CONSTRUCTION SPECIFICATION

CONSTRUCTION SPECIFICATION

FOR

SEWER AND DRAINAGE WORK

Document Security           

: Level 1   : Level 2   : Level 3   : Level 4   : Level 5

Document Issue Purpose

: For Approval  : For Review  : For Information  : For Construction  : Internal Use

Contents

1.        GENERAL                                                           ------------------  3

       1.1    Scope                                               ------------------  3

1.2    Definitions                                         ------------------  3

2.     APPLICABLE STANDARDS AND SPECIFICATIONS           ------------------  3

3.     MATERIALS                                                   ------------------  4

4.     MATERIAL HANDLING                                        ------------------  5

              4.1       Protection of Material                            ------------------  5

              4.2       Handling                                           ------------------  5

              4.3       Deformation and Damage                           ------------------  5

         4.4       Delivery and Storage                               ------------------  5

4.5        Repair/Replacement                              ------------------  5

5.      WORKMANSHIP                                             ------------------  5

              5.1       Trench Excavation                                   ------------------  5

              5.2       Pipe Bedding                                        ------------------  7

              5.3       Dewatering                                         ------------------  7

              5.4       Pipe Laying                                         ------------------  7

              5.5       Pipe Joint                                     ------------------  8

              5.6       Wrapping                                    ------------------  8

              5.7       Concrete Pit                                  ------------------  8

              5.8       Backfilling                                       ------------------  8

           5.9       Protection                                     ------------------  9

           5.10   Cleanup                                         ------------------  9

6.     TESTING AND INSPECTION                                   ------------------  9

              6.1       Leak Test (Water-tightness)                           ------------------  9

              6.2       Inspection                                          ------------------ 10

              6.3       Tolerance                                     ------------------ 11

7.            SUBMITTALS                                           ------------------ 11

              7.1       Material Data                                        ------------------ 11

              7.2       Working Procedure                                  ------------------ 11

              7.3       Working Drawing                                    ------------------ 12

              7.4       Report of Test and Inspection                     ------------------ 12

              7.5    Qualified Welders List                           ------------------ 12 
1.       GENERAL

1.1    Scope

          This specification covers the general requirements for the sewer and drainage system works in the XXXX Nanhai Petrochemical Project, Nanhai, China.

          Any deviation and/or additions to this specification, if required in individual cases, shall be communicated to and approved in writing by CONTRACTOR, prior to commencement of the works.

1.2     Definitions

The following terms are used herein as defined below:

2.       APPLICABLE STANDARDS AND SPECIFICATIONS
The following project specifications shall apply to the sewer and drainage system works.

          Chinese Standard

          GB50268-1997                         Codes for the construction and acceptance of water-supply & drainage pipe-lines

          GB700-1988                             Carbon Structural Steel

          JGJ81-1991                             Specifications for Welding of Steel Structure

          Project Specification

          SP-8310-0000-0009           Drainage Specification

          SP-8310-0000-0010           Earthworks Specification

          Technical Specification, Design and Engineering Practice

          DEP 34.11.00.11-XXXX    Site Preparation and Earthworks

          DEP 34.14.20.31-XXXX    Drainage and Primary Treatment Facilities

          DEP 31.40.10.19-XXXX    GRP Pipelines and Piping Systems

          Design and Construction Specification

          SP-8310-1000-0001 (S-000-1310-0001)   Detail Engineering Design Data for Civil and Structure

          SP-8710-1000-0101 (S-000-1641-0001)   Construction Specification for Earthwork

          SP-8710-1000-0102 (S-000-1642-0001)   Construction Specification for Concrete Work

          ASTM Standard (American Society of Testing and Materials)

          ASTM F1142-1998                   Standard Specification for Manhole Cover Assembly,

                                                        Bolted, Semi-Flush, Oiltight and Watertight

          ASTM F1143-1998                   Standard Specification for Manhole Cover Assembly,

                                                        Bolted, Raised, Oiltight and Watertight

3.       MATERIALS
All materials shall be as specified on drawing and specifications. Substitutions shall be approved in writing by CONTRACTOR.

  3.1 Underground Piping Material

Specification of each line class for underground piping shall be in accordance with SP-8230-0000-0002 乬Piping Material Specification乭.

(1)    For Accidentally Contaminated Drain (ADC(AOC))

Glass Reinforced Plastic Pipe (GRP) : Line Class 17120-N

(2)    For Continuously Contaminated Drain (CCD(COC))

Glass Reinforced Plastic Pipes (GRP) : Line class 17120-N

         (3)       For Vent Pipe

               Carbon Steel Pipe (Galvanized) : Line class HOLD

 3.3 Concrete and Mortar

         Refer to SP-8710-1000-0201 (S-000-1642-0001) 乬Construction Specification for Concrete Works乭.

  3.2   Steel Material

         Steel materials shall comply with Chinese Standard GB700-88, Q235B.

  3.3 Manhole Covers and Gratings

         Manhole covers shall comply in all respects with the requirements of ASTM F1142 and F1143

Grating cover and frames may either be a manufactured item or site fabricated. Proposed design and free area shall be submitted for approval prior to ordering or fabrication.

4.       MATERIAL HANDLING

 4.1   Protection of Material
All materials shall be stored in such a manner as to protect them from deterioration and contamination from whatever source.

Wrapped carbon steel pipe work shall be protected from the direct rays of the sun and damage to wrapping, such as cuts, perforations, peel-backs, etc.

 4.2   Handling
          Full care shall be taken to prevent the deformation and damage of materials during their handling.

       To avoid damage to coating or pipes and fittings special care and attention shall be taken when lifting, moving and placing pipe on site. Impacts shall be avoided.

       Ropes, cables and hooks shall not be used during handling.  Instead, wide leather or canvas straps shall be used and shall be of a length suited to the diameter of the pipes.

 4.3   Deformation and Damage
          Piping materials shall be inspected to ensure that there is no deformation or damage. If such       irregularities are observed, shall be informed to CONTRACTOR immediately.

 4.4   Delivery and Storage

        Materials delivered to site shall be inspected for damage, unloaded, and stored with the minimum of handling. Inside of pipes and fitting shall be kept free of dirt and debris.

        Materials shall not be stored directly on the ground.

        They shall be placed on wide timber bearers with interplacing of a protective material such as                    straw rope, felt or kraft paper strips and sacks of sand or sawdust.

        The inflammable or combustible materials shall be stored in a ventilated warehouse to protect                    them from direct sunlight and high temperature.

4.5   Repair/Replacement

In the event of damage, immediately make all repairs and replacements necessary to the approval of PMC/CONTRACTOR with no additional cost.

5.      WORKMANSHIP

5.1   Trench Excavation

Excavation for underground pipe work shall be carried out in accordance with SP-8710-1000-0101 (S-000-1641-0001) 乬Construction Specification for Earthwork乭 and the following instructions.

        Before commencing any excavation, the SUBCONTRACTOR must obtain details and locations of              existing underground pipes, drains, cables, etc. and the precaution taken to prevent damage.

        Damage resulting from lack of proper precautions or neglect by SUBCONTRACTOR shall be made           good at his own expense.

        If there is any interference by existing underground facilities, the SUBCONTRACTOR shall inform CONTRACTOR immediately.

        Adequate temporary measures shall be taken to prevent slips, cave-ins and slides.

    Trenches at any point below the top of the pipe shall be not smaller than the outside diameter of the pipe plus the following width to permit satisfactory jointing and thorough tamping of the bedding material under and around pipe unless otherwise specified on the drawing or approved by PMC/CONTRACTOR.

                   Trench Depth              Clearance between       Clearance between

                                      Trench wall and Pipe         Pipes in Common Trench

          Less than 1.50 m                    20 cm                    30 cm

          1.50 乣 3.00 m                     50 cm                    30 cm

          3.00 乣 4.50 m                    100 cm                    30 cm

          More than 4.50 m                150 cm                    30 cm

If a trench is over-excavated, the over-excavated portion shall be replaced with Common fill material in accordance with Sec.5.2 in SP-8710-1000-0001 (S-000-1641-0001) 乬CONSTRUCTION SPECIFICATION EARH WORK乭.

All trenches and excavations over 1.2m deep shall be sloped, shored, benched, braced, or otherwise supported. When soil conditions are unstable, excavations less than 1.2m in depth shall be sloped, supported, or shored. Sloping shall be at a minimum ratio of 1:1 Minimum bench width shall be 0.6m.

        Surface material should be set aside for use in subsequent reinstatement. All excavated material          should be stacked at least 1.0m from the edge of the trench where depth of excavation is less than 1.0m.

For depth below 1.0m, the excavated material shall be moved double the depth in distance from the excavation edge.

5.2     Pipe Bedding
A bed of clean sand fill material shall be laid and compacted to 100mm minimum thickness over the full width of the trench. The bed shall be scooped out locally at pipe sockets where socketed pipes are used. The bed thickness under sockets shall not be less than 50mm.

       Pipes shall be adjusted to line and level to ensure that pipe barrels rest uniformly on the bedding. Where sidefill is required, further selected backfill material shall be laid and compacted uniformly by hand halfway up each side of the pipe.

5.3    Dewatering

          Provide with sufficient number of dewatering pumps and protect the trench from entering water        by banking soil along trench.

 5.4   Pipe Laying

         Before installation and prior to lowering into the trench, the pipe shall be inspected for defects.

         Any pipe or fitting found to be defective before or after laying shall be replaced at no addition             cost.

         Installation of gravity pipe work shall commence at the downstream end of the system.

        Immediately following the excavation of the trench, the pipe shall be laid and jointed in accordance with the manufacturer乫s recommendations and as detailed on the drawings. Brick or other hard blocks shall not be placed under the pipes for temporary support.

The full length of each section of pipe shall rest solidly upon the pipe bed. Pipes shall not be laid when trench conditions are unsuitable for the work. When work is not in progress open ends of pipes, fittings and valves shall be securely closed so that no water, sand or other substance will enter the pipes or fittings.

Each length of pipe shall be laid in a true straight line both in the horizontal and vertical planes, the levels and/or gradients shown on the drawings. The interior of the pipe shall be cleared of all superfluous materials. As soon as possible after the joint is made, sufficient backfill material shall be placed along the pipe to prevent pipe movement of line or grade.

        Study sight rails, to the approval of PMC/CONTRACTOR, shall be placed at each end of the pipelines and in any event at not more than 35m apart. A third sight rail shall be used wherever possible to guard against accidental displacement of sight rails.

        Bonding rods shall be robust construction clearly painted and accurately made to the various lengths required, the lower end being provided with a shoe of sufficient projection to rest on the invert of the pipe. The invert of each pipe shall be checked during laying.

5.5       Pipe Joint

        Pipe joints shall be made water tight to prevent infiltration or exfiltration.

        Prior to making joints, all surfaces shall be thoroughly cleaned and prepared as required for the                         type of joint to be made.

       Provision shall be made to prevent floating of pipe in the event the trench is flooded after jointing is completed.

        Installation procedure for Glass Reinforced Plastic (GRP) shall be in accordance with the relevant manufacturer乫s recommendations as approved by PMC/CONTRACTOR.

5.6     Wrapping and Coating for Carbon Steel Pipe
Work of external wrapping to be applied in accordance with the following specifications and drawings. No internal coating shall be applied.

          DEP 31.40.30.32-XXXX           External fusion bonded epoxy powder coating for line

          39-8310-1000-0103 (D-000-1316-0003)   Standard drawing for Sewer and Drainage Pipe Connection

5.7     Concrete Pits

Concrete work for sewer boxes such as manholes, sump boxes, valve boxes, catch basins, shall be carried out in accordance with SP-8710-1000-0201 (S-000-1642-0001) 乬Construction Specification for Concrete Work乭.

         Completed sewer boxes with joints shall be watertight.

         Sewer boxes shall be precast or cast in situ reinforced concrete and set vertically to build the manhole up to surface level.

              Manhole, concrete structure or sewer pipe shall not be installed in water.

5.8     Backfilling
All backfill materials shall be in accordance with SP-8710-1000-0101 (S-000-1641-0001) 乬Construction Specification for Earthwork乭.

Clean sand fill material shall be laid in 100 mm layers and hand compacted to a level 450 mm above top of  pipe. Common fill material placed and compacted in 300 mm layers. Mechanical compactors shall not be used until there is at least 450mm hand compacted cover over the crown of the pipe.

5.9    Protection and Safety

         All pipe open ends and terminations for later connections of pipe shall be securely sealed plugged or capped during progress of the works to prevent entry of foreign matter. Plastic, shaped hardwood, metal plugs or drain plugs shall be used. Screwed-up paper or cloth pushed into pipe ends will not be acceptable and shall not be used.

          Underground pipe under working areas shall be adequately protected to prevent mechanical       damage from trucks, cranes, etc.

          Protect existing facilities and underground facilities during excavating, installation and                        backfilling.

          Partly constructed manholes shall be provided with timber or metal temporary covers.

All open excavations such as trenches and manholes shall be clearly marked by barricades in accordance with project safety specification.

5.10   Cleanup

At completion of the works SUBCONTRACTOR shall clear out and flush drains, manholes etc with clean water. Drains shall be rodded trough, where necessary, to ensure clearance of debris and leave the system in clean working order with all traps sealed with water.

          As soon as the work is completed and approved, the area and roadway surface shall be restored to                   the equivalent of its original condition.

          Surplus soils shall be removed to approved stock pile areas.

6.    TESTING AND INSPECTION

 6.1 Leak Test (Water-tightness)

        Any test requirement shall refer to sec.11 in SP-8310-0000-0009 乬DRAINAGE SPECIFICATION乭.

(1)      Sewer Piping

       Sewer pipes shall be tested for water-tightness by filling water to a head of not less than 2.0m      above the soffit of the pipe at the high end but not more than 2.4m at the low end.

       Unless otherwise agreed by PMC/CONTRACTOR the test shall commence one hour after filling the test section, at witch time the water level in the feed pipe shall be made up to produce the required test head.

       The test shall be continued for sufficient time to allow PMC/CONTRACTOR to inspect the pipeline and satisfy himself regarding its water-tightness and in any case for not less than on hour.

       The system is deemed to have passed the test if there is no fall in the head of water during the test period.

       Testing requirements for Glass Reinforced Plastic (GRP) pipe shall be confirm to manufacture乫s recommendation.

(2)  Sewer box
Each sewer box shall be tested for water-tightness in the presence of PMC/CONTRACTOR by filling with water to a level not exceeding 1.2m above the pipe soffit level and allowed to stand for up to 8 hours.

       SUBCONTRACTOR shall be responsible for locating, making good any leakage乫s and the work will be accepted as satisfactory only when a visual inspection for water-tightness reveals no leaks or external damp patches. This test is to be carried out prior to placing of the backfill material.

(3)  Record of tests
    The SUBCONTRACTOR shall keep a complete record of all tests carried out after installation and shall    supply the CONTRACTOR with a copy of the records as the testing proceeds and at the end of the              Contract. The SUBCONTRACTOR shall submit to the PMC/CONTRACTOR for approval a test record sheet.

6.2   Inspection

(1)    Pipes

       Deformation, damage and injury of pipes and fittings

       No damage to coatings and wrappings, where applicable.

(2)    Excavation, trenching and bedding

Width/depth of trenches, removal of rock and unstable or unsatisfactory material, and bedding requirements.

(3)    Pipe laying

Pipe size/elevation/alignment, direction of spigot or tongue end, dewatering, grade, cleaning of bell or grooved ends, cleanliness inside the pipe, mortar bead and protection of joints.

(4)    Joining pipes

Jointing for GRP piping.

Welding and wrapping for Carbon Steel Piping.

(5)    Backfilling

       Material, compaction

6.3       Tolerance

(1)     Pipe elevation          :      1/500

(2)     Concrete pits elevation   :    亇10 mm

7.    SUBMITTALS

7.1   Material Data
       The following documents or specimens shall be submitted to PMC/CONTRACTOR for approval prior to     commencing any works to be concerned.

(1)   Complete materials list of all items proposed to be furnished and installed under this specification.

(2)   Manufacturer乫s specifications and other data required to demonstrate compliance with the specified requirements.

(3)   Manufacturer乫s recommended installation procedures which, when approved by PMC/CONTRACTOR, shall become the basis for inspecting and accepting or rejecting actual installation procedures used on the work.

(4)   Samples of materials for PMC/CONTRACTOR approval.

7.2   Working Procedure
       Working procedure shall be submitted to PMC/CONTRACTOR and shall include at least the following:

(1)     Working sequence and procedure of demolition, protection and re-building of existing facilities

(2)     Excavation and backfill

  (3)     Pipe installation, type of tool and equipment

  (4)     Joining between pipe and pipe, pipe and concrete.

  (5)     Handling, storing of pipes and other materials

  (6)     Detail of leak test

  (7)     Wrapping of underground pipe, repair of any damage to coatings and wrappings

7.3   Working Drawings
       Working drawings shall be submitted to PMC/CONTRACTOR and shall show at least the following:

(1)        Pipe fabrication drawings

(2)        Section of excavation

(3)        Detail of demolition of existing obstacles

    (4)    Detail of reinstatement of existing facilities

    (5)    Detail of protection of existing facilities

    (6)    Detail of temporary safety protection for the work

7.4   Report of Test and Inspection

(1)        Inspection report for materials

(2)        Report of leak test

7.5     Qualified Welders List

A list of welding personnel with their respective qualification records attached, shall be submitted to PMC/CONTRACTOR for written approval. Welding personnel shall include welders, welding operators, tackers and welding supervisors, and shall be qualified in accordance with Chinese Standard JGJ 81.