storage areas and bins and
hoppers shall be regularly emptied and cleaned to remove any accumulated containments.
Contractor shall at all times maintain, on Site or at the mixing plant, sufficient quantities of each type
of aggregate to ensure continuity of work.
4.4.7

Washing of Aggregates

In order to comply with the requirements in the specification, washing of aggregates may be required.
The water used shall comply with the requirements of the mixing water.
4.4.8

Water

Water which is to be used for mixing concrete, curing concrete and any other operation affecting
steel or formwork which could subsequently come into contact with fresh concrete shall at all times
comply with the requirements of BS 3148. It shall be fresh, clean, potable and free from any
substances that may be deleterious to concrete or steel. The pH of water used in concrete work shall
be not less than 5.0 and not more than 8.0.
Under no circumstances shall sea water be used for mixing or curing concrete.
Contractor shall avoid water being contaminated by earthy, vegetable or organic matter, acid or
alkaline substances, substances or other deleterious matter in solution or suspension which will
impair the strength or durability of the concrete.
The water shall enter the mixers at as low a temperature as possible. Every effort shall be made to
protect water pipes and tanks from the sun, e.g. by burying, shading, insulation or painting white.
Where flaked or crushed ice is added to the water for concreting it shall be stored in such a manner
as to prevent thawing and refreezing into larger pieces.
4.4.9

Concrete

Contractor shall design the proportion of each concrete mix in accordance with the recommendations
of BS 5328 to obtain concrete of a homogeneous structure which can be worked into the corners and
angles of the formwork and around reinforcement without segregation of the material or excessive
bleeding of free water at the surface and shall also, on striking of formwork, present a uniform face
free from honeycombing and crazing. When hardened, the concrete shall have the required strength,
maximum density and low porosity.
The final proportions of cement aggregates and water shall be such that the weight of cement used is
the least amount which will produce concrete complying with the Specification.
82

The classes of concrete mix that shall be used for new jetty are set out in Table 4-2:
Table 4-2:
Class

Section of the jetty work and application

C40/50

Structural concrete

All C40/50 concrete shall contain silica fume as a cement replacement to a minimum of 5% and a
maximum of 10% by weight of the total cement content.
Contractor shall submit the following data to Project Manager for review before using any concrete
mix:
1. Nature and source of all materials.
2. Full details of tests on trial mixes.
3. Proposed quantities of each ingredient per cubic meter of compacted concrete.
The required characteristic cube crushing strengths, cement type, minimum cement content,
maximum water ratio and nominal maximum aggregate size for each class are shown in Table 4-3.
The initial design mix shall have a preliminary target mean strength of at least 15 N/mm2 greater than
the specified minimum cube strength for concrete having a characteristic strength of 40N/mm2 and
above. No single result shall be less than 85% of the specified characteristic strength.
Table 4-3: Maximum water ratio and nominal maximum aggregate size.
Class of

Nominal

Max. Water/

Concrete

Max Agg.

Cement

Content in

Size

(+ silica fume)

Concrete

Ratio by weight

kg/m3

C40/50

20

0.38

Cement Type

ENV197-1 CEM

Min. Cement

400

II/A-P 42.5

The preliminary and works cube strengths detailed above are for concrete cured within the standard
curing temperature range specified in BS 1881. Where actual curing temperatures are higher than
within the standard range, cube strengths to be achieved will be correspondingly higher. Project
Manager will determine the increases in cube strengths to be achieved with increases in mean curing
temperatures.
The total chloride content arising from all ingredients in a mix including cement, water and admixtures
shall not exceed 0.05% chloride ion as a % of the weight of cement in the mix (0.08% when
expressed as an equivalent NaCl).
The total sulphate content, expressed as S03 of all the ingredients in a mix including cement, water
and admixtures shall not exceed 4.0% of the weight of cement in the mix.
For the chloride permeability reference is made to the Rapid Chloride Permeability Test (RCPT)
(AASHTO T-277-831 and ASTM C1202). The RCPT value shall not be greater than 1000 coulombs
after 28 days, for the C40/50 concrete.
4.4.10 Trial Mix and Workability
Trial mixes shall be produced under full scale production conditions using representative samples of
cement and aggregates of both the C40/50 mix. One series of the C40/50 shall be with micro silica

83

and the other without, otherwise they shall be identical. Three separate batches shall be produced
each on a separate day. The workability of each batch shall be determined and at least 9 cubes shall
be made for each batch, three for test at 7 days, three for test at 28 days, and three for chloride
permeability testing.
The trial mix proportions will be accepted if the average strength of the nine cubes tested at 28 days
is not less than 3.5N/mm2 below the target mean strength. If the range of the strength of the three
cube results in any one batch should exceed 15% of the average of that batch the trial mixes shall be
repeated.
Contractor shall take suitable precautions to ensure that the approved mix proportions are
maintained in the concrete that is actually deposited.
The quantity of water used in mixing the concrete shall be controlled by an approved water
measuring device. The workability shall be adjusted by the use of a super- plasticizer and mix of
aggregates. The water content of the mix shall be maintained at the limits given. Contractor is to
maintain on Site a suitable apparatus for checking the water content of the aggregate.
Concrete will only be accepted for placement if its workability is within the following limits at the time
of placement:
Slump test 1/3rd of the trial mixes mean or 20mm whichever is the lesser value Compacting Factor
0.03 of the trial mix mean.
The slump of the concrete will be determined from samples taken from the mixed concrete just
before the concrete is placed. The slump tests and/or compacting factor tests shall be carried out in
accordance with BS 1881.
4.4.11 Production and Delivery
Batching
The proportions of cement and aggregate in the concrete shall be measured by weigh-batching. The
weigh-batching plant shall be of a type which will accurately control the quantities of materials. The
equipment shall have an automatic system that records the amount of each constituent material in
each batch.
Cement shall be weighed on a separate weighing device to that used for the aggregates.
Alternatively, the cement may be measured by using a whole number of bags in each mix (split,
damaged or partly full bags shall not be used).
Each ingredient shall be measured to an accuracy of better than plus or minus 2.0%.
The amount of water shall be measured by volume or by weight.
Separate containers and measuring devices shall be used for admixtures.
The scales of all weigh batching plant and all liquid dispensers shall be zeroed daily and calibrated at
intervals not exceeding one week. Contractor shall provide all weights, materials and labour for
calibration and tests and shall retain all certificates as record documents.
Truck mixers shall not be used for the batching and mixing of concrete.

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Mixing
Concrete shall be mixed using a batch type mixer/s of approved design. Mixing shall continue until
there is a uniform distribution of the materials and the mass is uniform in colour and consistency. The
minimum mixing time shall be not less than that recommended by the manufacturer of the
equipment.
The mixer shall have mechanical/electrical controls to ensure that concrete cannot be discharged
until the required mixing time has elapsed and that the entire batch is discharged before the mixer is
recharged.
If densified micro silica is used, the mixer must be suitable for breaking up the granules and
dispersing the micro silica into the mix.
Detailed procedures for the batching and mixing of the concrete giving the sequence of adding
materials and mixing time, dry and wet, shall be worked out and included in Contractors quality plan.
Plant production capacity, with the chosen mix design, shall be specified in the quality plan.
The method of releasing the water into the mixer shall be such that the full measured quantity is
discharged in one operation and the flow is stopped automatically by a valve or syphon arrangement
only when the full quantity of water has been released. Arrangements which allow the discharge of
partial quantities of mixing at the discretion of the mixer driver shall not be used.
The amount of concrete mixed in any one batch shall not be less than three quarters of, nor exceed,
the rated capacity of the mixer. The whole of the mixed batch shall be removed from the mixer before
materials for a fresh batch enter the drum.
Contractor shall ensure that the mixing efficiency of the equipment is not impaired by the build-up of
cement and mortar on the mixing drum blades. On cessation of work, including all stoppages
exceeding 15 minutes, the mixer and all handling plant shall be washed out with clean water.
The first batch of a production run shall contain 15% less coarse aggregate in order to compensate
for the coating of the interior of the mixer.
Transporting
The concrete shall be discharged from the mixer and transported to the Plant by means which shall
prevent contamination, segregation or loss of ingredients, and ensure that the concrete is of the
required workability at the point and time of placing.
Concrete shall be transported in truck mixers or agitators. The concrete shall be continually agitated
during transportation and until discharge. Transportation of such concrete shall be in accordance with
BS 5328.
The drum of the truck agitator or truck mixer shall be completely clean and empty before it is filled
with concrete. Trucks shall not be loaded in excess of the manufacturers rated capacity, which shall
be displayed on the vehicle in terms of volume of mixed concrete. Trucks shall be discharged within
45 minutes after the introduction of the water to the cement.
Transit mixer trucks shall have their drums painted with heat reflective paint or covered with hessian
which is to be kept wet to achieve evaporative cooling.
The concrete shall be placed in the form as soon as possible after mixing before the initial set of the
concrete has started. No concrete shall be placed after this period has elapsed.

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Contractors attention is drawn to the need to ensure that every precaution is taken to minimize the
loss of workability of the concrete during transit. Concrete shall be transported from the mixer to the
forms as quickly as conditions will allow and the work shall be streamlined and co-coordinated so that
delays are eliminated. Also the temperature of the concrete shall be kept as low as possible, see
Clause 4.4.15.
No additional water shall be added to the concrete after it has been discharged from the mixer.
Under no circumstances shall water be added if the initial set of the concrete has taken place.
Each consignment of concrete shall be accompanied by a docket giving the class of concrete and the
time when the mixing water was added.
4.4.12 Ready Mixed Concrete
The supply and delivery of Ready Mixed concrete shall comply with the recommendations of BS
5328 and all relevant provisions of this Specification.
Prior to obtaining concrete from a ready-mixed supplier Contractor shall submit the following
information to Project Manager for review:
-

Ready Mixed Concrete Supplier

Location of Plant
Details of suppliers of all materials to be included in the concrete including
relevant test certificates
Standard Deviation (strength) currently achieved by Plant (N/mm2)
Design Standard Deviation (strength) (N/mm2)
Target Mean Strength (N/mm2)
Total chloride and sulphate ion content of concrete (%)
Total equivalent alkali content of concrete (Kg/rn3)

Contractor shall arrange for the supplier to provide the facilities stated in Clause 13.1 of BS 5328.
A ticket shall accompany each delivery and shall contain the following information:
-

Name or number of ready-mixed Concrete depot

Serial number of ticket
Date
Registration number of delivery vehicle
Name of purchaser
Name and location of project
Concrete mix designation
Cement content
Free water/cementitious material ratio
Workability
Type of cement
Nominal maximum size of aggregate
Type name and quantity of admixtures, if included
Quantity of concrete in Cubic meters
Time of loading.

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Tickets shall be retained as record documents by Contractor.

No water shall be added to the mix after it has left the ready mixed concrete plant.
4.4.13 Placing
Every delivery of concrete must be sampled and checked for workability by the slump or compaction
factor method prior to placement. Concrete outside the workability limits shall not be used. Also, the
concrete shall be rejected and not placed if the initial set has taken place in any part of the batch.
Contractor shall submit to Project Manager for review all details of his proposed method of placing
and curing the concrete before commencing work. If required, Contractor shall be prepared to
demonstrate the adequacy and effectiveness of his proposed method.
All surfaces shall be free of standing water. The concrete shall be deposited as nearly as Possible in
its final Position, and shall be placed in such a manner as to avoid segregation to the concrete and
displacement of the reinforcement, waterbars or formwork
The concrete shall be consolidated by high frequency mechanical vibrators in such a manner as to
obtain complete compaction without segregation or excessive laitance or the formation of "cold"
joints. Particular attention shall be made to ensure that concrete is thoroughly worked into the
corners of the formwork and around all reinforcement, waterbars and pipes.
Contact between the vibrators and reinforcement or formwork shall be avoided and on no account
shall vibration be used for the purpose of distributing concrete horizontally.
Vibrators shall operate at a frequency of not less than 5,000 cycles per minute.
4.4.14 Blinding layer
All horizontal or sloping surfaces of reinforced concrete that bear on the ground shall be protected by
a layer of blinding concrete 75mm thick.
Contractor shall place the blinding layer of concrete in such a way, and at such a time, as to ensure
that the exposed surface of the ground on which the blinding layer of concrete is to be placed does
not deteriorate after excavation through exposure to weather, traffic or other reasons.
4.4.15 Curing
All concrete shall be adequately cured and protected from the harmful effects of sunshine, drying
winds, rain or running water.
Contractor shall be aware of the importance of adequately curing the concrete, particularly during the
early stages of hardening.
All exposed surfaces shall be protected immediately on completion of placing and compaction of the
concrete. Curing shall be such as to ensure full hydration of the concrete and shall be carried out by
keeping all exposed surfaces on the concrete moist by means of wet hessian or similar absorbent
material. The surface of the concrete shall be protected by application of an approved curing
membrane until the concrete has set sufficiently to take the weight of coverings.
All shuttering shall be loosened as soon as possible and provision made for curing water to run down
inside them.

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Timber formwork covering the concrete shall be covered and moistened with water at frequent
intervals to keep it from drying out during the curing period. Metal formwork exposed to the sun must
be shaded from its direct rays, painted white or otherwise protected during the curing period.
The wet curing shall continue for a minimum of 7 days. Exposed surfaces shall be protected against
contamination by atmospheric chlorides until 28 days after the concrete was placed.
Following completion of wet curing concrete shall additionally be cured by having its exposed
surfaces sealed by approved membranes. Application of liquid curing membrane shall be by a lowpressure spray at the rate recommended by the manufacturer. Under no circumstances shall
seawater be used for curing concrete.
Throughout the curing period all the exposed surfaces shall be adequately protected from excessive
heat gain from the sun by tenting or reflective covering.
All concrete shall be protected from anything which may interfere with the process of setting or cause
damage before the concrete has set.
During curing Contractor shall undertake all measures necessary to ensure that the temperature
gradient between the core and the surface of all concrete elements being cast does not exceed 20
C.
Contractor shall submit with his Method Statement proposals for identifying the actual temperature
gradient of the cast elements.
Any concrete not cured strictly in accordance with this Specification shall be broken out and re-cast.
4.4.16 Concreting in Hot Weather
In general the recommendations ACI 305 Recommended Practices for Hot Weather Concreting and
ACI 308 Recommended Practice for Curing Concrete shall be followed.
The temperature of the concrete at the time of placing shall not exceed 32 C.
Every effort shall be made by Contractor to keep the temperature of the concrete at the time of
placing as low as possible. If the temperature of the concrete is likely to exceed 24 C at placing,
special measures shall be taken to control the temperature. Such measures shall include some, and
if necessary all, of the following:
1. Aggregate stockpiles shall be protected from the direct rays of the sun by shades. The stockpiles
shall not be watered.
2. Water for mixing concrete shall be cooled by means of mechanical equipment or the addition of
ice. Storage tanks shall be painted white or sited under shade and distribution pipes shall be
insulated or painted white.
3. Cement shall be stored in the shade. Bulk storage containers shall be painted white.
4. The mixing plant and delivery equipment shall be painted white and sited under shade wherever
possible. The interval between mixing and placing shall be kept to a minimum.
5. Reinforcement, metal conduit, etc, shall be kept in the shade for a minimum period for four hours
before concreting.

88

6. Immediately before the concrete is placed, formwork, conduit, etc, shall be sprinkled with cool
water.
7. During the curing period exposed concrete surfaces shall always be protected from the direct rays
of the sun, and the formwork shall also be protected.
8. In a prevailing arid wind, temporary wind breaks shall be provided.
Contractor shall provide and use an ample and clean water supply, hose and fog nozzles. Sea water
will not be allowed for any concrete, curing or compaction works.
Concrete shall not be mixed or placed when the shade air temperature on Site is 37C or above.
4.4.17 Testing
Samples of concrete being placed shall be taken and 150mm test cubes made, in metal moulds. In
general, 3 No. cubes will be required from each concrete pour. The slump test and/or compacting
factor test will be required for each set of test cubes. The temperature of the concrete shall be
recorded at the time of deposition.
The method of making, storing and testing of work cubes shall comply with BS 1881.
Contractor shall ensure that every precaution is taken during hot weather to take samples and form
cubes as quickly as possible and to then immediately protect the cubes from drying and temperature
rise by placing them in damp Conditions.
The Cubes shall be transferred to standard moist curing conditions in a laboratory after a day. During
the transfer they shall be protected and handled carefully.
Concrete shall be assumed to have achieved its characteristic strength when, at 28 days:
a) The average strength determined from any group of four consecutive test results exceeds the
characteristic strength by: 3N/mm2 for concrete having a characteristic strength of 20N/mm2 to
40N/mm2, 21mm2 for concrete having a characteristic strength of less than 20N/mm2 and 3.8N/mm2
for concrete having a characteristic strength of 50NJmm2.
b) The strength determined from any test result is not less than the characteristic strength minus
3N/mm2 for concrete having a characteristic strength of 20N/mm2 to 40N/mm2 and 2N/mm2 for
concrete having a characteristic strength less than 20N/mm2 and shall not be less than 85% for
concrete having a characteristic strength of 50N/mm2.
The quantity of concrete represented by any group of four consecutive test results shall include the
batches from which the first and last samples were taken together with all intervening batches. A test
result failing to comply with clause (b) above shall represent only the batch from which the sample
was taken.
Contractor shall prepare and test at his own expense additional concrete cubes where he requires to
demonstrate to Project Manager that a concrete element has achieved a particular compressive
strength after a period other than specified for routine tests. Such cubes shall be cured under the
same conditions as the related element.

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Where the concrete is proved unsuitable by the above criteria Contractor shall remove the related
concrete and replace it by new concrete of the specified strength.
Samples from each class of concrete in production shall be tested for potential alkali-aggregate
reaction by casting into prisms of dimensions not less than 200 x 75 x 75mm.
For each concrete mix to be tested one prism shall be made using mix constituents and proportions
identical to those used in the Works and a second prism made from concrete with its alkali content
artificially raised to 6kg/m3 equivalent sodium oxide by the addition of potassium hydroxide. The
prisms shall be fitted with measuring points such that change in length can be measured at intervals
during storage in conditions of 100% R.H and 38C.
Sample storage and measurement shall be as described in clause 11 of draft BS 4 812 Part 123.
In the event that the expansion of the prisms exceeds 0.05%, Project Manager shall immediately be
informed.
As an alternative to the prism test specified above, Contractor may perform mortar-bar tests to ASTM
C227-81.
Core samples from on Site poured concrete shall be obtained at a rate of one for each day of
concreting for the first 4 weeks, thereafter twice weekly provided stable and acceptable results are
achieved. Cores shall be taken randomly from concrete that is at least 28 days and not more than 90
days old. Cores shall be tested for chloride permeability in accordance with ASTM C-1202.94 and
shall meet the requirements of the acceptance testing of the concrete.
Chloride and sulphate content of hardened concrete shall be tested at a rate corresponding to one
test for each week of concreting. The tests shall be performed in accordance with BS812, Part 117
and 118.
Sampling for chloride and sulphate content tests shall be in accordance with the following procedure:
a) The material shall be collected from a dry vertical surface at least 28 days old.
b) The area above the sampling point shall be cleaned with a brush.
c) The material shall be sampled by drilling with a hammer drill with a 20mm drill bit. The drill dust
shall be collected underneath the drill in a polythene bag. One sample shall contain concrete from a
30mm deep hole.
d) Each test shall be the average value of three individual tests collected in the same area of the
concrete member.
The density of silica fume shall be tested weekly if densified micro silica is used.
4.4.18 Formwork
Formwork shall be to BS 5975, BS 8110 and Technical Report 13 of the Concrete Society and the
Institution of Structural Engineers.
The formwork shall be in every way adapted to the structure and to the required finish of the
concrete. It shall, unless otherwise stated, be made either of sound and seasoned timber wrought
and of sufficient thickness, or of treated plywood or other approved material suitably supported.
The formwork shall be fixed in perfect alignment and securely braced so as to be able to withstand
deflection, displacement or movement of any kind, the weight and pressure of the moist concrete and
the weight and movements of men, materials and plant.

90

The supporting struts to formwork shall be adjusted and fixed in position by suitable means and
where necessary placed on timber bearers to prevent them from sinking into the ground or from
causing injury to finished work.
Where it is necessary to use spacers or ties through a wall for supporting the shutter above, such
spacers or ties shall be of approved pattern. The holes left in the concrete shall be neatly pointed
with an approved expanding grout as soon as the formwork is stripped.
Concrete shall not be placed against vertical or inclined blinded earth faces in lieu of formwork.
Before any concrete is placed all formwork shall be carefully examined and cleaned out, and the
inside face shall be treated with an approved mould oil, which must not come into contact with the
reinforcement or be allowed to collect in the bottom of the formwork. Upon every occasion on which
the formwork is stripped it shall be thoroughly cleaned and oiled, if necessary, before re-use.
The responsibility for the removal of any formwork after concreting rests with Contractor.
Formwork shall be removed without causing damage or excessive deflection to the concrete.
Before soffit formwork and props are removed the concrete shall be exposed by removal of the side
formwork in order to ensure that it has sufficiently hardened.
The minimum time which must elapse between pouring concrete and removal of formwork, shall not
be less than that required for the concrete to achieve a minimum compressive strength of 10N/mm2
or twice the stress to which the member will be subject at the time of striking, whichever is the
greater.
The work of removing such formwork or supports shall be carried out under the personal supervision
of a competent Foreman in Contractors employment. Contractor shall be responsible for any injury to
the work and any damage caused by or arising from the moving or striking of formwork or supports.
Formwork and supports shall resist all loads to which they will be subjected without detriment to the
finished concrete.
Where the finished surface of concrete is at a slope greater than 1:50 a top shutter shall be used.
A 50mm x 50mm chamfer shall be formed on all arises exposed in the finished work.
Joints, including those in form linings and between forms and completed work, shall be constructed
to prevent loss of grout or fine materials.
Formwork shall be in good condition, clean and free of concrete remnants. Portions of shutters at the
level of each lift shall be removable to ensure a thorough clearing out of any rubbish.
Release agents shall be applied to formwork surfaces in contact with concrete using the minimum
quantity necessary to obtain a clean release. Care shall be taken to keep the steel reinforcement,
embedded items or hardened concrete free from any such coating material.
Any liquid applied to the formwork surfaces in contact with concrete shall be compatible with any
finish to be applied to the concrete.
No metal part of any fixing device for securing forms shall remain within the concrete cover stated in
Clause 4.4.25 or otherwise shown on the Drawings.

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4.4.19 Embedded Articles

Special care shall be taken to ensure that articles to be embedded are securely fixed in the correct
position and templates and other temporary supports shall be provided as necessary.
Items to be embedded in concrete shall be clean and free from oil or foreign matter that would
weaken the bond of the concrete to these items.
Contractor shall accurately and securely install in the formwork all required inserts, anchors, joint
elements, bolts, sleeves and any other items as required.
4.4.20 Surface Finish
Contractors attention is drawn to the importance of producing concrete work having maximum
possible durability. In this regard Contractor shall pay particular attention to ensuring that the surface
finish to concrete work shall, by appropriate reduction of porosity, adequately reduce the potential
ingress of corrosion inducing elements.
A Controlled Permeability Formwork (CPF) liner shall be installed against the inside face of the
formwork.
The CPF liner shall be used on all in situ and precast reinforced concrete surfaces which in their final
construction shall be either soffits or vertical sides.
The CPF liner shall be shall be used strictly in accordance with the manufacturers written guidelines.
A smooth true surface is required to all exposed surfaces of the concrete work formed using
formwork. Such surfaces shall be perfectly true and free from all imperfections and every endeavour
must be made to obviate the necessity for surface treatment of the concrete after the removal of
moulds. For this purpose the shuttering used for such surfaces shall be wrought and thickened
boards of a properly seasoned timber accurately and closely fixed together or lined, laminated
plywood shuttering or other approved material.
Contractor shall take all means possible during striking of shutters to avoid the necessity for surface
treatment after removal of the shuttering. Directly after the shuttering has been removed, all broken
corners and such parts of the surface where the face has been removed shall be made good with
suitable cement mortar to bring same to the general level of the surrounding surface. All exposed
surfaces shall be thoroughly rubbed down, if necessary with power operated carborundum grinders,
to obtain alignment of the surface. All arises shall be formed with a 50mm chamfer unless otherwise
shown.
All fins and work out of true which cannot be rectified by rubbing down must be tooled off with power
operated machines, together with any surfaces which are in any way defective, and made true by
rubbing in cement mortar with a wood float; the mortar shall be composed of one part of the binder
(cement and silica fume) to two parts of approved fine sharp sand with a maximum water to binder
ratio of 0.40.
The upper trafficked surfaces of the jetty head and approach shall be wood float finished.

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4.4.21 Reinforcement
Mild steel reinforcement shall conform to BS 4449 with a specified characteristic strength of 250
MN/rn2 and high yield reinforcement shall conform to BS 4449 or BS 4461 with a specified
characteristic strength of 460 MN/rn2. Mesh fabric reinforcement shall comply with the requirements
to BS 4483.
Contractor shall supply Project Manager with a certificate stating the process of manufacture and test
sheet signed by the maker of the reinforcement giving the results of mechanical tests applicable to
that type of reinforcement. The chemical analysis of the reinforcement shall also be provided.
Contractor shall obtain the manufacturers certificates for each delivery of reinforcement which he
shall retain as record documents. These certificates shall state that the reinforcement complies with
and has been tested at the frequency specified in the appropriate British Standard Specification. The
chemical analysis reported in the manufacturers certificate shall include the nitrogen content.
If required, test specimens from the reinforcement delivered on Site shall be taken by Contractor and
sent for testing, and no reinforcement shall be used in the Works until such testing has been carried
out.
Reinforcement intended for use in the Plant shall be delivered clean and free from dust, mill scale, oil
and grease and shall be stored on or near the Site in a dry weatherproof building of adequate size.
The reinforcement shall at all times (in store, during cutting and bending and prior to fixing) be kept
on racks or supports of sufficient height to keep the bars clear of the ground and suitably placed to
prevent excessive deflection of the bars.
The reinforcement shall be inspected prior to fixing and all rust, mill scale, oil, grease, paint,
retardants or preservatives and harmful other matter removed by wire brushing or, if necessary, grit
blasting down to bare metal. Placing of concrete shall be carried out as soon as is practicable after
fixing of reinforcement.
Immediately prior to placing concrete all reinforcement shall be washed liberally with water of equal
quality to that used for mixing the concrete to remove windblown dust, salts or other contaminants
Excess water shall be removed from the forms prior to placing the concrete.
4.4.22 Bending of Reinforcement
All reinforcement is to be cut in accordance with BS 4466.
Unless otherwise specified the minimum mandrel diameter to be used in the bending of
reinforcement rods shall be 4 times the diameter of the bar for mild steel reinforcement and 6 times
the diameter of the bar for high yield reinforcement.
Straight portions of reinforcement shall be true and without kinks and bends and shall be kept in the
correct plane.
Reinforcement shall be bent cold by hand or power operated machines producing a gradual and
even bending motion.
Bending shall be completed before the steel is fixed in position. Reinforcement shall not be re-bent.
Bending and subsequent straightening of reinforcing bars projecting from existing concrete shall be
carried out as follows:
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a) The minimum distance from an existing Concrete surface to the beginning of a bend, and the min
inside diameter of the bend shall be:
Bar Size
10 25 mm
32 mm over
32 mm

Min Distance from Surface to

Beginning of Bend
3 Bar Diameters
4
5

Min Inside Diameter

6 Bar Diameters
8
10

b) Bars of 10mm to 16mm diameter inclusive may be bent once without heating; heating is required
for subsequent straightening or bending.
Bars 20mm to 32mm inclusive may be bent once and subsequently straightened heating is
required in all cases.
Bars having a diameter greater than 32mm may be bent only after review by Project Manager;
heating IS required in all cases.
c) Heat shall be applied as uniformly as Possible over a length of bar equal to 10 bar diameters.
The centre of the heated length shall be at the middle of the arc of the completed bend. The bar
temperature shall not exceed 350 Deg. C.
The temperature shall be maintained constant during bending or straightening operations
Temperature measuring crayons or a contact pyrometer shall be used to determine the
temperature. Care shall be taken to prevent quenching of heated bars either by application of
water or by a high volume of air.
d) Straightened bars shall be visually inspected before and after straightening to determine whether
they are cracked or otherwise damaged.
Bars not exceeding 32mm in diameter not Projecting from concrete may be bent without heating
in accordance with this Section providing no local section is re-bent or straightened, and the area
of the bend is inspected for cracks.
Reinforcement shall not be cut using oxy-acetylene or electric equipment.
4.4.23 Welding of Reinforcement
If reinforcement in concrete is used for providing electrical earthing, the relevant reinforcing bars shall
be welded together. All welding shall be carried out by fully trained and experienced workmen
capable of carrying out vertical and overhand as well as down hand welding to the satisfaction of
Project Manager.
The slag shall be such that in making the vertical run the metal lies reasonably flat and free from
overhanging folds.
Suitable provision shall be made to prevent distortion of the reinforcement. Bars to be butt welded
shall be held in a suitable jig sufficiently rigid to prevent movement during welding and cooling.
4.4.24 Placing of Reinforcement
The number, size, form and position of all steel bars, links, stirrups and other members of the
reinforcement shall be in exact accordance with the working drawings. To prevent displacement
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before or during concreting the bars shall be secured one to the other and steel supports shall be
provided between layers of reinforcement. They shall be fixed by means of soft annealed mild steel
wire of 1 .6mm thickness (16 gauge) or proprietary ties. The end of typing wire shall be bent inwards
away from the concrete faces.
All reinforcement shall be washed with clean water, in accordance with the Specification herein,
immediately prior to placing concrete; standing water is to be removed from the formwork.
Spacer blocks shall be used to ensure the correct cover to reinforcement. The distance between
spacers shall be sufficient to ensure that the correct cover is maintained throughout the length of the
reinforcement. Spacers are to be purpose made cement mortar blocks of a thickness corresponding
to the necessary cover. Such blocks, shall not exceed 50mm in length or breadth, and shall be
composed of one part of the binder used (cement and silica) to two parts fine sand with a maximum
water to binder ratio of 0.40. Tying wire shall be embedded into one face of the blocks.
No other material whatsoever shall be used to keep the reinforcement in the shuttering, except that in
certain cases, subject to review by Project Manager, Contractor may use plastic spacer blocks of an
accepted design.
4.4.25 Cover to Reinforcement
Concrete cover to all reinforcement shall in no case be less than 75mm.
4.4.26 Cutting Concrete
No concrete or steel in the reinforced concrete work shall be cut in any way.
4.4.27 Faulty Works
Contractor shall at his own expense remove and reconstruct any portions of the work which give
evidence before or after the removal of the formwork that the concrete was insufficiently compacted
in the formwork or that any bars of the reinforcement have been omitted, incorrectly placed or
displaced, or that the formwork has been incorrectly positioned or displaced, or which give any
evidence of fault, defect or injury from any cause whatsoever which may Prejudicially affect the
strength, durability, water tightness or alignment of the work.
4.4.28 Joints
Contractor shall submit details of the type and location of all Construction joints he wishes to make to
Project Manager for review. In the case of the principal items of concrete work, these proposals will
be regarded as major temporary works and sufficient drawings, etc. covering the whole structure
must be submitted in advance of the start of the work to enable the complete concreting plan to be
accepted.
All construction joints will normally be required to be keyed or toothed and four clear days allowed
between adjacent pours.
The whole surface of concrete which has set shall have been thoroughly roughened and cleaned of
all loose and foreign matter and laitance before further concrete is placed. Wherever practicable as at
horizontal joints, laitance shall be removed whilst the concrete is still green so as to expose the tops
of the larger aggregate particles without undue erosion of the mortar. Where concrete already
deposited has set but not set hard, laitance shall be removed and the surface roughened by wire
brushing and washing, cares being taken not to disturb the underlying mass. Where the concrete first
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poured has set hard, any skin or laitance shall be removed and the surface roughened by hammering
with an approved pattern Power Operated bush hammer followed by wire brushing to remove all
loose particles When carrying out this method of preparation, care shall be taken to avoid breaking
off the arises of the joint face or shattering or loosening exposed particles of coarse aggregate.
Immediately before depositing fresh concrete, the face of the joint shall be thoroughly washed after
which the excess water shall be removed. The fresh concrete shall be forced hard on to set faces of
concrete by means of compacting and vibrating tools.
Free joints to allow for expansion, contraction or shrinkage shall be formed at positions appropriate to
the design of the structure.
Joint filers and sealing compounds shall be of approved manufacture, and used in accordance with
the makers instructions as appropriate to the type of joint, vertical, inclined or horizontal. The
compounds shall be of a type resistant to chemicals that they may be exposed to.
4.4.29 Tolerances
Positive tolerances given in Table 4-4 are the measurements by which the concrete is permitted to
exceed the stated dimensions. Negative tolerances are the measurements by which the concrete can
be short of the stated dimensions. Departure from alignment is the permissible deviation from the
centre line horizontal or vertical face or edge of the concrete.
No reduction shall be permitted in the cover to reinforcement because of a specified negative
tolerance in a concrete section.
Abrupt changes of surface alignment of concrete such as may occur at badly made construction
joints will not be allowed even though the concrete surfaces are within the permissible tolerances.
Table 4-4: Positive Tolerances.
Structure

Tolerance
Concrete placed in Dry (mm)

Concrete in structures against which backfill is placed

+25 -05

Concrete in structures not backfilled

+10 -05

Upper surfaces of concrete

+05 -05

Cross-sectional dimensions of concrete members

+05 -05

Departure from alignment of precast units

+10 -10

Overall plan dimensions of precast units

+10 -10

Position of embedded items

+05 -05

4.4.30 Precast Concrete

The manufacture of precast concrete components shall be in accordance with the recommendations
contained in BS 8110.
The moulds of all precast concrete works shall be to the accurate dimensions and shapes as shown
on the drawings and shall be of sound construction. Moulds shall be thoroughly cleaned before each
casting. Exposed faces shall be trowelled smooth. All edges of the precast units shall be formed with
a 25mm chamfer.

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The standard of workmanship and the quality of materials used in the manufacture of all precast
components shall comply with the relevant clauses of this Specification.
Detailed records of mixes, cubes, curing methods, dates of manufacture, etc., shall be kept and
submitted to Project Manager within 7 days of manufacture.
All precast members shall be marked with a unique reference.
Contractor shall be fully responsible for supplying adequate lifting points and any additional
reinforcement and equipment as necessary to ensure the safe handling, transport and erection of the
precast members.
Holes left in the precast units to facilitate lifting shall be neatly pointed with an approved expanding
grout as soon as the planks are finally positioned. Stacking of precast units shall be properly carried
out after curing in a separate area set aside for that purpose and so arranged that the units may be
removed and used in the order in which they were cast.
Generally the external faces of precast units which will be visible after their inclusion in the Jetty shall
be finished with a fair face equivalent to that described in Clause 4.4.20. The surface of precast units
which will act as bearing surfaces for further precast units shall be given a steel trowel or equal
approved finish. All other internal surfaces of precast units shall have surfaces prepared as
construction joints as described in Clause 4.4.28.
Levelling devices shall only be released or removed with Project Managers approval.
At all stages of construction, Contractor shall adequately protect installed precast concrete units and
other concrete associated therewith to prevent damage to permanently exposed concrete surfaces,
especially arises and decorative feature
Damaged concrete elements shall not be dispatched to Employers Site and elements which Sustain
damage during transportation shall be removed from Employers Site and replaced at Contractors
expense. The same provision shall apply to precast elements damaged prior to or during erection or
thereafter. Only minor repairs will be permitted to be carried out to precast elements at the Site.
4.4.31 Method Statement
Not less than 28 days before the commencement of concrete works Contractor shall provide a full
and detailed method statement for concrete works to Project Manager for review. The Method
Statement shall cover all aspects of concrete works including the following:
a)
b)
c)
d)
e)
f)

Sources of all materials for use in concrete mixes with test certificates and results.
Details of proposed concrete mix designs and program me for trial mix production.
Methods of storage of materials and production, delivery and quality control.
Arrangements for carrying out cube and other tests.
Methods of placing of concrete.
False work, formwork and methods of achieving specified finishes including proposals for trial
panels.
g) Details for production of precast concrete
4.4.32 Bedding of Precast Units
Precast concrete units shall be bedded in cement mortar composed of one part cement to three parts
sand.

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Sand for mortar shall be naturally occurring sand or consist of crushed rock or gravel or a
combination thereof. It shall be clean hard and free from impurities to BS 1199 and 1200 and in
accordance with Clause 4.4.3. Sand shall be well graded from 4.3mm down in accordance with Table
1 of BS 1199 and 1200.
Mortar plasticizer if used shall be subject to acceptance by Project Manager shall comply with BS
4887 and shall be used in the proportions and manner recommended by the manufacturer.
The water content of mortar shall be just sufficient to ensure a dense mortar with adequate
workability, when towelled or worked into place. Mortar that has begun to harden shall not be used in
any part of the Plant.
All materials shall be accurately gauged by gauge boxes and mechanically mixed and used within 30
minutes of first mixing. Re-tempering of mortar will not be permitted. Gauge boxes and mixers shall
be kept clean.
Mortar joints shall be pointed with a neat flush joint as the work proceeds.
Joints shall be protected from the harmful effects of the environment for a minimum of three days
after completion.
Joints between or around precast members which are cast into the Plant shall be carefully sealed
using an approved tape or other means to ensure there is no grout loss during concreting.
4.4.33 Waterproofing
This work shall consist of furnishing and placing approved waterproofing membrane to concrete
surfaces.
Material - Waterproofing Membrane:
Dual Reinforcement-APP Modified Bitumen Waterproofing 5 mm thick Membrane.
Reinforcement is made of heavy non-woven polyester and fibre glass mat.
Thickness
Weight
Reinforcement
Penetration at 25C
Softening Point
Heat Resistance
Cold Pliability
Tensile strength
Ultimate Elongation
Lap Joint Strength
Tear Strength
Resistance to Static Indentation

5mm (ASTM D5147-95)

5.3 kg/m2
Nonwoven spun bonded polyester 220 g/m2 and reinforced fibre
glass mat 60 g/m2 (BS 747/1977)
15-25 dmm (ASTM D5)
155C (ASTM D36)
Non flowing after 2 hours at 145C
No cracking at -10C
Long. 1050 N/5cm (BS747/1977)
Transv. 900 N/5cm (BS747/1977)
Long. 50% (BS747/1977)
Transv. 50% (BS747/1977)
Long. 1100 N/5cm (UEAtc MOAT27:1983)
Transv. 950 N/5cm (UEAtc MOAT27:1983)
Long. 270 N (UEAtc MOAT27:1983)
Transv. 330 N (UEAtc MOAT27:1983)
Not perforated at 25 kg. (Class L4) (BS747/1977)

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Resistance to Water Pressure

Water Vapour Trans.
Resistance to Chemicals

No leakage at 1000mm water head/24 hours (BS747/1977)

0.2 g/m2 day (ASTM E96-90)
Resistance to alcohol, salt solutions, diluted acids and alkalies

Surface Preparation:
1. All concrete surfaces which are to be waterproofed shall be reasonably smooth and free from
projections or holes which might cause puncture of the membrane. The surface shall be dry, so
as to prevent the formation of steam when the hot asphalt or tar is applied, and, immediately
before the application of the waterproofing, the surface shall be thoroughly cleaned of dust and
loose materials.
2. No waterproofing shall be done in wet weather, nor when the temperature is below 2 C, without
special authorisation from the Project Manager.
Inspection, Delivery and Storage
1. All waterproofing materials shall be tested before shipment. Unless otherwise ordered by the
Employer, they shall be tested at the place of manufacture, and, when so tested, a copy of the
test results shall be sent to the Project Manager by the chemist or the inspection bureau which
has been designated to make the tests, and each package shall have affixed to it a label, seal or
other mark of identification, showing that it has been tested and found acceptable, and identifying
the package with the laboratory tests.
2. Factory inspection is preferred, but in lieu thereof, the Project Manager may order that
representative samples, properly identified, be sent to him for test prior to shipment of the
materials. After delivery of the materials, representative check samples shall be taken which shall
determine the acceptability of the materials.
3. All materials shall be delivered to the work in original containers, plainly marked with the
manufacturers brand or label.
4. Waterproofing material shall be stored in a dry, protected place. Rolls of waterproofing
membranes shall not be stored on end.
Installation of Waterproofing Membranes:
Waterproofing membranes shall be installed strictly in accordance with the manufacturers
instructions and shall be laid so that no air is trapped between it and the concrete surface or between
successive layers of sheeting. Unless otherwise specified, joints between sheets shall be lapped with
ends of at least 150mm and side laps of at least 100mm. The joints shall be arranged so, that at no
points are there more than three thicknesses of sheeting and, as far as possible so, that water will
drain away from the exposed edge.
Damage Patching of Waterproofing Membranes:
1. Care shall be taken to prevent injury to the finished membrane by the passage over it of men or
wheelbarrows, or by throwing any material on it.
Any damage which may occur shall be repaired by patching. Patches shall extend at least 0.3m
beyond the outermost damaged portion and the second ply shall extend at least 0.075m beyond
the first.
2. Proprietary waterproofing membranes shall be repaired according to the manufacturers
specifications and as directed by the Project Manager.

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Testing:
Unless otherwise agreed by the Project Manager in writing, at least one Site trial application of the
waterproofing system shall be carried out to determine the suitability of the surface preparation,
method of application and effectiveness of the protective layer. The size of membrane laid shall be
not less than 2.0m wide and 5.0m long.

4.5

Structural Steelwork

4.5.1

Steelwork and Connections - General

Contractor shall allow for deformation due to permanent loads and the process and sequence of
fabrication, erection and construction such that steelwork is completed to within the specified
tolerances.
Compatibility of dimensions and setting-out data of steelwork shall be verified by Contractor before
fabrication of steelwork commences. Fabrication drawings shall be submitted to the Project Manager
for review prior to commencement of fabrication process.
Contractor shall carry out the fabrication and erection design of all connections, supports and details
in accordance with this Specification. All connections shall be designed in accordance with BS 5950,
and for welded connections with BS 5135.
All steel work shall be designed and constructed in accordance with the relevant standards.
As far as possible, steel work shall be designed in tubular sections in order to minimise dust deposits
and to allow easy cleaning.
Shop connections shall be bolted. Welded connections if necessary shall performed in accordance
with the Employers HSE plans, and Employers approval shall be granted prior to any site welding
works. Bolted connections shall have a minimum of two bolts. Minimum bolt diameter shall be 20mm.
Fillet welds shall be of minimum size 6mm. The effective length of fillet welds shall be the full length
less 25mm at each end. Intermittent welds shall not be used.
Butt welds shall be full penetration.
Connection design shall provide adequate access for welding and inspection during fabrication. The
profile of the joint shall enable satisfactory non destructive testing to be carried out.
Drainage holes shall be provided in members and connections where water can collect during and
after erection. Reduced areas and sectional properties shall be computed and members
strengthened as necessary.
4.5.2

Materials

Structural Steel
All structural steel shall be new and comply with BS EN 10025: 1993 and with BS 5950: Part 2,
Section 2.5. All steel shall be Grade S235 JR for all sections other than steel sheet and tubular piles
which shall be grade S355 JO.
The grade of steel shall comply with Table 4 of BS 5950: Part 1 assuming k = 1 and the appropriate
conditions of exposure.
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The strength of the material shall in no way be affected by the work it performs. Every piece of
material shall be free from rust, scale and pitting and perfectly true to thickness throughout and out of
winding.
All bars, plates or rolled sections shall be straightened, freed from twist or otherwise trued before any
other work is done upon them. All steel shall be delivered in good condition undamaged and
generally free from corrosion. Any steel bent or otherwise damaged shall not be used in the Work.
All rolled sections, plates, etc., shall be of the sections and weights specified, subject to the rolling
margins as given in the relevant specification. Where the actual weight is more than 2.5% under the
specified or calculated weight, the materials shall not be used.
Contractor shall take any steps that may be directed, to satisfy Project Manager that the weights of
the various sections are those as shown on the approved drawings.
Stainless Steel
Stainless steel for sliding surfaces shall be Grade 316 S33 complying with BS 1449.
Bolts, Nuts, Washers and Direct Tension Indicators
All bolts shall be grade 8.8 with grade 8.0 nuts to BS 3692 unless noted otherwise on the drawings.
Black bolts shall comply with BS 4190 ISO Metric Black Bolts, Screws, and Nuts. Black bolts shall
have the short thread length.
Flat, circular and square taper washers shall comply with BS 4320 Metal Washers for General
Engineering Purposes.
Precision bolts shall comply with BS 3692 ISO Metric Precision bolts, Screws and Nuts.
Plain washers for black bolts, screws and nuts shall comply with BS 4320.
Holding down bolts shall be in accordance with BS 7419.
Use of Rivets will not be permitted.
Use of High Strength Friction Grip (HSFG) may be used with the structure that subject to vibration.
Welding Consumables
Welding consumables used in metal-arc welding of grades of steel complying with BS EN
10025:1993 shall comply with BS 5135. Welding consumables and the procedures used shall be
such that the mechanical properties of the deposited weld metal shall not be less than the respective
minimum values of the parent metal being welded.
Minimum Thickness
All gusset plates, end plates, stiffeners, flanges and webs of rolled sections and elements of built up
sections shall not be less than 12mm thick. The minimum wall thickness for hot rolled hollow sections
will be 8mm, Corrosion allowance shall be considered.
4.5.3

Documentation and Submissions

Particulars of Steel

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The manufacturers certificates for steel shall be made available for review by Project Manager in
accordance with BS EN 10025.
Fabrication Details
Contractor shall provide the following documents for review by Project Manager:
a)
b)
c)
d)
e)
f)

marking plans and details for holding down bolts and other embedded items.
fabrication drawings in accordance with BS 1192, welding symbols to BS 499.
connection details including calculations.
welding procedure details.
fabrication method statement
details of the Q.A. plan for structural steelwork together with full details of the stage control and
inspection documents.

On all drawings, welding procedure sheets, etc. terms and symbols relating to the welding and
cutting of metals shall be in accordance with BS 499 where applicable.
Where beams are fixed by end cleats to other members, complete contact shall be secured at the
connecting face. The face of the web cleat shall project no more than 3mm beyond the end of the
beam.
Where web cleats are fitted to beams for stability, the length of these cleats shall be not less than 1/3
of the overall beam depths.
Calculations and drawings shall be checked and Signed by Contractor before submission to
Employer.
Two copies of each document or two negatives of each drawing shall be submitted to Project
Manager for review at least four weeks before fabrication of the steelwork starts.
Fabrication shall not be commenced until approval has been received in writing. The drawings shall
be submitted in related batches such that Project Manager has sufficient time and information to give
full consideration to the proposals on the documents and for any changes to be incorporated and
resubmitted for approval. Unless otherwise specified or agreed in writing, a period off at least two
weeks shall be allowed from receipt of the documents by Project Manager to their return.
Two copies of the approved drawings shall be submitted to Project Manager before fabrication of the
steelwork starts.
Method Statement for Erection
A detailed method statement shall be submitted to Project Manager with all relevant supporting
drawings and calculations setting out the sequence of erection, including but not limited to:
a) erection marking plans
b) routes for delivering steelwork and laydown areas
c) sequence and methods of erection of steelwork including calculations and details of temporary
bracing/works to ensure stability
d) method of lifting and handling the components, crane capacity, crane positions and working
radius
e) method of preventing damage to protective coatings on steelwork during handling
f) procedure for aligning, levelling and plumbing steelwork, including temporary supports and
method of making beddings for bearings and
measures to protect existing works.
g) bolted connections tightening sequence.

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The particulars shall be submitted to Project Manager at least 4 weeks before erection of the
steelwork starts.
Welder Certificate
Only welding operators who satisfy the appropriate tests shall be employed on welding. Should an
operator fail in a first test, two further tests shall be undertaken immediately and for the operator to
qualify, must satisfactorily pass both these tests.
Operators, other than those engaged on tube welding, shall be tested by the tests as detailed in BS
EN 288-3, BS 4870, BS 4871 and BS 4872 as appropriate to the corresponding weld position and
using specimens of the parent metal to be employed.
Contractor shall pay all labour, plant and material costs with respect of testing of welding operatives
including independent testing authority costs.
Certificates endorsed by an inspecting authority shall be made available for review by Project
Manager to show that each welder has been approved in accordance with BS 4871 : Part 5. The
extent of approval of the welder shall be appropriate to the categories of welds which he will carry
out. The re-approval of welding operators shall be to BS EN 287-1, except that Project Manager
reserves the right to have any welding operator retested at any time. Contractor shall pay all labour,
plant and material costs with respect to the testing of welding operatives including independent
testing authority costs.
Welder certificates shall be submitted at least 3 weeks before fabrication of the steelwork starts.
Routine testing of all operators will be required every six months.
Project Manager also reserves the right to have any welding operator retested at any time during the
Contract.
4.5.4

Handling, Storage and Transport

Handling and Transport of Steelwork

Steelwork shall not be subject to rough handling, shock loading or dropping from a height.
During handling and transport of coated steelwork, the steelwork shall be separated from wires and
lashings by rubber padding in such a manner that the coatings are not damaged or discoloured. Free
ends shall be stiffened, measures shall be taken to prevent permanent distortion and machined
surfaces and faying surfaces shall be protected.
Steelwork shall not be lifted from the painting bed until the last applied coating is sufficiently dry or
cured for handling. Works coated steelwork shall be loaded and unloaded by hoisting equipment. It
shall not be moved by sliding or skidding.
Projecting ends of steelwork shall be adequately protected during transit. All bolts shall be suitably
packed and labeled. All machined surfaces shall be suitably protected against corrosion before
leaving the works.
Every care shall be taken when lifting painted steelwork to avoid damage to the paintwork. Nylon
ropes and slings shall be used wherever possible. Where chain slings are used padding shall be
inserted between chains and painted steelwork.

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Before, during and after delivery to Site, all steelwork shall be stored clear of the ground or other
supporting surfaces. Steel shall be stacked in an orderly manner so that no dirt or pools of water can
accumulate on the surfaces. Where cover is provided it shall be adequately ventilated.
Softwood timber bearers with a sufficient contact area to prevent crushing shall be provided at all
stages including transportation to Site. Bearers shall be level and sufficient in number to prevent
distortion of members.
Special consideration shall be given to the arrangement of bearers if articulated vehicles which allow
differential movement of bearers are used to transport steelwork. Vertical timber packing shall be
used to separate members when required and to prevent chafing to coatings.
Storage of Steelwork
Steelwork shall be stored off the ground on level supports above rainwater splash zones in well
drained areas in a manner which will not result in damage or deformation to the steelwork or coatings
or in contamination of the steelwork or coatings.
Covered places in which steelwork is stacked shall be ventilated.
Different types and sizes of steelwork shall be stored separately.
Steelwork shall be protected from exposure to conditions or deleterious agents which may affect the
steelwork or coatings. Should any contamination occur, the contaminating agent shall be removed
immediately by swabbing or brushing and the surfaces washed thoroughly with clean water.
All bolts, nuts and washers shall be protected and stored in dry conditions. Adequate precautions
shall also be taken to ensure that threads are not damaged or contaminated with dirt.
Wet paint films, steelwork surfaces which are to be primed or over coated and joint surfaces which
are to be assembled shall be protected from exposure to conditions which may affect the film or
surface.
Steelwork shall be stored in an enclosed workshop and protected from conditions which may affect
the steelwork after the steelwork has been cleaned until the following times:
a) When the second undercoat to painted steelwork has hard dried,
b) When the coating process to galvanized, electroplated or metal sprayed
steelwork has been completed,
c) When the sealer to metal sprayed and sealed steelwork has been completely absorbed, and
d) When the first undercoat to metal sprayed and painted steelwork has hard dried.
4.5.5 Fabrication of Steelwork
Fabrication of Steelwork: General
Fabrication of steelwork shall comply with BS 5950: Part 2, Sections 3 and 4 as appropriate and with
the following clauses.
The ends of all beams shall be square where required and flanges neatly cut away or notched where
necessary. All notches shall be kept as small as possible and shall be rounded in the inner corner.

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Butt ends of compression members shall, except where bolts carry compressive loads, have their
abutting faces machined after fabrication so that they are square to the member axes and in tight
bearing contact when erected.
The edges of all rolled sections shall be true and fair and they shall hold full to profile throughout.
The edges of all plates, gussets, rolled shapes and similar parts where sheared, shall be perfectly
straight, fair and free from burrs throughout.
All holes shall be drilled. No hole shall have its centre nearer to the edge or end of any piece than a
distance equal to the requirements of BS 5950. Flame is not permitted to use for making holes.
All bolts shall be of the exact diameter figured and the holes for these must not exceed the diameter
figured by more than 2mm.
The accuracy of all holes shall be such that when the work is assembled a steel gauge of 2mm less
diameter than the hole can be passed through irrespective of the number of thicknesses. No drifting
enlargement or elongation of any of the holes will be permitted.
All burrs shall be removed from the edges of drilled or reamed holes.
The nuts shall be a good fit on the bolts so that they can only just be turned by hand, and one clear
thread is to show through the nut after tightening is completed. All bolts shall have washers under the
nuts and shall be so screwed that the threaded portion does not bear upon the thicknesses
connected. Min. 2 threads shall be beyond the nut after bolts tightening
Where bolt heads or nuts bear upon beveled surfaces, they shall be provided with square taper
washers in accordance with BS 4320 to afford a seating square with the axis of the bolt. The pitch of
bolts shall not exceed that as specified in BS 5950.
Ends of columns at intermediate splices and where they bear on bases or caps shall be machined
after fabrication so that they are in tight bearing contact, i.e. to within 0.5 degrees.
All machining operations shall be performed after welding.
Where stiffeners are required to be fitted they shall be ground or machined and the surfaces on
which the stiffeners bear shall be cleaned of all loose mill scale or any deleterious matter to allow
tight bearing contact.
Base plates and caps shall be accurately machined over the steel bearing surfaces and shall be in
tight bearing contact over the whole area of the machined end of the stanchion or column. The
underside of base plates bearing on concrete need not be machined. Holes of not less than 40mm
diameter shall be provided in all base plates to facilitate grouting.
All members of mass exceeding 5 tons shall have their mass marked by cold stamping and painting,
markings will be inspected and where necessary repaired or replaced upon delivery to Site and at
regular intervals before erection.
Hollow section fabricated structures that are to be galvanized shall be provided with vent holes to
allow the expanding air to escape and to enable surplus zinc to drain from the sections when the
structures are withdrawn from the bath. These shall be sealed after the galvanizing process has been
completed unless otherwise instructed.

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Before leaving Contractors factory, all steelwork shall be stamped or suitably marked with paint
stencils in conformity with erection diagrams furnished by Contractor. Erection tags shall also be
provided and all members of mass exceeding 5 tons shall have the weight marked on the tag. Upon
arrival at Employers Site stencils and tags shall be inspected, repaired and replaced as necessary
and further inspected and made good at regular intervals before erection.
Plates, rolled and hollow sections to be cut to exact lengths, shall be accurately cold sawn or
machined. Hot sawing or machine gas cutting will be permitted for the ends of beams and other parts
not bearing in compression.
Tube ends, other than those cold sawn, shall be hand flame cut and dressed to fit accurately the
profile of the tube, etc. to which they are jointed.
Burrs left by the cold or hot saw shall be removed and gas cuts shall be dressed free from oxidised
metal to a neat and workmanlike finish.
Ends of tubes welded to plates, etc. shall be accurately formed so that the tube butts over its entire
area.
Fitted stiffening tubes, angles or plates to brackets, flanges to joints, tubes, etc., shall be accurately
shaped to fit the profile of the member stiffened.
Frames of tube or box connections shall be jig assembled and the ends of all tubes shall be sawn
and not flame cut, except for irregular profiles.
When sealing the ends of tubes, this must be carried out under the correct climatic conditions, to
avoid the trapping of excessive moisture.
Surfaces of steel in permanent contact are to be thoroughly cleaned and painted with one coat of
lead-based primer paint of a high build type where appropriate and brought together whilst still wet.
The only exception to this is friction grip bolt joints. These are NOT to be painted.
All structural components shall be clearly marked at their ends by punched figures, at least 15 mm
high.
Welding, Heating and Cutting
The layout and procedure shall be approved by the Project Manager and the sequence of all
operations shall be arranged to the Project Manager's approval, so as to minimize any distortion and
induced stresses.
As much as possible and practical, welding shall be done at the manufacturer's workshop and not on
the Site. Site welding as well as flame cutting needs the Project Manager's written approval.
Welding electrodes shall be appropriate for the used base metals and the chosen welding method,
and shall be able to satisfy tests.
The Contractor must always be able to produce documentation indicating that the electrodes used
comply with the Standards for the base metal on which they are applied, as regards resistance and
quality class.
The Contractor is to satisfy the Project Manager that the welding operators are suitable for the work
upon which they will be employed. For this purpose details of qualifications obtained by the operators
under any appropriate standard laying down qualification tests shall be submitted as evidence of their
efficiency and suitability. The names of the operators qualified in accordance with the foregoing

106

requirements, together with particulars of any test passed by each of them, shall be recorded and
made available to the Project Manager as and when required.
The Contractor shall provide each welding operator with adequate details of the approved welding
procedure to be adopted as necessary; such information may be given by means of charts or
drawings as found convenient. The welding procedure thus laid down shall be strictly maintained and
no variations will be permitted without approval of the Project Manager.
Welding shall be carried out by welders who possess a valid welding certificate for the appropriate
category of welding. A welder shall cease to carry out welding if any of the circumstances stated in
BS 4570, Clause 25.1, BS EN 287-1 or BS 4872 Part 1, Clause 6 as appropriate occurs.
Pre-setting, pre-bending, skip welding, back-step techniques and other measures shall be taken as
necessary to counteract shrinkage or distortion due to welding, gouging, thermal cutting or heat
treatment. Preheating shall comply in all respects with the requirements of BS 5135. No welding of
mild steel shall take place where the ambient or plate temperature is OEC or below. Where the
combined plate thickness is equal to 50mm or over and ambient or plate temperature is under 1OEC,
welding shall only be allowed where special precautions are taken to prevent too rapid a rate of
cooling and loss of heat.
Butt welds shall be complete penetration butt welds made between fusion faces, and the ends of the
welds shall have full throat thickness. On rolled sections, this shall be achieved by the use of
extension pieces, cross runs or other suitable means.
Butt welds in each component part shall be completed before the final assembly of built-up
assemblies.
Temporary welded attachments shall not be used.
Intermittent welds will not be permitted in view of the risk of moisture or salt ingress. Coated surfaces
to which welded attachments are to be made shall be cleaned to bare metal and all contaminants
removed.
Welding of Structural Hollow Sections
Welding of hollow sections to BS EN 10210-2 shall comply with BS 5135.
The end of one hollow section shall be accurately shaped to fit the other. This shall be done by using
properly prepared templates or equal approved methods. The correct fusion bevel shall then be cut.
Hollow section steelwork shall be assembled in jigs or on suitable surface plates on which shall be
drawn out the whole section of the structure. Members shall be aligned e.g. by the use of scribing
blocks, lines and squares and shall be held temporarily in position by the use of wedges and clamps.
When correctly aligned the structure shall be tack welded to BS 5135.
Where bolted flanges for connections, etc., are welded to hollow section structures, steps shall be
taken, either by pre- or post-heat treatment or by equal approved methods, to ensure the flanges are
rendered flat at the completion of the welding.
Where bolted or flanges for connections etc are welded to tubular structures, steps shall be taken,
either by pre or post heat treatment or by other suitable method to ensure that the flanges are
rendered flat at the completion of the welding.
Hollow section steelwork shall be continuously welded and the interior of all hollow sections shall be
kept clean, dry and free from loose scale and shall be completely sealed.

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In addition to the testing specified in Section 8.8 section of this Specification, any welding operator
engaged in welding tubular steelwork shall prove his proficiency by welding a specimen junction
where tubes intersect at an angle. The junction shall represent the most acute tube intersection on
which the welder will be engaged and the tubes used shall be representative with regard to material,
diameter and thickness.
Length of Bolts
The length of bolts complying with BS 3692, BS 4190 and BS 4933 shall be such that the end of the
bolt will project above the nut by at least two threads, but by no more than one nominal bolt diameter,
after tightening.
Length of Threads
The length of threads on bolts shall be determined in accordance with BS 3692, BS 4190, BS 4395:
Part 1 or BS 4933 as appropriate. Where additional locknuts or other nuts are specified, the thread
length shall be increased by one nominal bolt diameter for each additional nut.
Use of Nuts
Nuts shall not be used with bolts or screws which comply with a different standard.
Use of Washers
Washers shall be provided for bolts complying with BS 3692, BS 4190 and BS 4933 under the nut.
Washers shall be provided under both the nuts and heads of bolts in oversized and slotted holes.
Where bolt heads or nuts bear on beveled surfaces they shall be provided with square taper washers
conforming to BS 4320 affording a seating square with the axis of the bolt.
Tightening of Bolts
Bolts shall be tightened in such a manner that the contact surfaces of permanent bolted joints are
drawn into close contact. All contact surfaces which are to be bolted together shall have all bloom
rust and mill scale completely removed.
Defects in Steelwork
Defective components for steelwork shall not be used in the permanent work.
Contact Surfaces
All contact surfaces which are to be bolted together shall have all bloom, rust and mill scale
completely removed and shall be treated in accordance with Section 9 of this Specification.
After such connections have been completed the surface coating shall be made good by thoroughly
cleaning by mechanical wire brushing as necessary and applying two coats of a cold galvanizing
compound, strictly in accordance with the manufacturers instructions, to all surfaces from which the
galvanizing has been removed or damaged, and which remain exposed.
Surfaces of connections which have been treated in accordance with the Specification require no
further treatment.
The provisions of this clause apply to surfaces brought together at Employers Site.
Trial Assembly
Sufficient trial assemblies shall be carried out in Contractors works to prove the accuracy of the
workmanship.

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Where parts which have to fit together are manufactured in different works or for any reason cannot
be matched before dispatch to the Site, Contractor shall make adequate provision to ensure a correct
fit.
Approval of Fabricated Steelwork
Fabricated steelwork shall not be:
a) Covered with protective coatings, concrete or other material,
b) Erected, or
c) Dispatched from the plate of fabrication if fabricated off Employers Site
Until the steelwork, including any repaired areas, complies with the specified test and inspection
requirements.
Erection of structural steelwork shall be generally in accordance with BS 5950:
Part 2. Contractor shall provide all necessary cranes, tackle and equipment for unloading, storage
and erection of the steelwork.
Steelwork shall be secured in position by temporary supports and fastenings until sufficient
permanent connections are complete to withstand the loadings liable to be encountered during
erection. The temporary supports and fastenings shall be capable of withstanding loadings which
may be encountered during erection and shall not damage the steelwork or the protective coatings.
Bolted connections shall be aligned using drifts and shall be temporarily fastened using service bolts.
1. Contractor shall be responsible for the stability and safety of the structures, cranes and plant
during all stages of the work and shall provide all necessary temporary bracing, etc. to ensure
such stability and safety under all erection conditions.
4.5.6

Erection of Structural Steelwork

Alignment of Steelwork
Contractor shall be responsible for erecting the steelwork in such a manner that the alignment and
levels of the steelwork comply with the tolerances stated in this Specification; allowance shall be
made for the effects of temperature on steelwork.
Contractor shall, prior to the commencement of any stage of erection, satisfy himself that holding
down bolts are correctly positioned and set, both in line and level, to enable erection to proceed
without hindrance or delay.
Measures shall be taken to ensure that steelwork will remain stable before temporary supports and
fastenings are slackened or removed for lining, leveling, plumbing or other purposes. The temporary
supports and fastenings shall be re-tightened or replaced as soon as the adjustments are complete
and at the end of each continuous period of working.
Foundation Bolts for Steelwork
All anchor bolts, nuts and washers shall be hot dip galvanized.
Anchor bolts shall be of quality 8.8.
Determination of the types, numbers and dimensions of the anchor bolts and nuts shall be done
within one month after the Date of Commencement.

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The anchor bolts, nuts, washers and steel templates shall be supplied within three months after the
Commencement Date.
All necessary anchorage materials which are to be built into the foundations shall be supplied to Site
in time to be cast into the concrete works. Box Outs for subsequent inclusion of holding down bolts
will not be allowed.
Foundation bolts for steelwork shall be held firmly in the set position during fixing. Measures shall be
taken to ensure that the full movement tolerances are achieved and the bolts are not displaced
during concreting. Bolts and nuts, including the threads, shall be protected against damage,
corrosion and contamination.
Bolt pockets shall be kept dry and clean. Tubes which are cast in concrete for grouting bolt pockets
shall be securely fixed and sealed to prevent ingress of grout during concreting.
Bolts in bolt pockets shall be installed in such a manner that the bolt can be moved inside the pocket
as designed without hindrance.
Slinging and Hoisting
The slinging and hoisting shall be under the control of fully experienced skilled personnel.
Bundles of materials shall be secured by proper lashings so that the pieces will not separate, splay,
or slip out when raised. If required separate lifts shall be made.
Leveling of Column Slab Bases
Slab bases shall be leveled by means of suitable bolts and bearing plates, one on each corner of the
base slab.
Plumbing of Stanchions
Plumbing of stanchions shall be carried out by means of a theodolite and facilities for the checking of
stanchions shall be made available to Project Manager when required.
Staging
Staging to approved safety standards of adequate strength and area shall be provided by Contractor
to facilitate the work of erection and inspection.
Damage
Damage to any part of the structure either before or during erection shall be immediately brought to
the notice of Project Manager. No damaged part may be assembled in the structure without prior
reference to Project Manager.
4.5.7

Tolerances

Tolerances on Fabrication of Steelwork

All measurements shall be made with a steel tape related to a standard tape which has been certified
to be correct at 20C. The tape and steel to be measured shall be at the same temperature and
proper precautions shall be taken to tension the tape correctly.
Fabrication tolerances for steelwork shall comply with BS 5950: Part 2, sub-section 7.2 and the
following:
Length of any member 9.0m long and under: +0mm/-2mm

110

Length of any member greater than 9.0m long: +0mm/-3mm

Deviation from straightness: Length of the finished member/1000 or 10mm whichever is the lesser
value.
Deviation from squareness of fixed base plates to axis of column: 1:500.
Deviation from squareness of machined ends to axes of columns: 0.5mm.
Deviation from squareness of machined faces of end plates to axes of beam: 0.5mm.
Deviation of centre line of web from centre line of flanges in built-up members at web/flange junction:
Depth/200 or 10mm
Tilt of flanges of built-up members (measured as the offset from square of the underside of the toe of
the flange from its intersection with the centre line of the web):
For flanges up to 450mm width: 2mm
For flanges over 450mm width: 3mm
Where a tight bearing contact is required, the abutting parts shall be deemed to be in contact when
the following requirements have been fulfilled:
a) Over at least 60% of the bearing surfaces the gap between the surfaces shall not exceed
0.25mm.
b) Over the remainder, the gap shall not exceed 0.5mm.
The above acceptable tolerances shall be uniformly distributed over the whole of the abutting parts.
Notwithstanding the above permitted fabrication tolerances, the structure shall be erected to comply
with the specified erection tolerances.
Tolerances: Foundation Bolts
The position of cast-in foundation bolts at the top of base plates shall be within 3mm of the specified
position. The position of foundation bolts in bolt pockets at the top of base plates shall be within 5mm
of the specified position. The line of bolts shall not be tilted from the specified line by more than 1 in
40.
Tolerances: Erection of Steelwork
Steelwork shall be erected to within the tolerances stated below after lining, leveling, plumbing and
making the permanent connections. It should be noted that limits given are absolute and should not
be considered as cumulative.
Linear Dimensions
Permissible Deviation per l0m of length

6mm

Maximum Deviation in 25m or over (Except as under)

15mm

Plumb
Permissible Deviation per 1 5m of Height

5mm

Maximum Deviation in 45m or over

15mm

111

Levels
Alignment of Columns

3mm

Mean Level of Bases

3mm

Difference in level between bases of adjacent columns in line

3mm

4.5.8

Testing and Inspection of Steelwork

Tests at Fabricators Works

Tests shall be carried out on structural steel in accordance with BS 5400: Part 6, Clauses 5.2.1, 5.2.2
and 5.3. Tests shall be carried out by the Fabricator on samples selected by the Fabricator.
Samples to be Tested
Contractor shall give full access to Project Manager at all times to the place of fabrication and
storage for the purpose of inspection and testing.
Testing of Steelwork
All materials provided under this Contract shall be tested in accordance with the relevant British
Standard (BS).
Tests are to be carried out as detailed in the following clauses. Contractor shall give Project Manager
not less than 7 days notice of tests being carried out.
Mill test certificates shall be provided by Contractor to Project Manager upon request.
Reports of Tests on Steelwork
Contractor shall keep records of tests on steelwork. The records shall contain the following details as
a minimum:a)
b)
c)
d)

Procedure tested and exact location in the steelwork,

Results of tests compared to the required values, with any non-complying results highlighted,
Any tearing, cracking or other defects, and
Conclusion as to the overall acceptability of the parts of steelwork examined by the approved
testing consultant.
e) PQR
Reports shall be certified by Contractors authorized representative or by the approved testing
consultant who carried out the tests.
Non-compliance: Steelwork
If the result of any test on steelwork does not comply with the specified requirements for the test, the
test shall be carried out on additional samples from the batch. The number of additional tests shall be
twice the number of original tests.
The batch shall be considered as not complying with the specified requirements for the test if the
result of any additional test does not comply with the specified requirements for the test.
Samples: Steel
Samples of steel shall be provided from each batch of steel within 3 days after delivery of the batch
to the fabricators works or to Employers Site. The rate of sampling shall be as stated in the

112

Contract, and the position and direction of the samples shall be in accordance with BS 7668, BS EN
10113-1, BS EN 10155, BS EN 10210-1.
When tests are to be made away from the steelworks Contractor shall provide sample pieces 500mm
x 75mm for plates, or as near that as practicable and samples 500mm long of full section for angles,
joists, channels, flats, rods, etc.
The sample pieces will be selected and stamped by Contractor and as soon as selected shall be
dispatched to the Testing Works where test pieces will be made and tested and Test Certificates
obtained. These Test Certificates shall be made available to Project Manager if required. Any
material that does not meet the specified requirements shall be rejected.
In the event of any material not meeting the specified requirements being found incorporated in the
Plant Contractor shall remove the substandard material and replace it with material meeting the
Specification at his own expense.
Testing: Steel
The tensile test and the impact test shall be carried out on each sample of steel. The method of
testing shall be in accordance with BS 7668, BS EN 10113-1, BS EN 10155, BS EN 10210-1.
Quality grading of structural steel shall be carried out on steel which has not been tested for quality
grades by the manufacturer. Quality grading shall be carried out in accordance with BS 5400: Part 6,
Clause 3.5.4 or BS 5950: Part 2, Clause 2.5.6 as appropriate.
Testing: Welds General
The acceptance of the welded work shall depend upon the correct dimensions and alignment and
absence of distortion in the structure, upon satisfactory results, from the examination and testing of
the joints and the test specimens, the soundness of the welds and evidence of adequate training and
upon general good workmanship.
Examination and testing of welds shall be carried out after any post-weld heat treatment and before
the application of corrosion protective coatings. Deburring, dressing, grinding, and machining shall be
carried out after the visual inspection for cracks, surface pores and joint fit-up and before other
inspections and tests are carried out.
Ultrasonic testing
Ultrasonic testing for laminations and/or inclusions shall be carried out before
fabrication. Except where specified otherwise the standard of acceptance shall be
Grade LC2E in accordance with British Standard BS 5996: 1980 and Methods for
Ultrasonic Testing and Specifying Quality Grades of Ferritic Steel Plate (i.e. BS
5996: Grade LC2E).
When plates are to be cut to size away from the mills, the relevant tests are to be carried out when
the material has been reduced to its approximate size prior to fabrication and assembly.
The extent of ultrasonic tests shall be as follows:
(a) Plate Materials to BS EN 10025 Grade S235 and S235J0
Initially all main material for welded plate girders and welded box columns shall be examined in
accordance with BS 5996: 1980 and in accordance with the requirements of BS 5950. The extent
of testing may be varied and will depend on the results obtained. All main plate materials for
welded lattice girders shall be examined.
(b) Plate Material to BS EN 10025 Grade S355JR and S355J0

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All plate material Grades S355JR and S355J0 shall be tested in accordance with BS 5996: 1980
and the requirements of BS 5950.
(c) Welded Lattice Girders
All members fabricated in the form or plate or box girders shall be tested in accordance with (b)
or (c) above as may be appropriate.
(d) Runway Beams
The flanges of runway beams shall be tested for freedom from laminar defects and inclusion
clusters such as would preclude fitness for their purpose.
(e) Plate Material for Beam or Stanchion End Plates (all grades)
All plates to be used as end plates for beams or stanchions, in particular where moment
connections and subsequent heavy concentrations of weld occur, shall be examined and be in
accordance with BS 5996 Quality Grade L3
Non Destructive Testing of Welding (NDT)
Contractor shall satisfy himself as to the quality of welds by visual, magnetic particles inspection
(MPI), ultrasonic or radiographic inspection as appropriate.
Welds which are to be examined by magnetic particles inspection shall be dressed in order to ensure
a meaningful examination. Dye penetrate testing shall not be used for the examination of ferrite
welding.
All NDT shall be carried out by qualified operators.
Extent of Non-destructive Testing
Butt Welds
The extent of non-destructive testing of butt welds shall be as follows:
i) All welds shall be subject to 100% visual inspection and 10% magnetic particle inspection.
ii) In addition to the testing specified below Project Manager may indicate any other areas which
require further destructive or non-destructive testing.
iii) Butt welds in bottom (tension) booms of trusses shall have 100% ultrasonic or radiographic
inspection.
iv) Butt welds in top (compression) booms of trusses shall have 20% ultrasonic or radiographic
inspection.
v) All column web and flange plates which are composed of grade 43A steel will be deemed to be in
compression and radiographic or ultrasonic examination shall be carried out on the butt joints for
10% of the butt length.
vi) Column plates which are composed of steel other than grade 43A steel will be deemed to be in
tension and radiographic or ultrasonic examination shall be carried out on the butt joints for 100%
of the butt length.
vii) Tee butt welds connecting diaphragms to column plates, diaphragms to large plates, table plates
to stalk plates or fabricated tee sections and end plates to girder flanges forming beam end
moment connections shall have 100% ultrasonic inspection for laminations, Lamellar tearing and
weld defects. In the case of fabricated tee sections the inspection shall be car9ied out prior to
bolting or welding to main members.
Fillet Welds
Magnetic particle inspection (MPI) shall be carried out on 5% of all fillet welds.
Independent Testing
Project Manager may also require independent radiographic or ultrasonic or other non-destructive
testing examinations of butt and fillet welds to be undertaken.

114

The frequency of independent examinations will depend on the results obtained.

Testing: Repairs
Defects which have been repaired and adjoining areas which in the opinion of
Project Manager may have been affected by the repair shall be retested as instructed by
Project Manager
4.5.9

Miscellaneous steelworks

Open type flooring

Grating shall be fabricated of flat steel bars 30 * 5 mm with surrounding supporting flat bars. All bars
shall be welded together and hot-dipped galvanized after fabrication. Dimensions shall be in
accordance with actual live load. Minimum life load shall be 5.0 KN.m2. Fixing shall be done by
means of fixing clips.
Solid type flooring
All solid type flooring, including covers for passage of conveyors, ducts, etc., shall be fabricated of
chequered plates supported by steel beams. Dimensions shall be in accordance with actual live load.
Minimum life load shall be 5.0 KN/m2.
All solid type flooring shall be hot dip galvanized.
Stairways and ladders
Stairways shall be of the square grid type, equipped with kick rims and hand railing
Stair risers and supports shall be fabricated from rolled steel sections, adequately braced to form
rigid steel structures.
Ladders shall be of a welded steel construction, 450 mm wide and 25 mm single ring type with safety
loop and landings at intervals not exceeding 6 m.
Stairs and ladders shall have corrosion protection in accordance with the corrosion protection
specification.
Fire escape ladders shall be hot dip galvanized, in accordance with the in accordance with the
corrosion protection specification.
Balustrade, hand- and knee railing
All balustrades and hand railing shall be of a welded steel construction with bolted connections to the
foundations or the stair risers.
All hand railing shall include kick rims and knee railing.
Balustrade and hand railing shall be made of steel pipes with a minimum diameter of 42 mm or as
specified on the relevant drawings.
Knee railing and vertical supports shall be made of steel pipes with a minimum diameter of 33 mm.
All balustrades and hand railing shall have corrosion protection in accordance with the corrosion
protection specification.

115

4.6

Corrosion Protection

4.6.1

Structural Steelwork

The Contractor shall provide protective treatment to all metallic items, other than stainless steel
equipment, fittings and fixings. All workmanship and materials shall be in accordance with BS EN
ISO 12944 standards. Stainless steel bolts, screws, studs, nuts and washers shall be grade A4-80
according to BS EN ISO 3506. Stainless steel shall be grade 316 S33 in accordance with BS 970 :
Part 1 (EN Steel Number 1.4436) for forged steel and BS EN 10088-1 and BS EN 10088-3 for flat
rolled and long rolled forms, except for use in specialist applications where the appropriate grade
shall be used.
Contact between dissimilar metals such as stainless steel and carbon steel, galvanised steel
members and aluminium surfaces or between galvanised and un-galvanised steel members, shall be
prevented by means of insulating washers and grommets, of neoprene or equal and approved.
Unless otherwise agreed with Project Manager, members which are to be metal sprayed or
galvanized at Contractors works shall have all marks hard stamped in addition to being painted. The
hard stamping, to such a depth that it will not be obliterated by the coating, shall be done at one end
of the member and shall be ringed with a paint mark. Where steel is given part of the surface
protection before arrival on Site, the marks must be painted with a white paint that can easily be
covered with the final Site anti-corrosion treatment.
The following protective treatment schedule indicates the minimum requirements for protective
treatment of steelwork and metalwork. The Contractor shall ensure that protective treatments
provided have a minimum life to first major maintenance of 15 years under exposure C5-M and Im2
as appropriate in accordance with BS EN ISO 12944 (see table below for specific requirements),
unless stated otherwise. The acceptable level of coating failure at first major maintenance shall be
level Ri4 as defined by ISO 4628 / 3 and its included references. Any reference to galvanising shall
be defined as galvanising in accordance with BS EN 1461.
Table 4-5: Schedule of protective treatment to steelwork and metalwork
Item

st

Time to 1 major
maintenance

Protective Treatment

Jetty structures (For

general steelwork only.
For corrosion
protection of marine
piles, refer Chapter 2)

10 yrs

Galvanise plus paint, system A7.13

(2 pack polyurethane gloss finish)

Fender Panel
Steelwork

10 yrs

Hot dip Galvanise plus paint system

A7.13 (Polyurethane Paint system
under warranty)

10 yrs

Hot dip Galvanise, BS EN 1461

10 yrs

Stainless Steel

Fendr Chains and

Chain Anchorages
Fender Panel Cast-in
Sockets

BS EN 12944
Table A.7

Mooring Bollards

10 yrs

Ladders, walkways

10 yrs

Paint system A5M.07 with gloss

finish black
Hot dip Galvanise plus paint system
A8.03 (2 pack epoxy paint)
Galvanise, BS EN 1461

116

Table A.7

Table A.5
Table A.8

st

Time to 1 major
maintenance

Item
Pipework
brackets/hangers

10 yrs

Structural Steelwork
(Marine side)

10 yrs

Structural Steelwork
(Land side)
Vehicle Barriers and
handrails

Protective Treatment
Hot dip Galvanise plus paint system
A8.03 (2 pack polyurethane gloss
finish)
Hot dip Galvanise plus paint system
A7.13 (2 pack polyurethane gloss
finish)

10 yrs

Paint system A5M.02

10 yrs

Hot dip Galvanise, BS EN 1461

Manhole Covers &

Frames

10 yrs

Paint system A5M.02 (Two pack

epoxy - min dft 320 m). (not mating
faces)

Step Irons to Storm

water Manholes and
draw pits

10 yrs

Hot dip Galvanise plus paint system

A7.13 (2 pack epoxy system)

4.6.2

BS EN 12944
Table A.8

Table A.7

Table A.5

Table A.5

Table A.7

Schedule of Colour Finishes

The colour shall be to the approval of the Employer.

4.6.3

Protective Treatments

For all painted items, the Contractor shall submit to the Project Manager for approval a Paint System
Sheet stating full details of each paint system proposed indicating the following information:
Surface preparation;
System reference together with manufacturer's brand name and product reference;
Duplicate copies of the manufacturers data sheets including temperature, humidity and other
conditions at the workshop or on Employers Site under which the paint is to be applied;
Dry film thickness (DFT);
Colour;
Time to repaint.
The Contractor shall submit with this information, copies of a Paint Data Sheet, provided by the paint
manufacturer, for each of the paints he proposes to use. The requirements of the Paint System
Sheets shall only be adopted for the Works following the Project Managers approval.
The Contractor shall ensure that the paint manufacturers data sheets cover the conditions at Works
or at Site, including temperature and humidity, under which the paints are to be applied.
4.6.4

Painting

All paints shall be from an approved manufacturer. The complete paint system shall be obtained from
one supplier only. The fullest possible use shall be made of the Technical Services of the
manufacturer concerned.

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4.6.5

Safety

All due care shall be taken by the Contractor in the handling of materials and equipment for painting,
and the correct disposal of waste materials to prevent danger from fire, explosion or toxic fumes
being experienced by any person on the Site. A high standard of personal hygiene shall be practised
by all operatives including the use of protective clothing, gloves, masks and barrier creams to prevent
the risks of dermatitis or other complaints from occurring.
4.6.6

Storage of Paint

Paints shall be delivered in sealed containers of not more than 5 Liters. Each container shall be
marked on the side to show the following:

Manufacturers name;
Manufacturers paint reference number;
Intended purpose, type of pigment and binder;
Batch number, date of manufacture, expiry date and pot life;
Colour, gloss, drying time and flash point;
Instructions for storage.

No materials of any description shall be added to the contents of the containers except in strict
accordance with the manufacturers instructions and paints of different types or of different
manufacturers shall not be mixed together.
Each batch shall be dated on delivery and shall be used strictly in order of delivery. Paint not used
within the shelf life period specified on the containers or within 18 months of the date of manufacture
- whichever is the lesser, shall be replaced.
Paint shall be stored in sealed containers in a locked store where it will not be exposed to extremes
of temperature. The temperature of the store shall be kept between 4C and 27C unless the storage
conditions recommended by the manufacturer allow temperatures outside this range. Any special
storage conditions recommended by the manufacturer shall be observed.
4.6.7

Sampling and Testing

Samples for testing may be taken both from the sealed containers and from the workmens kettles on
the works. Any work coated with materials, the samples from which prove unsatisfactory, shall be
cleaned off and re-executed, and work on which the paint is found to be unduly thin shall be
repainted, all to the satisfaction of the Project Manager and at the Contractors own expense.
A sample of blast cleaned steel plate may be required by Project Manager for review. The sample
shall be 150mm x 150mm x 6mm and shall be enclosed in a sealed, colourless, transparent
wrapping.
The grade of steel and the method of blasting shall be representative of those which will be used in
the permanent work.
A sample of painted tin plate for each painting system may be required by Project Manager. Each
plate shall be 150 mm x 75mm x 1mm and shall have smooth edges and 10mm corner radii. The
plates shall be brush cleaned and painted on one face with the painting system in such a manner that
each coat is stepped back from the underlying coat in equal strips.
Details of the method of plugging vent holes required for hot dip galvanizing of hollow sections shall
be submitted to Project Manager for review.
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4.6.8

Paint Trial

A painting trial shall be carried out for each painting system to demonstrate that the proposed
materials and methods of application will produce a painted surface which complies with the specified
requirements.
Paint trials shall be carried out at the place where painting to the permanent work will be carried out
and using the employees and equipment which will be used to carry out painting to the permanent
work.
Painting trials shall be carried out on blast cleaned steel.
If the painted surface produced in a painting trial does not comply with the specified requirements for
the paintwork, the cause of failure shall be established by Contractor and particulars of proposed
changes shall be submitted to Project Manager for review. Proposed changes to the paint
formulation, other than an adjustment in the amount of thinner, shall be carried out at the paint
manufacturers works before the final painting trial and before the first batch of paint is delivered.
Painting shall not commence until the painted surface produced in painting trials complies with the
specified requirements for paintwork.
Unless previously agreed with Employer, the materials and methods of application used in a painting
trial which complies with the specified requirements shall not be changed.
4.6.9

Prepared Surfaces

The Contractor shall advise the Project Manager in good time of his blasting and painting operations
to enable inspection and testing to be carried out. The Contractor shall carefully inspect and prepare
all surfaces to the approval of the Project Manager.
Surfaces of steelwork or metalwork that have been previously primed are to be examined to ensure
that they have been properly prepared before priming and that the primer is of a suitable type, firmly
adhering and in good condition. If the condition of the surfaces or of the primer is unsatisfactory and if
the surfaces of any small items remain un-primed, then the surfaces are to be thoroughly cleaned by
mechanical chipping or wire brushing to remove all defective primer and all rust and loose scale back
to the bare metal. If necessary, the primer shall be stripped off completely. The surfaces are then to
be primed immediately with the appropriate primer.
If the condition of the surfaces and the primer is satisfactory then the surfaces are to be thoroughly
cleaned to remove all dirt, grease, etc. Any metal exposed as a result of damage to the primer is to
be wire brushed and scraped to remove rust and primed immediately with the appropriate primer.
Surfaces that have been galvanized are to be thoroughly cleaned to remove all dirt, grease, and all
salts remaining from the galvanising process neutralised. The surface shall then receive an etched
primer compatible with the specified paint system.
After preparation, the required protective treatment shall be applied.
The Contractor shall examine all surfaces prepared by others and if the working surfaces or
conditions are in any way unsuitable he shall advise the Project Manager immediately in writing. The
Contractor shall keep all working surfaces clean and properly brushed off as the work proceeds.

119

The Contractor shall take appropriate measures to ensure that pre-painted piles make allowance for
any variation in toe level of the driven piles. Tubular steel piles shall be finished with a surface
coating down to a minimum of 2m below LAT or 0.5m below bed level whichever is the lower.
4.6.10

Preparation of Bare Metal Surfaces

Soil, concrete and other adherent matter shall be removed immediately from steelwork or coated
surfaces and the surfaces shall be made good.
Dust, soot, grit, detritus, metallic or other loose particles shall be removed by vacuuming after
steelwork surfaces have been blast cleaned or before coated surfaces are washed or steam cleaned.
Oil and grease shall be removed by emulsion cleaners, by steam cleaning or by high pressure water
jets before removing rust and mill scale or over coating. Oil and grease shall not be removed by
turpentine or other solvents. If steam cleaning is used, steam cleaning shall be carried out after the
greasy deposits have been removed by scraping and a detergent shall be added to the feed water of
the steam generator.
Salts, chemicals, corrosion or paint degradation products, including rust-spotting on blast cleaned
surfaces and zinc salts on zinc coatings or zinc-rich paints, shall be removed by washing with
detergent solution before coating steelwork surfaces or over coating.
Surfaces which have been cleaned using cleaning agents shall be rinsed with fresh water to remove
all traces of cleaning agent.
Blast Cleaning
All steelwork to be blast cleaned shall be treated in accordance with BS 7079 Preparation of steel
substrates before application of paints and related products Grade Sa 2 using automatic impeller
machine blasting or manual blasting as appropriate. The maximum grade of abrasive permitted shall
be as specified in the above British Standard. Non-metallic abrasives will only be permitted for use
with portable equipment where agreed with the Project Manager.
The abrasive used for blasting shall be free from contamination and any recovered material shall be
cleaned to the satisfaction of the Project Manager before reuse. The maximum amplitude peak to
trough of the blast cleaned surface shall not exceed 100 microns.
A sample blast-cleaned panel measuring not less than 150 x 150 x 6 mm adequately protected by
sealed transparent wrapping, shall be submitted to the Project Manager for approval before any work
is commenced. The approved sample shall be retained by the Project Manager for comparison with
prepared steelwork.
Blast cleaning shall be carried out in a fully enclosed space separated from the place of painting. The
enclosed space shall be fitted with dust extractors and filters to prevent the dispersal of dust outside
the enclosed space.
Hand Cleaning
All steelwork to be manually cleaned, by grinding disc, power wire brush, chipping hammers, or
needle guns shall be of a type which will not result in damage to the surfaces being cleaned and
treated in accordance with BS 7079 Grade St 2.
Wire brushes and brooms shall not be used for cleaning coated surfaces.
Mechanical Cleaning of Steelwork

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Mechanical cleaning of steelwork shall be carried out using carborundum grinding discs or other
power-driven tools followed by steel wire brushing and dusting to remove all loosened material which
is not firmly bonded to the metal surface.
Excessive burnishing of the metal through prolonged application of rotary wire brushes shall not be
carried out. Visible peaks and ridges shall be removed. Pneumatic chipping hammers shall not be
used.
Pickling
All steelwork to be galvanized shall be pickled in diluted hydrochloric acid.
Unless otherwise described in the Contract, exposure times for blast cleaned or coated surfaces
other than at joints shall not be longer than those in table below. Outside refers to any area outside
a fully enclosed workshop. The exposure times tabulated refer to any part of the surface cleaned in
accordance with this clause:
Table 4-6: Maximum Exposure Times

S1 Blast Cleaned

Max Exposure Times

Enclosed Workshop
1 hour

S2 Metal Sprayed

4 hours

S3 Mechanically Cleaned

48 hours

S4 Chemically Cleaned

As agreed with Project Manager

Maximum exposure of 8 weeks with up to 2 weeks of
this time outside
24 hours
Nil
48 hours
Nil
48 hours
Nil
As agreed with Project Manager

Surface

S5 Blast Primer on S1
S6 Etch Primer on S1
S7 Primer on S3
S8 1st Undercoat on S4, S5, S6 or S7
S9 Subsequent Undercoats

Outside
Nil
Nil
Nil

For surface condition S5 where blast primed steelwork is exposed outside, the minimum dry film
thickness of paint over the peaks of the blast cleaned steel shall not be less than 13 microns.
4.6.11

Paint Preparation

All paint shall be prepared and applied strictly in accordance with the manufacturers instructions. All
painting shall be carried out by skilled and experienced painters under constant supervision of
competent qualified staff.
Paint shall be thoroughly stirred when the containers are opened and when fresh supplies are being
transferred to paint pots. All paints shall be strained free from skins, etc. Paint shall be supplied from
the Contractors paint store to the painters ready for application.
Two pack or any similar chemically cured type paint shall not be used after the expiration of the pot
life stipulated by the manufacturer and such paints shall not be mixed with fresh paints.
4.6.12

Paint Application

All paint coatings shall be applied in accordance with BS EN 12944 and the manufacturer's
instructions.

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All brushes, tools, pots, kettles, etc., used in carrying out the work shall be clean. They shall be
thoroughly cleaned before being used for a different type or class of paint.
A controlled working procedure shall be adopted for all painting and surface preparation. Blasting
primer shall be applied as soon as possible after blasting operations are complete and shall in any
case be applied within 3 hours for an enclosed workshop. The paint system shall be built up to the
required dry film thickness (DFT) prior to removing the steelwork from the controlled environment to
an external situation.
Paints shall not be applied when the ambient temperature or the relative humidity falls outside the
limits recommended by the manufacturer, nor shall such paints be applied when the temperature is
likely to fall below the specified minimum during the curing period.
Paints shall not be applied externally during rain, fog or mist, or where the amount of moisture on the
surface, or that likely to be caused by subsequent condensation, may have a harmful effect.
Unless otherwise described in the specification, a coat of paint shall be applied by one of the
following methods:
Brush;
Roller supplemented by brush where necessary;
Air pressure spraying;
Airless spraying;
Spray-painting will not be allowed where the soiling of adjacent surfaces is likely to occur, unless
these surfaces are adequately protected, and neither will spray-painting be allowed in the case of
paints containing lead.
The Contractor shall ensure that the spreading capacity of the paint is fully in accordance with the
manufacturers instructions and that the spreading rate is controlled to maintain the required paint
thickness. The specified dry film thickness of the adopted paint system shall be adhered to at all
times and any areas exhibiting a lower film thickness shall be brought up to the required standard.
The Contractor shall note that the addition of diluents to painting materials shall only be permitted
with the agreement of the Project Manager. Any solvent used shall be fully compatible with the paint
product, shall be approved for use by the paint manufacturer and shall be limited to adding up to 5%
of solvent per unit volume.
In cases where the specified film thickness is insufficient the Project Manager shall determine
whether re-preparation of the surface and re-application of the complete paint system is necessary or
Making Good by rubbing down and re-applying the coating.
The Contractor shall allow for adequate drying periods between successive coats and shall consult
with the paint manufacturer regarding drying periods for each individual coating.
A minimum of 24 hours drying time shall be allowed for between each composite coat of paint and
the Contractor shall take particular care with areas of flanges, bolt holes and sharp angle edges
where a build up of paint may occur.
The Contractor shall take particular care with areas that are susceptible to corrosion such as welds,
sharp edges and joints etc., in addition to areas where there may be difficulty in achieving the
required dry film thickness. The Contractors attention is specifically drawn to Clause 4.3.5 of BS

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5400: Part 6. A stripe coat shall be applied to all such areas before the application of each coating
providing the additional coat does not result in a dry film thickness in excess of that recommended by
the paint manufacturer. Any defective area resulting from non-compliance with this specification shall
be Made Good at the Contractor's expense. The defective area shall be identified by the Project
Manager and the Contractor shall remove the paint system completely, re-prepare the surface and
re-apply the complete paint system.
The Contractor shall take care in the handling of all steelwork after the application of the blast primer.
Particular care shall be taken during transportation of steelwork to the Site and the Contractor shall
make full use of suitable lifting slings, harnesses, rubber protected chocks, chains and lashings on
vehicles, trucks and decks.
Any steelwork to be stored on Site shall be suitably supported on timber packers such that no painted
surfaces shall be in contact with the ground. Areas of paint damaged during handling, transportation
or erection shall be cleaned back to base metal and the full specified paint system re-applied. The
paint layers shall be feathered and shall overlap the existing paint system by a minimum of 50 mm.
Prior to the application of further coats while on Site and after installation, the original coat shall have
all damaged and defective areas repaired and made good and the entire surface cleaned to remove
any dirt, oil or grease or contamination by salts.
The Contractor shall also provide the Project Manager with all equipment as necessary to undertake
his own inspections including wet and dry film thickness gauges of an approved design. Dry film
thickness achieved shall be demonstrated to the Project Manager for each coating in accordance
with the procedures set out in BS 3900.
4.6.13

Shop Painting

The paint shop in which the protective system is to be applied shall be approved by the Project
Manager before the work commences and shall be of such design and construction that the specified
conditions of temperature, humidity and cleanliness are maintained throughout the Contract period.
Steelwork shall not be moved outside the paint shop until the shop-applied protective treatment is
complete.
4.6.14

Storage of Steel and Fabricated Steelwork

The Contractor shall take precautions to minimise exposure to chemical pollution of steel awaiting
fabrication.
Fabricated steelwork which is stored, awaiting delivery to Site or erection, shall be kept clear of the
ground and shall be laid out or stacked so as to prevent water or dirt accumulating on or against any
of the surfaces. Suitable packing shall be placed between layers of stacked steelwork. Where cover
is provided it shall be ventilated sufficiently to keep condensation to a minimum.
Care shall be taken during loading, unloading, stacking and erection of any painted steelwork to
minimise damage to the protection system. All slings, ropes and chains used to handle the steelwork
shall be protected with rubber sheaths or similar. The Contractor shall Make Good to the approval of
the Project Manager all paint work damaged during fabrication, transport, assembly and erection.
4.6.15

Metal Coatings

Where metal coating are required for threaded fasteners the following standards shall apply:

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BS 4921 Sherardized coatings on Iron and Steel Articles.

BS 3382 Parts 1 and 2, Electroplated Coatings on threaded Components (Cadmium and Zinc). This
Standard shall cover the electroplating of components up to and including 36 mm in diameter.
The minimum thickness of coating shall be 5 microns.
Where the metal coating is by a hot dip process the Contractor shall be responsible for the provision
of all holes required for purposes of filling, venting and draining. The Contractor shall propose the
location, size and method of plugging where required of all such holes which must be approved by
the Project Manager before fabrication commences.
Metal coatings which will be over coated with paint shall be passivated.
Allowance for the thickness of the metal coating shall be made in the sizes of the threads of metal
coated threaded components. Nuts shall not be tapped oversize by more than 0.4 mm.
Damaged areas of metal coatings shall be rubbed down to remove excessive roughness, cleaned
and made good by the use of an aerosol zinc rich paint containing an aluminium pigment, to give a
repair coating thickness of 100 microns.
Metal coatings required on part of a component shall be completed before the rest of the component
is painted.
Where a metal coating is required only on part of an assembled section it shall be applied before the
rest of the section receives its priming coat.
Where nuts and bolts are to be metal coated, attentions is drawn to the additional clearances
required on screw threads as shown in BS 4921, Table 2.
All hot dip galvanising shall be in accordance with B.S. 729: "Hot dip galvanised coatings on iron and
steel articles".
Hot dip galvanising shall be carried out after all shaping, trimming, filing, welding and fitting has been
completed.
The coating shall be smooth, continuous and free from flux strains.
The coating shall be sufficiently adherent to withstand normal handling conditions without peeling or
flaking.
Articles shall be evenly coated on all sides.
The coating weight shall be not less than 610 g/m2, which is equivalent to a coating thickness of 85
micrometer.
4.6.16

Handling of Coated or Painted Steelwork

The Contractor shall exercise the maximum care in handling, transportation and erection of protected
steelwork so that damage to the coating may at all times be avoided. The use of properly assigned
slings and soft non-adherent packs shall be used throughout.

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4.6.17

Repairs to Damaged Area

Areas of paint which have been damaged during handling, storing, loading and off loading,
transporting and erecting shall be cleaned to bare metal by grit blasting, grinding wheels or other
approved means and the edges of the undamaged paint bevelled by at least 50 mm.
The full specified painting system shall then be re-applied and the new paint shall overlap the existing
paintwork by at least 50mm.
All steelwork which is to be painted in coal tar/epoxy which has been damaged or been stripped to
permit welding shall be repaired using an equivalent approved coal tar/epoxy suitable for application
on wet or damp surfaces. In some instances this will have to be carried out under tidal conditions. In
all circumstances the steel surface shall be adequately cleaned as specified in BS EN 12944 and
coated to provide the paint thickness corresponding to adjoining surfaces. The Contractor will submit
full proposals for the approval of the Project Manager which demonstrate the paint manufacturers
agreement to the proposal.
4.6.18

Bolted Connections

High Strength Friction Grip (HSFG) Bolted Joints

The interfaces of all HSFG bolted joints shall be cleaned as specified, left unpainted masked off to
protect them until the joint is bolted up. Blast primer or metal spray as appropriate shall be taken 10
mm to 20 mm inside the perimeter of the joint area.
Subsequent paint coats shall be stopped off progressively at intervals of 75mm from the bolted joint.
Before the joint is made the facing surfaces shall be lightly hand wire-brushed to give a clean surface
free of corrosion products and any foreign matter. Immediately after the joint has been made the
primed steelwork shall be hand wire-brushed and the specified painting systems completed.
Other Bolted Joints
For shop joints the Blast primer shall be applied to parent and joint material. The joint shall be
assembled immediately after the first undercoat of the painting system has been applied to the parent
and contact surfaces.
For Site joints all surfaces, excepting those of fasteners, shall receive in the shop the paint system
which is applied to the parent surfaces.
4.6.19

Welded Joints

The Contractor shall ensure that areas within 200 mm of known Site welds shall not be painted until
all welding and testing is completed. Where this is not practicable the Contractor shall ensure that the
paint coat is removed by grinding and each coat is stepped back to enable preparation of fusion
faces for welding.
Welds and surfaces which have been affected by welding shall receive the preparation and protective
systems which are applied to the parent surfaces. Where paints other than blast printers are to be
applied to the parent surfaces before the making of a joint, they shall be stepped back at 50 mm
intervals commencing at 200 mm from welded joints and at 10 mm from the perimeter of all other
joints.

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4.6.20

Treatment of Completed Joints

Within 14 days of the joints having been made and passed by the Project Manager, the parent and
joint materials, exposed parts of bolts, nuts and washers, weld and weld affected areas shall be
prepared and painted.
All bolted joints shall be sealed against the ingress of moisture. Before painting commences, and
subject to the approval of the Project Manager, gaps at joints shall be plugged with approved filler.
The perimeter of all joints shall be sealed with subsequent coats of paint.

4.7

Fixtures and Fittings

4.7.1 General

Contractor shall submit to Project Manager for review the names of all suppliers and manufacturers
of proprietary or fabricated items prior to entering into any agreement for the supply of such items.
Project Manager may order the removal from Employers Site of any materials not so approved.
4.7.2 Miscellaneous Metalwork
Fabrication Drawings
Contractor shall prepare fabrication drawings and associated documentation for all items of
Miscellaneous Metalwork, and copies of these shall be submitted to Project Manager for review in
accordance with Clause 4.5.3 of this Specification.
Materials and Workmanship
Materials and workmanship for Miscellaneous Metalwork shall comply generally with the
requirements of Section 4.5 of this Specification.
Surface preparation galvanizing and painting of Miscellaneous Metalwork shall be in accordance with
the requirements of Section 4.5 of this Specification.
Steel used in fabrication of Miscellaneous Metalwork shall be new material of Grade S275 to BS EN
10025: 1993 or equivalent unless noted otherwise on the drawings.
Handrails and Ladders
Handrails shall be provided to stair cases and elevated platforms except where their provision would
obstruct mooring lines.
Handrails shall be designed and detailed by the contractor in accordance with BS
6399: Part 1 and BS 5395: Part 3 as appropriate.
All handrails shall be steel, fabricated generally in accordance with Section 4.5 of this
Specification, and shall be finished with a galvanized metal coating and decorative paint system in
accordance with this Specification.
Handrail standards shall be at maximum 1.5 meter centres. Minimum 100mm high kick plates shall
be provided.
Handrails and standards may be solid bar or hollow tube with minimum 3.25mm wall thickness.
Full details of the proposed handrail layout shall be submitted to Project Manager for review prior to
commencement of fabrication.

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Access, maintenance and safety ladders shall generally comply with BS 4211 and the
recommendations of BS 5395 Part 3.
4.7.3

Life-Saving Equipment

The life-saving equipment shall ne provided in accordance with international standards. The lifesaving equipment shall be mounted on posts.
4.7.4

Metal Decking

Materials used in construction shall comply with BS 4360: 1990. Rolled steel sections shall comply
with BS 4: Part 1 and BS 4848: Part 2.
Generally steel decking shall be designed to support a uniformly distributed load of 5kN/m2 with a
maximum deflection not exceeding 1/200 of the span and to withstand three times the design load
without collapse.
Open type steel decking shall comply with BS 4592 except where amended below.
The minimum thickness of load bearing bars shall be 5mm and the load bearing bars shall have a
minimum depth of 1/40 x span but not less than 20mm. They shall span in the shortest direction and,
where practical, the pattern shall be continuous at the meeting point of separate pieces of decking.
Floor panels shall be clipped down to the supporting steelwork so that each individual panel is held
by a minimum of four clips. Studs shall be welded to the supporting steelwork.
All panels shall be removable and fixing shall be such that where a panel is removed, the remaining
panels will remain firm and replaced panels are safe against displacement and dropping through
before the clips have been fastened.
Each panel shall have an edge bar on the bearing edges, which shall have a thickness not less than
the load bearing bars.
4.7.5

Fendering

General
Contractor is responsible for the detailed design of fendering to the jetty including support steelwork,
and all fittings.
Fender units, facings, fixings, chains and fittings for fendering shall be obtained from approved
specialist suppliers and manufacturers and shall be fabricated, assembled, installed and tested in
accordance with manufacturers instructions and recommendations.
Steelwork shall comply with Section 4.5 of this Specification and shall be protected against corrosion
in accordance with Section 4.6 herein.
Fender Units
Rubber fenders shall be of approved manufacture, having physical properties totally suitable for the
climatic and environmental conditions at Employers Site and for the use required in service.
Contractor shall submit to Project Manager for review full details of the physical properties of the
proposed fendering including:

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Manufacturers literature, including a list of physical properties of the rubber for the fenders;
A report on compression load tests and characteristic load-deflection and energy-deflection
curves.

Contractor shall check all tender dimensions and fixing details with the fender manufacturer before
preparing his fabrication details for the suspended steel fender faces and support steelwork.
Project Manager may require fenders supplied by Contractor to be tested at the place of manufacture
and test certificates submitted for review before dispatch.
Fender Chains
Fender chains shall be electrically welded and stud link chain complying with Grade
30 Class 1 to BS 6405 or equivalent approved.
The chains shall be provided with shackles at each end and turnbuckles, or other suitable means of
adjusting the chains to the accurate lengths required. Shackles, turnbuckles and any other fittings
shall have equivalent loading capacities to the chains in which they are installed.
Contractor shall ensure, by the provision of suitable turnbuckles and the inclusion of non-standard
links, as necessary, that the lengths of chains to be provided will be as recommended by the fender
manufacturer and that the orientation of the links at the ends of the chains will be as required for the
steelwork connections thereto.
Contractor shall be responsible for checking the lengths and details of all chains and shall submit to
Project Manager for review full details of all chains and fittings.
Polyethylene Fender Panel Facings
The front faces of fender panels shall be fitted with approved ultra high molecular weight low-friction
polyethylene rubbing pads and shall be installed in accordance with the manufacturers instructions.
4.7.6

Quick Release Mooring Hooks

Quick Release Mooring Hooks shall be of the self-supporting open type fitted with safety catches as
necessary and connected to a swivel bracket in such a manner as to allow the free movement of the
hook assembly in any plane. The mooring hooks shall be capable of operation both manually and by
an electric remote control system. Quick release mechanisms and shall be single, double or triple
hook units with integral capstans.
Holding down bolts shall be suitable for casting into the reinforced concrete deck structure.
Mooring hooks and bases shall be manufactured in cast steel to BS 3100 or similar equal approved
standard.
All materials shall comply with the relevant British Standards.
The safe working load of each hook in single, double or triple hook assemblies shall be as dictated in
Contractors design and acceptable to Project Manager. The minimum factor of safety against yield
shall be 1.25 and against ultimate failure shall be 2.5.
All hooks shall be capable of being released separately from the mooring point area under both full
load and no load conditions.

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Mooring hooks shall be designed to accept loading in the vertical plane from the horizontal to a
minimum angle of inclination above the horizontal of 300. Hooks in single hook assemblies shall be
designed to accept loadings in the horizontal plane through minimum load sectors of 180 deg. Hooks
in double hook assemblies shall be designed to accept loading in the horizontal plane through
minimum load sectors of 1300.
Outer hooks in triple hook assemblies shall be designed to accept loading in the horizontal plane
through minimum load sectors of 130 and the inner hook, through a minimum load sector of 1100.
The capstans shall be of the integral type mounted with a vertical axis on the top of the hook base
and shall have a minimum load capacity of 1.5 tonnes and a minimum line speed of 30
meters/minute.
Capstan motors shall be reversible in operation and capable of holding loads when stopped. Motors
shall be suitable for multiple starts and shall be supplied with foot switches, junction boxes and
emergency stop buttons.
All electrical components shall comply with the requirements of Electrical System Specification.
Notwithstanding the information given therein, motors shall be designed for the maximum ambient
temperature.
The capstan motors shall have motor enclosures to lP65 and shall be Exe.
Proof load testing to working load shall be carried out on all hooks under supervision of Lloyds
Register of Shipping or equivalent body using approved apparatus and include testing of the quick
release system.
Test certificates shall be issued for all hooks.
Material test certificates shall be provided.
Assemblies shall be designed to require the minimum of maintenance in service.
Electrical isolation of the mooring hooks shall be possible.
Contractor shall provide instruction manuals for review by Project Manager.
The instructions are to include a detailed description of each item accompanied by drawings,
operating instructions, maintenance instructions and made into a finished handbook ISO Standard
210 x 297 (A4 size).
The assemblies shall be suitably primed prior to leaving the manufacturers works with an inorganic
zinc rich or other approved coating applied in accordance with the manufacturers recommendations
to give a total minimum dry film thickness of 75 to 100 microns applied to a surface blast cleaned to
Swedish Standard SA21/2.
After installing and testing quick release hook assemblies shall be painted in accordance with Clause
4.6 to give a final paint system.

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4.7.7

Bolted Connections

All connections shall be bolted with bolts and nuts to BS 3692 which shall be fitted with one flat
circular washer conforming to BS 4320 under each nut.
Where bolt heads or nuts bear on bevelled surfaces they shall be provided with square taper
washers conforming with BS 4320 to afford a seating square with the axis of the bolt.
The size and location of all bolts shall be clearly shown on Contractors shop drawings.
Holding down bolt assemblies shall be of approved manufacture and shall be fitted with washer
plates of angles and nuts, etc. as required by their design.
Purpose made templates shall be provided to facilitate accurate positioning of holding down bolts
during the placement of concrete.
Holes shall be drilled accurately to template. Burrs and arises shall be removed from the edges of
holes before the parts are assembled. Holes shall not be punched unless the Project Manager gives
permission.
No holes shall be gas cut, either during fabrication in shops or during erection at Site.
The diameters of holes shall not exceed the size of the bolt under its head by more than 2 mm,
unless otherwise approved by the Project Manager. Holes for turned and fitted bolts shall be reamed
to give a light drive fit.
Drift pins will be allowed only for bringing together the several parts of the structures, etc. and shall
not be used in such a way as to distort the work or enlarge the bolt holes.
Bolts and nuts shall be of quality 8.8.
All bolt connection shall have one bolt, one nut and two washers. In all cases the bolts shall project
not less than one full thread through the nut after tightening.
4.7.8

Tide Gauges

Contractor shall provide and maintain 225mm x 50mm hardwood tide gauges fixed in positions
accepted by Project Manager.
Gauges shall be painted with three coats of oil paint on the marked face with alternate meters in red
and white respectively and all markings picked out in black.
4.7.9

Navigation Lights

Navigation lights shall comply with the requirements of the International Association of Lighthouse
Authorities Regulations.
The lights shall be designed and installed to provide minimum maintenance and maximum ease of
access.
The lights shall be installed so as not to interfere in any way with the operations of other equipment
on the jetty.
The lights shall be fitted with devices to deter sea birds from alighting on them.

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An emergency back-up power supply shall be provided and kept available for immediate use in the
event of a break in the main power supply.
The characteristics of the lights shall be to the approval of the port authority.
4.7.10

Depth Contour Buoys

Depth contour buoys shall be steel skirted, of 2.2 meters diameter, moored with 38mm chain and
sinker adequate to anchor the buoys in design extreme environmental conditions.
The buoys will be appropriate for open sea conditions, with a focal height of 3.0 meters.
The buoys will each be fitted with North Cardinal topmarks, solar powered lantern and radar reflector.

4.8

Drainage and Services

4.8.1

Floor Drains Jetty

The surface-mounted drains to the jetty shall be from the 1460 Series by Wade International (U.K.)
Limited or similar approved manufacturer. The cast iron drain body shall have a 150mm diameter
outlet, Wade Specification Code F106 with a hinged square opening grating code M501.
The outlet pipe shall be 150mm diameter uPVC to BS 4660 and shall be internally caulked into the
cast iron drain body.
The drain bodies shall be cast into the structural concrete topping at the levels and locations to be
designed by Contractor. Special precast concrete planks shall be provided with holes to
accommodate the drain bodies and outlet pipes. The pipes shall project 150mm below the soffit of
the concrete deck and shall be surrounded by Grade C40/50 in situ concrete. Contractor shall
provide suitable formwork for the surround. Such formwork shall subsequently be carefully removed.
4.8.2

Cable Ducts

Cable ducts shall be of either of the following types:

(a) PVC Cable Ducts
Shall be of an approved manufacture with flexible joints
(b) Concrete Cable Ducts
Shall be concrete pipes with ogee joints to BS 5911, standard class.
All electrical ducts entering draw-pits, buildings and basements shall be provided with approved
bell-mouths.
Each electrical duct whose length exceeds 3 meters shall be provided with a draw-wire, which shall
be of galvanized steel or 6mm nylon rope. The length of draw-wire installed shall be such that 1mm
of draw-wire extends from each end of each duct. The free ends of the draw-wire shall be neatly
coiled or otherwise stowed.
Every duct or set of ducts shall be proved and its draw-wire shall be installed. The ends of the duct or
its bell-mouth where provided, shall then be sealed to a depth of 50mm with plastic sealing
compound and a single coat of bitumastic paint shall then be applied over the ends of the ducts and
the seal.

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4.8.3

Ducts

All pipe-laying shall be done by skilled and experienced men.

All glass reinforced plastic pipes used in the Plant shall be installed and tested in accordance with BS
5480: Parts 1 and 2 and shall comply in full with the manufacturers recommendations.
Each length of and duct shall be accurately laid and shall be true to line and gradient from point to
point.
All ducts shall be clean before laying and jointing. No damaged or defective pipes shall be used. All
service systems shall include bends, tapers, junctions and other special pipes of whatever pattern
required. Provision shall be made for all cutting, coring, drilling holes, making good and connection to
new and existing work.
Proper implements, tools and facilities shall be provided and used by Contractor for the safe and
convenient performance of the work. All pipes, fittings and valves shall be carefully installed in such a
manner as to prevent damage to the materials.
All pipes and fittings shall be assembled strictly in accordance with the written instructions of the
manufacturer.
When pipes pass through walls a flexible joint is to be fitted, situated as close as possible to the
outside face and permitting a minimum deflection between adjacent pipes of 3 degrees.

4.9

Geotechnical Investigation

The Contractor shall be fully responsible for the planning, detailing and specifying the soil
investigations and shall obtain approval of the Project Manager before starting the investigations.
4.9.1

Boring activities

The following describes the activities required to obtain the required information:
- Set-out borehole locations by means of a D-GPS system
- Delivery of marine equipment
- Drilling of 15 geotechnical boreholes until a depth of approximately 25 to 30 meters below the
seafloor (or less due to refusal of bedrock)
- Execution of 15 Dynamic Penetration Tests (DPT); each one at the same location as the
boreholes)
- Execution of 15 Vibro-core boreholes until a depth of 4 meters below the seafloor
- Site supervision by a geotechnical engineer
- Shipping of the samples to a qualified geotechnical laboratory
- Laboratory analysis of the extracted samples and cores
- Delivery of the geotechnical report.
4.9.2

Boreholes

A total 15 boreholes are required:

9 boreholes along the axis of the FUF at intervals of 50 meters
2 boreholes at the location of the unloading platform, and
1 borehole at the location of each of the 4 mooring dolphins.

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4.9.3

Marine Equipment

Due to the lack of adequate marine equipment fit for the execution of the activities described above,
the contractor is required to ship his own facility (for instance a sectional barge) to Monrovia.
4.9.4

Laboratory Analyses

The geotechnical engineer will have to propose a laboratory testing program to the client to be
executed upon completion of the field work. The geotechnical engineer has to propose the number of
samples to be used for each of the tests listed below. In general these tests fit the requirements of
the assignment:
- Grain size analyses, including hydrometer
- Particle shape determination
- Atterberg limits
- Organic content
- Gamma plus water content
- Minimum/maximum density
- Oedometer tests
- Triaxial testing
- Calcium Carbonate content.
4.9.5

Deliverables

The Geotechnical Report should present the following data:

- All borehole logs and DPT graphs
- Methodology, equipment and photographs
- Location map with exploratory holes
- Geotechnical longitudinal profiles and cross sections, including soil layers and boring logs
- Laboratory test results
- Foundation advice (exclusive pile calculations for the FUF).
4.9.6

References

The following References shall apply to this Specification:

1. BS 1377: 1990: Parts 1-9 Methods of test for soils for civil engineering purposes.
2. International Society of Rock Mechanics (1985), Suggested Method of Determining Point Load
Strength. I.S.R.M. Mm. Sci. & Geomech. Abstr. Vol. 22, pp5l-60.
3. BS 5930: 1981 - Code of Practice for Site Investigations.
4. Brown, E.T. (1981) edition. Rock Characterisation, Testing and Monitoring, I.S.R.M. Suggested
Methods. International Society Rock Mechanics Commission on Testing Methods

DRAWINGS

This section includes the following drawings, showing the reference design. This reference design is
for bidding purpose only.
9V1468.03.001
9V1468.03.002
9V1468.03.003
9V1468.03.004
9V1468.03.006

General Layout_Existing Situation

Jetty Layout
Loading Platform_Layout and cross sections
Access Trestle_Layout and coss sections
Pump House Platform_Layout and cross sections

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9V1468.03.007
9V1468.03.008
9V1468.03.009
9V1468.03.010
9V1468.03.011

Pump House_Building Layout, cross sections and views

Electrical Systems
Flow Diagram
Mooring Dolphins_Layout and views
Breasting Dolphins_Layout and views

SUPPLEMENTARY INFORMATION

This section includes the following supplementary information:

1
2
3
4

Bathymetric Survey Freeport of Monrovia, Survey Report, Royal Haskoning, June

2005
Extracts from Preliminary Engineering and Economic Investigations for the
Rehabilitation and Extension of the Freeport of Monrovia, Volume 2, Actual situation
of the port and site investigations, Rhein-Ruhr Ingenieur-GES MBH, 1978
Environmental Soil Investigation, Port of Monrovia, Royal Haskoning, March 2006
Report of the underwater inspection at the Freeport of Monrovia, Liberia. The Oil
Jetty, Classdiving, June-July 2005

ANNEX 1 ESTIMATED BILL OF QUANTITIES

This BOQ is based on preliminary design and is not to be considered reliable by the bidders.
DREDGING

ITEM

ITEM DESCRIPTION

UNIT

QTY

Dredging and disposal of material

m3

39,000

UNIT

QTY

LOADING PLATFORM
ITEM

ITEM DESCRIPTION

Steel pipe pile 660x14.2mm,

S355, length 29.80m

nr

14

Coating length 20m

m2

580

Reinforced concrete fill length

3.80m

m3

18

Reinforced concrete beam

20.00x1.00x0.80m

nr

134

Reinforced concrete beam

8.00x1.00x0.80m

nr

Reinforced concrete deck

t=500mm

m2

300

Reinforced concrete edge beam

70

Ladder including sliding fender

nr

Railing

43

10

Catwalk support

nr

11

Hose area
Reinforced concrete beam

43

12

Grating

m2

79

UNIT

QTY

Trestle foundation
Steel pipe pile 660x14.2mm,
S355, length 16.30m

nr

70

Coating length 10m

m2

1,450

nr

10

ACCESS TRESTLE
ITEM

ITEM DESCRIPTION

Steel pipe pile 660x14.2mm,

S355, length 22.50m
(from pump house to loading
platform)

Coating length 16m

m2

332

Reinforced concrete fill length

3.50m

m3

11

Reinforced concrete beam

5.00x1.00x0.80m

nr

80

Steel girder HE700A

930

Steel girder HE200B

310

Walkway
Steel girder UNP200

930

135

10

Steel bracing L100.100.10

658

11

Grating

m2

465

12

Railing

930

PUMPHOUSE
ITEM

ITEM DESCRIPTION

UNIT

QTY

Pump House foundation

Steel pipe pile
660x14.2mm, S355, length
17.75m

nr

Coating length 11.25m

m2

94

Reinforced concrete fill

length 3.25m

m3

Reinforced concrete beam

7.00x1.00x0.80m

nr

Reinforced concrete deck

t=500mm

m2

42

Reinforced concrete edge

beam

26

Pump House
Steel column HE160A

38

Steel column HE160A (roof)

31

Steel column UNP140

38

10

Construction Pump House

nr

DOLPHINS
ITEM

ITEM DESCRIPTION

UNIT

Mooring Dolphins

136

QTY

DOLPHINS
ITEM

ITEM DESCRIPTION

UNIT

QTY

Steel pipe pile 660x14.2mm,

S355, length 32.7m

nr

16

Coating length 10.2m

m2

339

Reinforced concrete fill length

2.20m

m3

11

Reinforced concrete base

6.00x6.00x2.00m

m3

144

Corner protection

18

Ladder including sliding fender

nr

Railing

25

Triple Quick Release Hook

nr

Breasting Dolphins
Steel pipe pile 813x14.2mm,
S355, length 38.25m

nr

20

10

Coating length 18.5m

m2

945

11

Reinforced concrete fill length

2.25m

m3

22

12

Reinforced concrete base

8.50x8.00x2.00m

m3

292

13

Corner protection

13

14

Ladder including sliding fender

nr

15

Railing

32

16

Double Quick Release Hook

nr

17

Fender SCN2000 including

Fender Panel

nr

18

Catwalk support

nr

19

Catwalk
Steel girder 813x14.2mm, S355

42

20

Coating steel girder

m2

110

137

DOLPHINS
ITEM

ITEM DESCRIPTION

UNIT

QTY

21

Steel girder IPE200

42

22

Grating

m2

42

23

Handrail

83

UNIT

QTY

INSTALLATIONS
ITEM

ITEM DESCRIPTION
Product pipelines

12" CS pipeline for Gas oil

485

10" CS pipeline for Gasoline

485

8" CS pipeline for Jet-A1/Kerosene

485

12" flexible hose for Gas oil, 24m

nr

10" flexible hose for Gasoline, 24m

nr

8" flexible hose for JetA1/Kerosene, 24m

nr

Utility Pipelines
7

3" CS pipeline for slops

485

2" CS pipeline for nitrogen

485

2" CS pipeline for fresh water

415

Spill prevention
10

2 m3 Slops

nr

11

1 kW slops pump

nr

nr

80

Pedestal mounted crane

12

Pedestal mounted crane

Fire fighting

13

12" CS pipeline for firewater

138

INSTALLATIONS
ITEM

ITEM DESCRIPTION

UNIT

QTY

14

Diesel-powered fire pack

nr

15

Electric fire pack

nr

16

Jockey pump

nr

17

5 m3 Foam tank incl. injection

pump

sum

item

18

Fire water monitor (mounted on

crane)

nr

sum

Item

Fire detection and alarms

19

Fire detection and alarms

Electrical

20

Illumination Posts walk ways

nr

19

21

Illumination Posts work areas

nr

22

400 VAC Cable

465

23

115 VAC Cable

685

24

400 to 115 VAC Transformer

nr

25

Cable tray

685

26

Auxiliary Items (valves, manifolds,

instrumentation etc.)

sum

item

139