Professional Documents
Culture Documents
CONTENTS
SUB-SECTION 1
SUB-SECTION 2
132
SUB-SECTION 1
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TABLE OF CONTENTS
1.0
2.0
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
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1.1 Introduction
The works covered by this Technical Specifications and forming the Supply Extensions to
Burkina Faso Bittou & Haml involves the design, manufacturing, testing, supply,
transportation to site, off-loading, erection and commissioning of plant and equipment for
the supply of power to Bittou and Hamele in Burkina Faso.
1.2 Scope of Project
The project has been packaged into two (2) sections as follows:
Section 1:
Under this section, it is intended to construct a 20km line using 120mm2 ACSR on steel
towers, same as the subtransmission lines in the Northern Ghana. The sending end of the
line will be connected to the VRA network at Bawku Substation, through outdoor 34.5kV
switchyard and the receiving end will be terminated at the switching/metering station to be
constructed close to the CEPS check point in the Upper East border.
The Bawku Substation has indoor 34.5kV metal-clad switchgear panels. This comprises an
incoming line from Bolgatanga and then outgoing feeders to Dapaong (in Togo), Garu, and
then to a 34.5/11.5kV power transformer. The station also has 11.5kV distribution panels
for the networks in the Bawku Township and its environs and Auxiliary supplies.
Under this project, the Bawku Substation will be modified by constructing outdoor 34.5kV
switchyard complete with an incoming feeder, bus bars, outgoing feeders, and protection
and control panels. The incoming to the outdoor bus bar will be via an underground cable
from the existing panel that currently supplies communities located between Bawku and
Danvonga, all in the Upper East region including Garu. The outgoing feeders will serve
Garu (and the other communities), Bittou and provision of a spare breaker for future 34.5kV
supplies from Bawku.
The detailed scope of the works comprises:
Civil works associated with the above works including site survey, substation site
clearing, leveling, filling and compaction, equipment plinths, foundations, etc.
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Section 2:
135
Nandom in Upper West region is served by a 34.5kV steel tower subtransmission line from
Wa.
Approximately 15km, 34.5kV steel tower line using 120mm2 ACSR will be constructed from
the last steel tower line in Nandom to terminate at the switching/metering station to be
located close to the Ghana CEPS check post in the Upper West border.
The detailed scope of the works comprises:
2.0
Civil works associated with the above works including site survey, substation site
clearing, leveling, filling and compaction, equipment foundations, etc.
2.1
Bawku Substation
Additional site surveys necessary for detailed designs and erection of all works
under the project scope.
Detailed geotechnical investigations necessary for the design and construction of all
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2.2
Provision of construction site services, including but not limited to temporary water
supply, electric power, telephone and fax services, and sewerage system and site
toilets.
Provision of covered storage accommodation and site offices required for the
Contractor's plant, equipment and staff. The Contractor shall keep the sites clean
and tidy and shall remove all waste and surplus material daily to a location
designated by the Engineer.
Layout, supply, construct, equip and service accommodation for Engineer's staff.
Earthworks required for the construction of the station embankment including site
sterilization against weed growth and protection of embankment slopes.
Design and construction of the foundations for the 34.5kV outdoor equipment
including but not limited to switchgear and support structures.
Design and construction of all cable trenches and ducts, pits, tunnels and duct
banks.
2.3
Design and construction of the foundations and steel support structures for the
switching/metering and other related devices to include site survey necessary for the
erection works.
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SITE CONDITIONS
2.4.1
Site Visit
The Contractor is deemed to have visited the site prior to submission of Tender and
examined the existing site conditions under which the Contract is to be executed. The
Contractor is deemed to have acquainted himself fully with local conditions and
constraints, means of access to and from the site, services, the arrangement and
condition of the proposed Contractor's working and storage space accommodation
requirements and all other requirements for the proper completion of the Contract.
Failure to have fully investigated the site shall not relieve the Contractor of the
responsibility for estimating properly the difficulty or cost of successfully performing
the Works. Failure to have visited the site or to have obtained necessary information
is at the Contractor's own risk and responsibility and any claim for such failure will not
be considered.
2.4.2
Site Survey
The extent and existing levels of the Site for the new substation are shown on the
relevant drawings included in the Appendices to the Contract Documents. The
Contractor shall carry out any additional but relevant surveys that may be required for
the design and construction of the Project.
2.5
SOIL INVESTIGATION
Any reputable competent company to be tasked to carry out the Soil Investigations
shall do so with the approval of the Engineer. The Contractor shall be responsible for
acquainting himself with local standards regarding Geotechnical criteria. The soil
investigation shall be carried out in accordance with BS 5930 or other approved
standard. A copy of the soil investigation report shall be submitted to the Engineer.
Acceptance by the Engineer of the soil investigation report shall in no way relieve the
Contractor of his sole responsibility with regard to the stability and safety of his
design.
2.6
METEOROLOGICAL DATA
General meteorological data for the site is summarized below. The Employer does not
accept any responsibility for the accuracy and correctness of the data supplied and it
shall be the responsibility of the Contractor to establish all the meteorological data
deemed necessary for the satisfactory design and construction of the facilities. The
climate at the site is tropical and semi arid.
The following data is indicative of the climatic conditions.
Ambient air temperature
400C
100C
300C
Relative Humidity
70 - 95%
Barometric Pressure
1034.6
1000.5
maximum
minimum
average (annual)
Maximum
mbar maximum
mbar minimum
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1010.4
mbar average
Wind Velocity
34 m/sec
Rainfall (normally occurs during the wet season)
Maximum
Minimum
Average
Maximum No. of Rainfall Days per year:
Maximum No. of Thunder Storm Days per year:
2.7
SITE PREPARATION
2.7.1
Site Clearance
maximum
1414.3 mm/year
333.1 mm/year
799.6 mm/year
126 days occurring mainly in
the wet season.
129 days occurring mainly in
the wet season
The Contractor shall be responsible for all clearance and other work required for
preparation of the site.
The Contractor shall clear the entire substation site of all trees and shrub. In addition the
Contractor shall grub up tree stumps and roots from the site completely and burn or
otherwise disposed off as directed by the Engineer.
Following site clearance, the site shall be excavated throughout, down to at least
150mm below existing natural levels or as otherwise directed by the Engineer.
Excavations resulting from grubbing and uprooting big trees shall be filled with approved
material in layers not more than 250mm loose thickness and each layer shall be
compacted to the same density as that of the adjoining ground but in any case not less
than 95% of the materials, optimum dry density.
2.7.2
Anti-Termite Treatment
Visible Termite Presence
Where the presence of termites is indicative, termite nests shall be searched for, and if
any is found, it shall be opened at the top, the Queen extracted and destroyed. The
nests shall then be treated with an anti-termite chemical approved by the Engineer and
the Environmental Protection Agency, (EPA). The chemical shall be applied strictly
according to the directives of the manufacturer. Nests and surrounds shall be removed
2 to 3 days after treatment and the area excavated and material removed to a depth not
more than 500mm. This treatment shall be carried out in addition to the treatment for
No Termite Presence as specified below.
No Termite Presence (Termite presence not indicative)
After removal of the vegetative top soil, the resultant top soil of the entire project site
shall be loosened to a depth not less than 250mm and the loose soil treated with an
anti-termite chemical approved by the Engineer and the Environmental Protection
Agency (EPA). The chemical shall be applied strictly according to the directives of the
manufacturer. The loose soil shall then be compacted back into place before the
formation of embankment commences.
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The embankment, its slopes and drainage facilities shall all be within the boundaries
of the site depicted by the benchmarks provided on the site plan included in the
enquiry drawings.
For the purpose of pricing for the embankment works the contractor shall assume
the substation grade level to be 200mm below existing ground levels. Depending on
the soil conditions on site the Engineer may direct the contractor to excavate below
the grade level to provide a sub-grade course. The cost of such additional works
shall be paid for under a provisional sum based on unit rates provided in the
contract.
The embankment shall have layers of sub-base and/or base materials compacted in
accordance with clause 2.2 of General Specification for Materials and Workmanship
as follows:
300mm thick approved laterite base course well compacted on top of the subbase.
Apart from taking geotechnical considerations of stability and strength into accounts,
the thickness of the sub-base shall be such that the final level of the compacted
base course of the embankment shall not be less than 300mm above the existing
natural ground level at any point.
Starting from the centre-line along the longer side, the top of the embankment shall
be given a 1% slope towards the side drains.
The side slopes of embankment shall not be steeper than 1:2 (vertical: horizontal)
and shall be protected from erosion by stone pitching.
The top and bottom peripheral edges of the embankment shall be protected with
250mm thick concrete strip and toe respectively.
The yard shall be finished with 100mm thick 25 - 50mm broken stone or chippings.
The embankment shall be designed for the more onerous effects of:
-
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2.7.4
140
The contractor shall submit a detailed geometric and geotechnical design of the
substation embankment, based on the requirements of this specification, for
approval by the engineer before starting the construction.
The contractor shall arrange for continuous field geotechnical testing of each layer of
the embankment to ensure compliance with the requirements of this specification
and the approved geotechnical designs.
Site Sterilization
The top surface and side slopes of the embankment shall be sterilized by the application
of a chemical mixture to prevent weed growth.
The sterilization mixture shall be subject to the approval of the Engineer and the
Contractor shall provide an approval letter from the Environmental Protection Agency
(EPA) Ghana, authorizing its use.
The area to be treated shall be uniformly covered with the mixture at the rate
indicated by the manufacturer.
The area treated shall be wetted immediately following the application so as to cause
penetration into the surface or as directed by the manufacturer.
All surfaces of the embankment shall be sterilized as specified above, and in the case of
the side slopes, before stones are pitched thereon.
2.8
2.9
2.9.1
DESIGN REQUIREMENTS
Design Criteria
Design of the works shall be based on the following standards or their equivalent:
Foundations:
Structural Concrete:
Structural Steelworks:
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2.9.2
141
Liquid Retaining
Structures (Concrete)
Blockwork/Brickwork:
Seismic Design:
Sound Insulation:
Loads
General
Buildings, equipment foundations, support and ancillary structures shall be designed
for the worst combination of dead loads, construction loads, live loads, plant loads,
impact and dynamic effects due to operation of plant, crane loads, short circuit forces,
maintenance loads, earth pressure, wind loads, seismic loads, temperature effects,
etc.
Dead Loads:
Dead loads shall include all loading due to the self-weight of all
permanent structural and non-structural components such as
columns, beams, foundations, floor slabs, walls, partitions,
finishes, cladding, etc.
This shall include loading due to installation of plant equipment
Loads:
Live Loads:
All live load values proposed for the design shall be subject to the
approval of the Engineer.
Live loads in equipment areas shall include plant/equipment loads
and circulation/access loading. Plant/equipment loading
conditions associated with assembly and maintenance activities in
combination with circulation/access loading shall be considered
and the worst condition adopted for design.
Stairs and access platforms not subject to assembly /maintenance
2
loads shall be designed for a live loading of 3kN/m .
Tunnels and covers to trenches, pits, manholes in roads, loading
bays, etc., shall be designed for the more onerous effects of:
-
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Seismic Loads:
All structures shall be designed for seismic loads in accordance with the
Uniform Building Code published by International Conference of Buildings
Officials, California, USA.
The following criteria shall apply:
Analysis
Quasi-static approach
Acceleration
0.2g (m/sec )
Loading Combinations
1. Dead Load + Live
2. Dead Load + Wind Load + 50% Live Load.
3. Dead Load + 50% Wind Load + Short Circuit
Forces
4. Dead Load + Seismic Load without Wind.
Temperature
2.9.3
Design by Tenderer
The Tenderer shall submit with his Tender a design portfolio, which shall include at
least the following items:
.
An account of the design method proposed for use for each part of the
Works; design criteria used (loading, permissible stresses and such like);
assumptions in respect of foundations.
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Tenderers shall submit with their Tender, details of the qualifications and experience
of the senior staff to be employed on the design. The Contractor shall notify the
Engineer and obtain his approval of any change of designer during the course of the
Contract.
2.9.4
Design by Contractor
Experienced and competent engineers shall carry out the design of the Works. The
design shall be consistent with the highest professional standards of skill, care and
diligence.
The Contractor shall be entirely responsible for the adequacy of the design of the
Works, notwithstanding any approvals given or comments made by the Engineer in
respect of the designs, drawings and calculation submitted by the Contractor.
2.9.5
Calculations
Calculations shall be produced in accordance with the relevant procedures as
described in the Contractor's Quality Control/Assurance Manual approved by the
Engineer.
All design calculations shall be submitted to the Engineer for his approval.
Calculations shall be in English and submitted in duplicate and shall be accompanied,
if requested, by two English language copies of Standards and Codes of Practice
used and approved by the Engineer. Approval by the Engineer of any calculations
shall not relieve the Contractor of responsibility for that calculation or for the safety,
suitability and adequacy of any part of the Works designed in accordance with that
calculation.
The Contractor is at liberty to use any software/programme in the design of the works.
However, the contractor shall clearly explain the design procedure (input, output,
parameters etc) used in the calculations by the software /programme to enable
checking of the designs. Computer printouts that do not allow interpretation of results
or explain the design procedure will be rejected and the calculations considered as
not submitted.
Before being submitted to the Engineer for approval, all calculations, including
computer printouts, shall be checked by an engineer in the design office of the
Contractor, who shall be of similar competence to the originator of the calculations.
The originator shall not act as the checker of his own work.
2.9.6
Drawings
All drawings shall be produced in accordance with the relevant procedures as
described in the Contractor's Quality Control/Assurance Manual approved by the
Engineer.
All drawings shall be submitted to the Engineer for his approval before construction
commences either in part or whole. Drawings shall be in English and shall be
submitted in duplicate, together with a reproducible copy. Approval by the Engineer
shall not relieve the Contractor of responsibility for the safety, suitability and adequacy
of any part of the Works.
Drawings and other documents shall satisfy the following requirements, where
appropriate, before they are submitted to the Engineer for review:
The contractor shall ensure that all drawings submitted to the Engineer for review
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2.9.7
Submissions
The detailed design, including calculations and drawings, for all the works to be
carried out, shall be submitted to the Engineer for approval. Such submissions shall
be in accordance with an approved programme.
Submissions shall be made in an orderly and timely manner, during the periods
shown for design approval in the Works Programme, such that the Engineer shall
have adequate time for their detailed examination and for checking and approving any
necessary revisions. A period of one month shall be allowed for the Engineer's
checking and approval of any design submission from date of receipt of submission to
date of notification of approval or comments.
In programming submissions the Contractor shall allow for the possibility that a
resubmission may be necessary before the start of any part of the Works.
Each design submission shall be serially numbered and dated and shall refer to one
subject matter only. Each submission shall be accompanied by a summary sheet,
which lists the documents comprising the submission. Where a submission includes
revisions of documents previously submitted the summary sheet shall include a
reference to the original submission number.
2.9.8
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which will be prepared during the period of the Contract and the anticipated
numbers thereof. The list shall be updated as necessary and the status of each
drawing/document shall be indicated under one or other of the following heading:
-
All changes and modifications to the Master Drawing Files and the Master
Technical Instruction Files shall be highlighted in red markings.
2.10
FOUNDATIONS
2.10.1
General
Foundations and support structures shall be provided for buildings, transformers,
switchgear, and other equipment specified for the project as appropriate.
All foundations shall be designed in accordance with BS 8004 or similar approved
standard.
The detailed design of all foundations shall be the responsibility of the Contractor.
Foundations shall be designed based on the stress resultants obtained from analysis
of the worst combinations of loading and on the serviceability requirement of the plant
and buildings. The Contractor shall submit design calculations and working drawings
for all foundations to the Engineer for review and approval prior to commencement of
construction. Acceptance by the Engineer shall in no way relieve the Contractor of his
sole responsibility for the adequacy of the foundations. The derivation of static and
dynamic loading used in the design shall be in line with the recommendations given in
Part 1 of CP 2012 or similar approved standard.
All precautions for limiting and isolating vibrations shall be taken. Vibrations shall not
have any harmful effects on adjacent structures or processes. For all equipment
foundations subject to vibration the foundation shall be cast in a continuous single
pour with no cold joints. The Contractor shall include for approval, methods of curing
such foundations.
Where the ground is excavated, for any reason, below the underside of the proposed
foundation the void shall be filled with concrete to the approval of the Engineer.
The depth of foundations shall be determined based on the recommendations of the
geotechnical investigations conducted by the contractor and approved by the engineer
but in any case shall not be less than 700mm from the top of the compacted base
course.
All foundations shall be reinforced with steel and where not required on the basis of
the calculations, nominal reinforcement shall be provided.
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2.11
DRAINAGE SYSTEM
2.11.1
146
Rainfall run-off and general drainage of the substation yard shall be carried by
appropriately sized reinforced concrete perimeter open channel drains to an
appropriate outfall not less than 15m from the edge of the substation embankment and
as shall be approved by the Engineer.
To prevent possible flooding of the station in extreme precipitation conditions, e.g. 50year return period flood, the final level of the compacted laterite base course of the
substation yard embankment shall be at least 0.3m above existing ground levels of the
adjoining areas.
Cable trenches shall be provided with adequate slopes and their invert levels shall be
such that the trenches can drained through an appropriately sized uPVC pipes into the
nearest point in the perimeter drains where gravity flow can be achieved.
In order to prevent flow of water into the control buildings, cable trenches shall be
sloped and drained away from the control building. In addition, the design of the cable
entry into the control room shall be such that they are as much as possible, water and
air tight.
Appropriately designed french-drains to direct run-off to the perimeter drains shall be
provided to drain off substation yard areas cut-off by cable trenches.
2.11.2
Catchment Drainage
The engineer in conjunction with the contractor shall study the project site and
determine the need to provide additional drainage to divert runoff from the catchment
area away from the substation. When it is determined that catchment drainage is
required to minimize the risk of the substation against flooding the engineer shall liaise
with the local planning authority and provide a suitable design for construction by the
contractor. The cost of construction shall be paid using the provisional sum earmarked
for such work based on the unit prices provided by the contractor in its Tender price.
2.12
WATER SUPPLY
Only potable water shall be used for construction and shall be supplied to the site by
the Contractor in tankers and kept in water storage facilities which shall be provided on
site to meet constructional requirements at all times.
2.13
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duct banks, special designs shall be incorporated to prevent damage to such services.
The design and construction of driveways shall take full account of the information
provided by the Site Investigation and embankment soil test results. There shall be no
special treatment required for areas earmarked for driveways other than that which is
required for the general finishing of the entire substation yard.
The conceptual layout of the roads is shown on the conceptual drawings. The final
layout shall be determined by the Contractor in accordance with this Specification and
to the approval of the Engineer.
2.14
2.9.1
Yard Surfacing
The yard surface is defined, as any area of the site not occupied by buildings,
foundations, cable ducts, or by other structures or equipment.
The substation embankment shall be restored to its level of compaction /consolidation
and design slope after equipment foundations and grounding mat have been backfilled
and well compacted.
The yard shall then be finished with a 100mm thick course of 25-50mm broken stones
or chippings.
2.9.2
Fencing
The boundary fence and entrance gates shall be made of galvanized steel chain-link
fencing and galvanized steel pipes as specified in the General Specification for
Materials and Workmanship. The height of the fence and the gates shall be 1.90m
vertical with a further 0.5m extended outwards from the site at 450 on to which 3 No.
rows of barbed wire shall be fixed as specified in this specification. The mid-sections of
the fence shall be kept taut by the introduction of steel stiffeners.
Fence posts shall be of galvanised tubular steel of diameter 50mm for intermediate
posts and 75mm for angle and tensioned posts, 3.0 metres apart, on the average
centres. The fence posts shall have concrete foundations projecting 100mm above the
finished laterite level but flushing with the top level of the crush rock. The top of the
concrete foundations of the steel pipes shall be cambered to prevent water stagnations
that might lead to rusting.
The vehicular and pedestrian gates shall be plastic coated chainlink with galvanized
steel frames/posts of type, size and strength to be approved by the Engineer.
The widths of the vehicular and pedestrian gates in fully opened position shall be 5.0m
and 1.0m respectively. Where, feasible, vehicular gates shall be provided at both the
entrance and exit points of the fence with respect to the substation access road.
2.15
148
Primary Cable trench serving as the main cable collector to the control building.
Secondary Cable trench normally feeding cables at right angles into the primary
trench.
2.15.2
Duct Banks
2.15.2.1
Materials
Pipes shall be in accordance with the following standards:
uPVC Pipes
2.15.2.2
BS 3505, BS 4660
Installation
Ducting shall be by 100mm diameter pipes minimum laid on sand bedding at least
450mm deep from the compacted laterite level from equipment to the nearest
secondary cable trench. Separation between the pipes shall be 80mm minimum.
They shall be laid true to line and level, and all joints shall be accurately formed in
accordance with manufacturer's instructions. After installation, each duct shall be
thoroughly cleaned by water, air, rodding or other approved method. The duct shall
also be proved by drawing a mandrel through it. The diameter of the mandrel shall
be 95 % of the internal diameter of the duct.
2. 15.2.3
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2.16
Reception
Conference room that can provide seating for 10 persons furnished with one (1)
No. large Conference Desk, size 3000(L) x 900(W) x 750(H), Fifteen (10) No.
office chairs size 400(W) x 400(L) x 800(H).
An office that can accommodate three (3) persons furnished with one (1) Airconditioner, one (1) Refrigerator 100 litres. It shall also be furnished with three
(3) No. Normal desks size 1500(L) x 800(W) x 750(H) with two (400 x200) right
side drawers and three (3) No. Office Chairs size 600(L) x 500(W) x 900(H) with
arm rests.
Kitchenette
Toilet Facilities
The Contractor shall be deemed to have included in his Tender, a sum for the
purpose of supplying equipment to the Engineer's office and for supplying logistics
for holding site meetings and refreshing participants during and after each meeting.
The total sum allocated shall be approved and expended by the Engineer.
2.17
These plans shall be filed with the Engineer and shall be revised and updated
periodically as required by the Engineer. The requirements of these plans are set
out in various clauses of this section of the Specification.
2.17.1
Site Security
The Contractor shall submit for the Engineer's approval a Site Security Plan showing
how he proposes to comply with the provisions of the Contract. The Contractor shall
comply with the Employers Security Regulations for the time being in operation and
shall instruct all persons employed on the Works regarding same.
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2.17.2
150
2.17.3
Site Sanitation
The Contractor shall provide and maintain to the satisfaction of the Engineer's and
the Statutory Authorities, adequate latrines and wash places for his employees on
various parts of the site, together with arrangements for sewage disposal and
drainage. When no longer required, the Contractor shall remove such latrines and
wash places, disinfect and fill in all pits, sumps and trenches and restore the sites to
a clean and sanitary condition. The Contractor shall pay any charges, which may be
levied by the Statutory Authorities.
The Contractor shall submit for the Engineer's approval a Site Sanitation Plan
showing how he proposes to comply with the provisions of the Contract.
2.17.4
Site Safety
The Contractor shall administer and control his site activities in a manner conducive
to the achievement and maintenance of adequate safety for the public, his
employees, his Sub-Contractors and their employees, the Employer and his
employees and the Engineer and his employees. This shall include regular
inspection of all temporary installations and portable tools and equipment.
Particular attention shall be paid to safe storage of combustible and explosive
materials.
The Contractor shall submit a Site Safety Plan setting out the Contractor's safety
policy and the proposals of the Contractor to ensure that such a policy is put into
effect during the period of the Contract. The Contractor shall inform himself of the
Employer's safety procedures and shall furnish a statement of his commitment to
work according to these procedures.
In particular, the contractor shall provide all the required safety ware and
identification tags for all his employees, his Sub-Contractors and their employees,
the Employer and his employees and the Engineer and his employees.
The Engineer shall have power to stop the works if in his opinion they are being
undertaken in an unsafe manner. All expenditure required and necessary for
carrying out the works in a safe manner approved by the engineer shall be deemed
to be included in the lump sum price provided in the schedule of prices.
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2.17.5
151
Safety Regulations
The Contractor shall instruct all persons employed on the Works regarding the
safety regulations of the Volta River Authority (VRA) and any other applicable
authority for the time being in operation on the site and all warnings issued regarding
operating plant, towers and the overhead lines and cables. He shall take all
necessary precautions and actions to comply with the regulations and shall provide
all necessary barriers and height gauges in such approved forms and positions as
directed by the Engineer. It is recommended that the Contractor pay particular
attention to these procedures, which will require detailed planning and co-ordination
of site works by the Contractor and will involve certain restrictions on the
Contractor's method of working.
2.17.6
2.17.7
2.17.8
Safety Officer
During the erection phase, the Contractor shall employ a personnel qualified in
safety and familiar with the type of work being performed, whose assignment shall
include initiation of measures for the protection of health and the prevention of
accidents and who shall see by personal inspection, that all safety rules and
regulations are enforced.
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SUB-SECTION 2
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CONTENTS
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
EARTHWORKS ........................................................................................................................154
STATION EMBANKMENTS .....................................................................................................159
CONCRETE WORKS ...............................................................................................................159
STRUCTURAL STEELWORK..................................................................................................179
WATER SUPPLY......................................................................................................................189
DRAINAGE WORKS ................................................................................................................190
MASONRY................................................................................................................................193
CARPENTRY AND JOINERY ..................................................................................................199
METALWORK ..........................................................................................................................202
BOUNDARY WORKS...............................................................................................................204
LIGHTING AND LOW VOLTAGE POWER ..............................................................................205
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2.1
EARTHWORKS
2.1.1
Excavation
2.1.1.1
General
154
Excavation Level
Foundations for structures shall be carried down to sound and undisturbed material,
to levels not higher than shown on or inferred from the Contract Drawings.
The drawings shall show, as near as it is possible and practicable to determine
beforehand, the depths for the proposed excavations, but such limits shall be finally
determined during construction.
2.1.1.3
Foundation on Rock
The excavated rock surface at foundation level shall be free of shattered or loose
particles of rock and shall be washed free of clay, silt and rock chippings etc., with an
air and water jet immediately before concreting begins.
2.1.1.4
2.1.1.5
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Exposed faces of the excavations shall be cleared of all material (including rock
fragments), which are liable to cause injury or damage by falling during the course of
the work. The Contractor shall take all precautions necessary for the safety of
adjoining structures by shoring, opening in short lengths, or otherwise. Excavations
shall be kept free from water until, in the opinion of the Engineer, the works therein
(including backfilling) will not be damaged by water, and the Contractor shall construct
any sumps or temporary drains which the Engineer may deem necessary for this
purpose. The excavations shall be of sufficient size to enable the work therein to be
properly executed, and shall allow for the supports, drainage facilities, and other
things required for this purpose.
In the event of excavations being carried out wider or deeper than approved they shall
be filled in to the required dimensions or levels with concrete or with other suitable
material, to the satisfaction of the Engineer.
2.1.1.6
2.1.1.7
2.1.2
Fill
2.1.2.1
Fill Classification
Fill shall be obtained from locations suitable for winning such material. The Contractor
shall inform the Engineer of the source from which he proposes to obtain fill matter.
Prior to approval of the source of the material, the Contractor shall carry out such tests
on samples of material as the Engineer may require ensuring that the material is in
accordance with this Specification. Only fill approved by the Engineer shall be used.
Fill shall be classified as follows:
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a)
b)
c)
d)
e)
f)
(a)
156
Soft Fill
Rock Fill
Rock Armouring
Hard Fill Type I
Hard Fill Type II
Hard-core
Fill for Transformer Pits
Soft fill shall be classified as plastic or non-plastic. Non-plastic materials shall be
those described as coarse soils or very coarse soils in Table 6 of BS 5930.
Plastic materials shall be all other materials described as "fine soils in the
above-mentioned table. Soft fill shall be placed at moisture content, which shall
be to the approval of the Engineer.
(b) Rock fill shall be hard durable rock free from dirt, earth loam, clay or organic
matter of such size and properties that it can be placed in layers as described in
this Specification. Soundness of won rock shall be tested by water absorption
test.
The stones shall not be more than 300mm or less than 50mm in any direction;
60% of the stone shall be between 200mm and 300mm in size.
(c)
Rock armouring shall be quarried and shall be hard dense stone of the best
quality obtainable, tested in accordance with the slake durability test specified by
the international Society for Rock Mechanics and shall be obtained from quarry
faces approved by the Engineer. The stone shall be prismoidal in shape and the
maximum dimension of any stone shall not be more than three times the
minimum dimension. Stone which has a tendency to fracture when dropped on
stone already placed shall be rejected.
(d)
Hard fill Type I shall be selected hard well graded material screened and
crushed as necessary to lie within the following grading of percentage by weight
when tested in accordance with BS 1377: Test 7A:
0 - 20% shall pass 75-micron aperture sieve
8 - 45% shall pass 600-micron aperture sieve
20 - 65% shall pass 5mm-aperture sieve
45 - 100% shall pass 10mm aperture sieve
85 - 100% shall pass 37.5mm-aperture sieve
100% shall pass 1 00mm aperture sieve
Free of stone over 75mm gauge.
Hard fill Type II shall be selected hard granular material with not more than 7%
by weight water soluble and shall be within the following grading of percentage
by weight:
Not more than 10% shall pass 90-micron aperture sieve. Not more than 28%
shall pass 355-micron aperture sieve. Not more than 50% shall pass 4mmaperture sieve. Free of stone over l50mm gauge.
(e)
Hard core shall consist of broken stone, concrete brick or coral varying in size
from 100 to 25mm. It shall be free of clay, soft material and deleterious matter
and shall be chemically inert.
(f)
Fill for transformer pits shall be broken stone graded 50 to 75mm with a
minimum of 40% voids when placed.
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2.1.2.2
157
Filling
2.1.2.2.1 General
Fill under all foundations and slabs shall be mechanically compacted at the optimum
moisture content. The minimum degree of compaction shall be of the maximum dry
density at the optimum moisture content. In situ density testing shall be carried out in
accordance with BS 1377 Test 15.
Backfilling of foundation pits and trenches shall be carried out only after the foundation
and structural works within the excavations have been inspected and approved by the
Engineer. All filling shall consist of approved materials, which shall be deposited and
compacted, in layers not exceeding 250mm loose depth. All filling shall be carried out
in a manner approved by the Engineer.
Filling of pipe trenches and associated excavations shall not commence until the
permission of the Engineer has been obtained.
Fragments of rock not exceeding 200mm in any dimension may be permitted in the fill,
provided that they are surrounded by fine material graded so as to ensure the
compaction of the fill without voids.
2.1.2.2.2 Soft Fill
Soft fill shall be placed at moisture content, which shall be to the approval of the
Engineer. In the case of plastic material, this moisture content shall be not more than
2 percent above the plastic limit for the material and in the case of non-plastic
material, it shall be within 2 percent of that of the material as excavated above the
water table. Soft fill shall be spread in layers of 200mm loose thickness and
compacted by eight passes of a 10 ton roller or such other approved plant and
methods to give 95% maximum dry density as determined in accordance with BS
1377, Test No.13 or 14.
2.1.2.2.3 Rock Fill
Rock fill shall (except where otherwise required near formation level or at external
surfaces) be of such size that it can be spread and levelled in layers not exceeding
450mm loose depth by a tractor weighing not less than 15 tonnes. Voids in each layer
shall be filled with rock fragments before placing the next layer. Each layer shall be
compacted after spreading by at least 12 passes of a towed vibratory roller with a
static mass per metre width of roll of at least 1800kg or other equivalent plant
approved by the Engineer.
Where material consisting of a mixture of rock and soft fill if used as filling, the material
shall contain sufficient soft fill for satisfactory compaction of the filling to the
satisfaction and approval of the Engineer.
2.1.2.2.4 Hard Fill
Hard fill Type I and Type II shall be placed in layers not exceeding l50mm and 300mm
respectively at optimum moisture content and compacted to 95% maximum dry
density as determined in accordance with BS 1377, Test No. 13 or 14.
Hard core shall be compacted in layers not exceeding 200mm thick.
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158
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2.2.
159
STATION EMBANKMENTS
Embankments shall be constructed in accordance with Clause 1 - Earthworks. Fill
material shall be strictly in accordance with the Engineer's direction and approval.
Embankments shall be constructed according to the lines and levels indicated, with
machines of the proper type and weight.
Compaction shall be carried out in layers of 200mm maximum thickness and no layer
shall be placed until the preceding one has attained the specified compaction ratio, i.e.
95% maximum dry density at Optimum Moisture Content.
Compaction shall be tested both on site and on samples taken from the embankment.
2
Tests shall be carried out in the number of three per 1000m , points of testing being
chosen at random by the Engineer.
2.3.
CONCRETE WORKS
2.3.1
2.3.2
Cement
Cement used in the works shall be in accordance with the following standards, BS 12
Ordinary Portland Cement, BS 4027 Sulphate Resisting Cement. Cement shall be
from a source approved by the Engineer.
2.3.2.1
Certificates
Each consignment of cement shall be delivered in sealed branded bags, barrels or
other approved container and shall be accompanied by a certificate from the
manufacturer showing that the cement has been tested and analysed and the date of
such tests and analysis and that such analysis complies in all respects with the
Standard and if required, the bags from each consignment shall be given a distinctive
seal.
2.3.2.2
2.3.2.3
Stock of Cement
In order to ensure due progress of the Works, the Contractor shall at all times maintain
on the Site a stock of cement sufficient to ensure continuity of work. No cement shall
be used in the Works until the Engineer has accepted it as satisfactory.
2.3.2.4
Returns
The Contractor shall make a monthly return to the Engineer showing the quantities of
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160
cement received and used during the month and in stock at the end of the month.
2.3.2.5
2.3.2.6
Rejection
The Engineer may reject any cement as the result of any test thereof notwithstanding
the manufacturer's certificate. He shall also reject cement, which has deteriorated
owing to inadequate protection or other causes or in any other case where the cement
is not to his satisfaction. The Engineer may reject cement, which has been stored on
site for a period greater than one month. The Contractor shall remove all reject
cement from the Site without delay and replace at his own expense.
2.3.3
2.3.3.1 General
Except as may be modified hereunder, the aggregate (fine and coarse) for all types of
concrete shall comply in all respects with BS882 "Concrete Aggregates from Natural
Source" or other approved standard. They shall be hard, strong and durable and shall
contain no harmful material in sufficient quantity to affect adversely the strength or
durability of the concrete, to attack the reinforcement. The maximum size of coarse
aggregate shall be 20mm for all concrete mixes.
2.3.3.2
Source of Aggregates
The source of aggregates shall be approved by the Project Manger and shall be open
to his inspection before the start of the Works and during their progress. Aggregates
shall be naturally occurring materials.
2.3.3.3
Physical Requirements
Fine and coarse aggregates shall comply with the following physical requirement:
(a)
(b) The clay, fine salt and dust content shall not exceed the following limits:
Coarse Aggregates
Natural Sands
Crushed Stone Sand
(c)
1% by weight
3% by weight
6% by weight
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161
accordance with BS 812 shall not exceed 25% and 35% respectively.
(d)
2.3.3.4
(e)
(f)
Fine aggregates shall be clean, sharp, coarse sand and shall be within Zones 2,
3 and 4 only of Table 2 of BS 882.
(g)
Chemical Requirements
Aggregates shall comply with the following chemical requirements:
2.3.3.5
(a)
Fine and coarse aggregates shall not contain more than 0.10% and 0.04% by
weight of chlorides (as NaCI) respectively. If either material exceeds the above
limits, the material shall still be acceptable in this respect provided the total
sodium chloride concentration is not greater than 0.50% by weight of cement in
the mix for reinforced concrete, irrespective of the origin of the chloride.
(b)
Fine and coarse aggregates shall not contain more than 0.4% by weight of acid
soluble sulphates (as SO3).
(c)
Fine and coarse aggregates shall not be potentially reactive with alkalis.
Aggregates to be washed
If necessary all aggregates, both fine and coarse, shall be washed mechanically by
the Contractor to remove clay, silt, dust and adherent coatings to the satisfaction of
the Engineer.
2.3.3.6
C 289
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SUPPLY EXTENSIONS TO BURKINA FASO
C 586
2.3.3.7
162
aggregate combinations
Standard Method of test for potential alkali reactivity of carbonate rock for
concrete aggregates (rock cylinder method).
Approval of Aggregates
As soon as practicable after commencement of the Contract and well in advance of
commencing concreting, the Contractor shall submit to the Engineer test results on
samples of all aggregates he proposes to use in the Works. The Engineer shall
require inspecting the sources of the proposed aggregates to be satisfied that the
proposed methods of working, the sources and the arrangements for washing shall
produce aggregates of regular quality complying with this Specification.
No aggregates for use in the Works shall be delivered to Site until the Engineer has
approved the aggregates to be used and the arrangements for washing, storage and
such like. Thereafter, the Contractor shall take samples from every 100 cubic metres
of each type of aggregate delivered to the site and submitted to the Engineer for
routine control tests.
Aggregates, which fail to comply with this Specification, or which have become
contaminated, defective or otherwise unsatisfactory, shall be removed from Site or
otherwise disposed of to the Engineer's satisfactions.
2.3.3.8
Storage of Aggregates
The Contractor shall at all times maintain on the Site such quantities of each type of
aggregate as are considered by the Engineer to be sufficient to ensure continuity of
work.
Each type and grading of aggregate shall be stored separately in bins, the floors of
which shall be of concrete or other approved material, having sufficient slope to
ensure adequate drainage.
Wet aggregate delivered to the Site shall be kept in storage for at least 24 hours, to
ensure adequate drainage, before being used for concreting.
Aggregates, which have been in storage for a long period, shall be removed from the
bins and rewashed by the Contractor, if required by the Engineer, to remove any
accumulation of dust, silt and deleterious substances.
2.3.4
Water
The mixing water shall have a pH value of between 6.5 and 8. Water shall be tested in
accordance with BS 3148 - the following limits shall not be exceeded:
Total Dissolved Solids
Suspended Solids
Chloride as NaCl
Chloride as Cl
Sulphates as SO3
Alkali HCO3/CO3
The methods of delivery and storing the water shall be to the approval of the Engineer.
2.3.5
Admixtures
Admixtures may only be used in concrete mixes with the prior approval of the
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163
Engineer. The use of admixtures, where permitted, shall be in accordance with the
provisions of BS 8110, Part 1.
Admixtures shall comply with ASTM Standard C 494, BS 5075 or other Standard
approved by the Engineer.
Admixtures for which no approved standard exists shall be identified by type and
proprietary brand name. The Contractor with his Tender shall submit proposal for the
use of such admixtures.
Admixtures shall be stored and handled so as to avoid contamination or damage to
their properties and in accordance with the manufacturer's recommendations.
2.3.6
Production of Concrete
2.3.6.1
Concrete Grades
Grade A
Grade B
Grade C
For the purposes of the above, the ground level in the concrete structure shall be as
designated by the Engineer.
2.3.6.2
(Ordinary
(Sulphate
(Sulphate
Portland)
Resisting)
Resisting)
370kg/m
220kg/m3
20mm
20mm
2.3.6.1)
Cement Type to ASTM C150-83a
Minimum Cement Content
Nominal Maximum Size of Aggregate
Maximum Water Cement Ratio
Characteristic Cube Strength at 28
350kg/m
20mm
0.45
0.42
2
25N/mm
0.42
2
30N/mm
15N/mm2
days
The concrete grades to be used in various parts of the Works shall be stated on the
Drawings and approved by the Engineer. Concrete grade and cover to reinforcement
shall be appropriate for the environmental conditions to which the concrete will be
exposed.
2.3.7
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164
Works.
The requirements to perform trial mixes as described below may be relaxed by the
Engineer on production of satisfactory evidence of trial mixes previously approved
using the same materials in the same proportions.
When the proposed mixes have been approved, they shall not be altered without the
written permission of the Engineer. If the Contractor shall apply for such permission,
the Engineer may require a repetition of the trial mix procedure.
The proportions of fine to coarse aggregate, cement to combined aggregate and the
water/cement ratio shall be determined by tests carried out in accordance with the
recommendations set out in "Design of Normal Concrete Mixes" published by HM
Stationery Office, London, or any other equivalent Standard to be approved by the
Engineer, so as to give concrete of the required strength and of the highest possible
density. In all cases, the water/cement ratio shall be the minimum practical, having
regard to the conditions of handling and placing and the necessity of achieving proper
compaction.
The Contractor shall make trial mixes using the approved material, the plant used for
these trials being, if possible, the plant which shall be used in the Works.
Three 150mm test cubes shall be made from each of three consecutive batches of
each mix proposed for the various grades of concrete and maximum sizes of
aggregate. The cubes shall be made, stored and tested at 28 days in accordance with
BS 1881. A further three cubes shall be taken from each batch for tests at 7 days. The
trial mix proportions shall be approved for strength if the average crushing strength of
each group of nine cubes exceeds the values for 7 day and 28 day (characteristic)
strength given in Table 7.1 BS 8110: by minimum of 35%.
The workability of trial mixes shall be tested in accordance with IBS 1881 using
samples obtained from the batch used for the test cubes. In addition concrete from
each trial mix, taken from the batches used for the test cubes, shall be placed and
compacted by the methods proposed for the Works. in a trial section of formwork
having a capacity of not less than 0.5m3 and representative of the sections to be
employed in the Works.
The Contractor shall submit full details of the trial mixes and test results and of the
mixes proposed for use in the Works, which must be based on the satisfactory results
of these preliminary tests and on the methods of mixing and placing the concrete in
the Works.
The Contractor shall be responsible for ensuring that the concrete conforms in all
respects with these Specifications, notwithstanding any approval given by the
Engineer to any mix proportions. If during the progress of the Works the Engineer is
not satisfied with the strength, workability or other properties of the concrete, he may
order the Contractor to provide additional cement, change the aggregates or vary the
grading and the Contractor shall immediately comply with such order and shall have
no claim for any expense or loss of time, occasioned by compliance with these
provisions.
The cost of all sampling and testing associated with this clause shall be borne by the
Contractor.
2.3.8
Mixing of Concrete
Aggregates shall be weighed in their separate sizes in accordance with the approved
mix design and the weights shall be corrected to allow for the free water contained in
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165
Ready-Mixed Concrete
Subject to the approval of the Engineer, the Contractor may elect to use ready-mixed
concrete.
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166
The name and address of the Works of the proposed Supplier shall be submitted to
the Engineer at least 6 weeks before concrete is scheduled for delivery, together with
a copy of the agreement between the Contractor and Supplier, details of the mixes
proposed, specifications and all other documents relating to the supply of concrete
and details of alternative supply arrangement in the event of failure of supply from the
proposed Supplier.
Details of the quality control procedures in operation at the ready-mix depot shall be
submitted to the Engineer for approval at the time of stating the intention to use readymixed concrete. Facilities shall be provided at the ready-mix depot for the Engineer to
inspect the batching and mixing of the concrete, the materials used, and samples of
materials shall be provided for any tests which the Engineer may wish to carry out.
Any inspection or testing carried out by the Engineer shall not relieve the Contractor of
his obligation to provide concrete fully in accordance with this Specification.
Ready-mixed concrete shall comply in all respects with BS 5328. The cement,
aggregates, admixtures and water shall comply with the requirement of this
Specification and the Engineer may require the Contractor to produce evidence of
compliance. Notwithstanding any approval by the Engineer, the Contractor shall be
responsible for ensuring that ready-mixed concrete complies in all respects with the
requirements of this Specification.
In respect of each grade of concrete to be supplied, the Contractor shall provide the
Engineer with a statement, certified by the ready-mixed concrete Supplier, giving the
following information:
(i)
(ii)
Details of any proposed change in the source or nature of any constituent material and
of any proposed change in the cement content from that last declared and agreed.
This information shall be given not less than two weeks prior to the date of the
proposed change, and the change shall not be made without the Engineer's approval.
Where a central or plant mixer is used, it shall comply with BS 1305 in so far as this
applies. The Contractor shall consult with the Engineer if any ambient conditions such
as high temperatures, traffic congestion etc. are likely to affect the quality of the
concrete as delivered
Before discharging the concrete at the point of delivery, the Supplier shall provide the
Contractor with a delivery note for each batch of concrete on which is printed,
stamped or written the following minimum information:
(a) Name of ready-mix concrete depot.
(b) Series number of ticket.
(c) Date.
(d) Truck number.
(e) Name of purchaser.
(f)
(g) Specified grade of concrete including, where specified, minimum cement content
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Type of cement.
(j)
The concrete shall be compacted and in its final position within 2 hours of the
introduction of cement to the aggregates, unless a longer time is agreed by the
Engineer. The time of such introduction shall be recorded on the delivery note. When
truck mixed concrete is used, water shall be added under supervision either at the Site
or at the central batching plant as agreed by the Engineer, but in no circumstances
shall water be added in transit.
Sampling and testing of the ready-mixed concrete after delivery to Site shall be in
accordance with this Specification.
2.3.10
Commencement of Concreting
No concreting shall be commenced in any portion of the Works until the preparations
have been approved and written permission given by the Engineer that concreting in
such portion of the Works may commence.
Adequate notice shall be given to the Engineer when work is ready for concreting to
enable him to attend all tests, inspections, checks, etc. as may be necessary.
2.3.11
Transporting of concrete
Concrete shall be transported from the place of mixing to the place of final deposit as
rapidly as practicable by methods, which shall prevent the segregation or loss of the
ingredients. It shall be placed as nearly as practicable in the final position to avoid
rehandling.
2.3.12
Placing of Concrete
The concrete shall be placed in uniform layers as soon as possible after mixing and
before the initial set has taken place. Vibrators shall not be used to spread the
concrete in layers from heaps but shall be used for compacting once the concrete is in
layers. Once the initial set has taken place, concrete shall not be subsequently
disturbed.
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The depth of lift to be concreted shall be determined by the Contractor and to the
approval of the Engineer.
Concrete shall not be thrown or deposited from a height greater than two metres.
Where chutes are used in the placing of concrete, they shall be of a design and used
at slopes approved by the Engineer.
The timetable for the depositing of concrete between construction joints shall be so
arranged that no face of concrete shall be left more than 15 to 20 minutes before fresh
concrete is deposited against it.
Pause for meals, changes of shifts, etc. and the distribution of the concrete among the
positions where work may be proceeding simultaneously must, therefore, be carefully
organised to ensure that the above-mentioned interval shall not be exceeded.
The method of depositing concrete underwater shall be to the approval of the
Engineer. Concrete shall not be dropped from any height through water. Where
bottom-opening skips are used they shall be of such a design that the bottom doors
open as the skip is lifted from the surface on which the concrete is being deposited.
The skips shall be full and covered with a woven canvas cover.
Concrete shall be placed evenly over the whole area enclosed by the shuttering and
the order of placing shall be approved by the Engineer. The size of shutters for
underwater concreting shall be such that a pour of concrete finishes level with the top
of the shutter.
Once placed, the concrete shall not be subsequently disturbed and shall not be
vibrated or rammed.
All pours of concrete between tide levels shall be carried out in the dry and with such
celerity and in such a manner that the top may be blanketed to the approval of the
Engineer before being covered by the rising tide. In the case of construction joints, the
blanketing shall be replaced immediately after the joint has been cleaned and
roughened as specified unless depositing of further concrete follows on the same low
tide.
Not withstanding the need for speed, all projecting reinforcement, shuttering and joint
faces shall be cleaned as specified and the concrete thoroughly compacted.
2.3.13
Compaction
All concrete shall be thoroughly compacted by vibrators during operation of placing to
ensure that it is homogeneous. It shall be thoroughly worked around the
reinforcement, around embedded fixtures and into the corners of the shuttering. The
method of carrying out this work and the number of vibrators to be employed on any
particular section of the work shall be to the satisfaction of the Engineer.
All vibration shall be carried out under the direction of a specialist supervisor and to a
plan approved by the Engineer. No workman shall be allowed to operate a vibrating
tool without having received instruction and training in its use. Vibrators shall be
immersion-type of approved pattern; they may be electrically or pneumatically driven.
Care shall be taken to avoid segregation and excessive vibrating.
2.3.14
Screeding
All surfaces of slabs or other members not required to be shuttered shall be screeded
in an approved manner to a smooth and dense finish by means of a wood float or
steel shod tamp, unless otherwise specified.
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2.3.15
169
Construction Joints
Construction joints shall be as shown on the Contractor's Drawings or as approved by
the Engineer. No additional construction joints shall be provided without the approval
of the Engineer, which approval shall only be granted in special circumstances.
Kickers and nibs, 150mm depth, shall be formed upon horizontal and vertical surfaces
respectively where subsequent lifts and bays of walls or columns are required.
On exposed surfaces, construction joints shall be carefully formed to produce a neat
straight flush line or, where required, shall be formed with a recessed joint feature.
Grout checks 25mm wide and 40mm deep shall be provided at all horizontal
construction joints where recessed joint features are not specified.
Suitable bonding chases shall be formed in the ends of other surfaces of sections
exceeding 200mm thick for the purpose of keying such section to those adjoining.
The chases shall be formed over the full length of the joint and shall have sloping
sides.
Unless otherwise specified, no slopes shall be allowed in connection with the
deposition of concrete. Where it is necessary for any reasons to terminate a bed,
such termination shall be against vertical timber shutter stepped as requested and as
approved by the Engineer.
At construction joints, the shutter shall, whenever practicable, be stripped as soon as
possible after pouring, subject to the approval of the Engineer and any skin or
laitance removed and the tops of the larger stones exposed by means of brushing
and washing.
At horizontal construction joints removal of laitance and exposure of the larger stones
shall be accomplished, whenever practicable, by means of washing and brushing
shortly after pouring, care being taken to obviate undue erosion of the mortar. After
cleaning, excess water shall be removed immediately to limit absorption by the
concrete. In cases where the concrete has set, but not yet hard, the removal of the
laitance and roughening shall be accomplished by wire brushing and washing or by
compressed air, care being taken not to damage the underlying mass.
Where at either vertical or horizontal joints the concrete has set hard, any skin or
laitance shall be removed and the surface roughened by hammering with an
approved power-operated "bush" hammer followed by wire brushing to remove all
loose particles. When using this procedure, care shall be taken to avoid breaking off
the arises of the joint face and loosening the stones from the mortar matrix.
Whichever of the above treatments has been given to the exposed surface, it shall be
cleaned from foreign matter by further wire-brushing if necessary and shall then be
thoroughly washed with clean fresh water and the surplus water blown off
immediately before depositing the fresh concrete.
Fresh concrete shall be forced hard onto the set faces. To this end, the compacting
tools and vibrators where appropriate shall be worked right up to the old faces and
into angles and corners formed between them and the shutters.
2.3.16
Movement Joints
Where it is calculated that movement joints are required in a structural reinforced
concrete frame, these shall be continuous across the entire cross-section of the
frame. That is, wherever the plane of the joint intersects with a member of the frame,
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Standby Plant
At all times when concreting is being carried out the Contractor shall have readily
available on Site sufficient standby plant to cover the operations of mixing,
transporting, placing and compaction of concrete in the event of breakdown of plant.
2.3.18
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heavy rain.
2.3.19
Curing
(a)
Method statements for the curing of all concrete shall normally comply with the
following minimum requirements and shall propose effective means of
preventing premature drying and the resulting effects of plastic shrinkage.
Where small quantities of concrete are being used, the Engineer may relax the
requirements of the following clauses. The Contractor's intentions in this
instance shall be clearly indicated in his method statements and approved by the
Engineer.
(b)
Exposed Surfaces
(i)
(ii)
The hessian shall be kept damp continuously using water of the quality
specified for concreting for a period of at least seven days or such longer
period as the Engineer may direct.
(iii)
(iv)
(c)
Formed Surfaces
(i)
(ii)
(iii)
(d)
When shade temperatures exceed 300C in any part of the day or when lower
temperatures in combination with high wind speeds are likely to lead to
premature drying, the Engineer may instruct any combination of the foregoing
methods to be used.
(e)
Curing Compounds
(i)
Curing compounds shall be stored and used strictly in accordance with the
manufacturer's instructions.
(ii)
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2.3.21
2.3.22
Concrete Cores
Where the quality of the finished concrete is considered by the Engineer to be
suspect, he may order 100mm or 150mm nominal diameter cores to be cut from the
hardened concrete for the purpose of examination and testing. The coring equipment
shall be subject to the approval of the Engineer.
If the estimated cube strength of any core as determined in accordance with BS 1881
is less than the appropriate specified minimum crushing strength or if in the opinion of
the Engineer the concrete fails to meet the specified requirements in other respects,
the concrete in that part of the Works shall be deemed not to comply with the
Specification.
The cost of cutting of the core specimen, preparing it for testing and making good the
cored hole shall be borne by the Contractor irrespective of the result of the test.
2.3.23
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2.3.24
173
Concrete Protection
Concrete protection provided shall be agreed with the Engineer and shall be based on
the results of the Site Investigation.
The following is the Specification for concrete protection.
Concrete surfaces to be protected shall be free from pinholes and other surface
defects. The Engineer's approval shall be obtained for any method of repairing surface
defects. Any preparatory filling required shall normally be carried out using an
approved non-shrinking mortar.
Surfaces to be coated with bituminous-based coating shall be wire brushed, either by
hand or with power tools. All dust and other loose materials shall be removed.
Concrete protection shall be provided for all concrete below ground level. Protection
shall consist of a 50mm layer of compacted sand and bitumen mix being cast on the
Grade C blinding concrete prior to pouring the foundation concrete. Two coats of
bitumastic paint shall be applied to the exposed faces of concrete below ground level
in contact with soil.
Where spaces are to be left between the underside of suspended ground floor slabs
and the ground level below, the underside of slabs and beams and the internal faces
of walls enclosing this space shall be painted with 2 coats of approved bitumastic
paint.
All traces of loose material, laitance, shutter oil, grease, wind blown deposits and other
contaminants, which could prevent the proper adhesion of, or result in adverse
reaction with the protective system shall be removed from the concrete surfaces to be
protected.
Blinding concrete prepared for receiving base slab protection shall be free from sharp
edges and projections. The surface shall be cleaned by an oil free air blast where
practicable or as otherwise directed by the Engineer.
2.3.25
Concrete Finishes
2.3.25.1 General
Where uniformity of colour is required in the surface finish of concrete, each material
shall be obtained from a single consistent source. Where surfaces are to be formed
using large formwork panels made up from individual plywood or timber sheets, the
individual sheets shall have uniform properties of absorption and surface texture.
Where a concrete surface is to be permanently exposed, only one release agent from
the formwork shall be used throughout the entire area. Release agents shall be
applied evenly and contact with reinforcement avoided. Where the surface is to
receive an applied finish, care shall be taken to ensure the compatibility of the release
agent with the finish.
If the Engineer so requires, a trial pour shall be made to test the suitability of the
materials and techniques to be used.
2.3.25.2 Classification of Finishes
Finished concrete surfaces shall be classified in accordance with the class listed
below. The class of finish required shall be shown on the Drawings.
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2.3.26
Formwork
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The use of proprietary type shuttering systems shall be subject to the Engineer's
approval. Full details of the proposed use of such systems shall be submitted to the
Engineer. Through struts or ties shall not be permitted in water retaining structures.
Formwork (including supports) shall be sufficiently rigid to maintain the forms in their
correct position and to correct shape and profile so that the final concrete structure is
within the limits of the dimensional tolerances specified.
Formwork shall be designed and constructed so that concrete can be properly placed
and compacted by vibration or otherwise without loss of material and so that the
concrete shall set and harden without injury.
2.3.26.3 Preparation
Formwork shall be cleaned before each use. Form release agent shall be to the
approval of the Engineer. They shall be applied carefully and sparingly and shall not
be allowed to come in contact with concrete surfaces or with items (including
reinforcement), which are to become bonded to the concrete.
Formwork with damaged edges or faces shall not be used until repaired to the
approval of the Engineer. Open joints in timber forms shall be sealed. Plywood
surfaces and cut edges shall be sealed to prevent the absorption of moisture.
Immediately before concreting, the forms and all other surfaces which shall be in
contact with the fresh concrete shall be cleaned of loose materials and debris
including shavings, woods chips, sawdust, piece of wire, nails, foamed plastic,
fragments of hardened concrete and mortar. Adequate clean-out holes shall be
provided for this purpose and subsequently securely closed so as to restore the
required formwork quality.
The use of compressed air for cleaning shall be subject to approval or precautions to
avoid the deposition of suspended oil on construction joint surfaces, reinforcement, or
other items, which are to be bonded to concrete.
2.3.26.4 Striking and Removal
The removal of formwork shall be subject to the permission of the Engineer. Striking
of formwork shall be in accordance with BS 8110.
2.3.27
Permanent Formwork
The use of proprietary type permanent shuttering system for suspended slabs shall be
subject to the Engineer's approval. The erection and use of such system shall be in
strict accordance with the manufacturer's instruction.
Permanent shuttering will normally have a ribbed profile and manufactured from
galvanised steel. Temporary propping where required shall be in accordance with the
manufacturer's instructions and the Engineer's consent shall be sought before
removal.
Care shall be taken in the use of such system to ensure that the appropriate fire
resistance rating is provided.
The steel sheets shall be placed in bundles at the manufacturer's work and wrapped
with a waterproof cover. Care shall be taken to ensure that this cover is not punctured
there or damaged in any way during transport to the Site of the work and that it
remains intact until the sheets are to be used.
In general, the use of profiled steel sheets in concrete slabs shall be in accordance
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2.3.29
Bolt Diameter
Tolerances
Up to l2mm
l3mm to32mm
33mm and over
+5mm
+7mm
+10mm
Reinforcement
177
2.3.29.4 Fixing
Concrete cover to reinforcement shall be as follows and as agreed with the Engineer.
Foundations
Columns External
Beams External
Beams Internal
Columns Internal
Slabs External
Slabs Internal
40mm
40mm
50mm
35mm
35mm
40mm
35mm
The suffit of all ground floor slabs whether or not in contact with the ground shall be
deemed an external surface and cover to the reinforcement shall be 40mm.
In no case shall the cover be less than specified or exceed the specified cover by
more than 5mm for concrete up to 300mm thick or not more than 10mm for concrete
over 300mm thick.
Bars, which intersect or pass over each, shall be securely wired together at the point
of intersection with 18 or 20 SWG soft iron wire.
Small concrete blocks specially precast to give the correct cover shall be used to
ensure cover on ground centring and slab shuttering and elsewhere as considered
necessary. They shall be made of mortar not leaner than 1 part of cement to 2 parts
sand. Other suitable methods approved by the Engineer may be permitted.
Support chairs for reinforcement shall be designed by the Contractor and approved by
the Engineer.
The use of proprietary type spacers or couplers shall be subject to the Engineer's
approval, and full details of proposals for their use shall be submitted at least 4 weeks
in advance of fixing reinforcement.
Welding of reinforcement shall be subject to the Engineers approval. The Contractor
shall submit to the Engineer complete details of proposals to weld reinforcement at
least eight weeks in advance of fixing reinforcement.
All reinforcement shall be cleaned free of salt depositions, loose mill scale and rust,
grease, set mortar or other harmful matter, by power brushing or acid dipping if
necessary. In particular the Contractor shall ensure that such reinforcement is
protected against chemical deposits at all stages of the work until the concrete is
poured.
Placed reinforcement shall be checked against the relevant Drawings before
concreting is permitted.
2.3.30
Precast Concrete
Units shall be provided by an approved Supplier, who shall submit details of the
design and manufacture for approval by the Engineer. The quality of the finish shall be
U3 and comply with Clause 2.3. of this Specification and as required by the Engineer.
Precast kerbs, bricks, blocks, sills and lintels shall comply with BS 6073 or BS 7263.
The concrete ingredients, grades, mixes, strengths, general quality, testing, mixing,
placing and curing shall be generally as described in the Specification. The surface of
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the finished units shall be smooth, dense and hard with clean sharp arises (except
where otherwise indicated), and shall be free from cracks, crazing, discolouration,
holes, fins, honey-combing, water-marks, dusting or shutter-marks.
Units shall be manufactured and cured in a properly equipped casting yard or shop
and the arrangements shall be subject to the inspection and approval of the Engineer.
The Contractor shall give adequate notice to the Engineer before dispatching precast
units to the Site, and if the Engineer so requires, shall provided facilities for inspection,
test - loading and dimensional checking of the units before they are dispatched. In the
case of units constructed in a factory or yard remote from the Site, details of the
concrete ingredients, mix design, and compression test cube results shall be made
available to the Engineer.
TOLERANCES
TOLERANCES mm
TYPE OF
STRUCTURE
TYPE OF
IRREGULARITY
TYPE OF FINISH
FORMED
Buried Concrete in
foundations,
culverts, retaining
walls, etc.
Exposed concrete
in columns, pipes,
retaining walls,
abutments, etc.
1
+20
-10
Variation in cross
section dimensions
Abrupt
*Deviation from
template in long
dimensions
UNFORMED
3&4
3&4
+10
+10
-5
10
10
10
10
10
10
10
Variation in cross
section dimensions
10
-5
10
-5
10
-5
Abrupt
5
*Deviation from
template in long
dimensions
10
10
10
Departure from
longitudinal level
* Departure from
transverse cross
3
section template
Deviation from md
straight edge on
3
longitudinal section
* Template for Formed Finishes shall be 1.5m long.
Template for Unformed Finishes shall be 3.0m long.
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2.4.
STRUCTURAL STEELWORK
2.4.1
Materials
179
Except where noted or agreed otherwise the particular grade of steel used shall be
determined in accordance with the design standard BS 5950 or approved equivalent
standard.
All steel in plates and sections shall comply with BS 4360 or similar approved
standard.
Structural hollow sections shall be hot rolled in Grade 43C to BS 4360. Welded coldformed structural hollow sections shall not be used unless agreed by the Engineer.
Identifying marks for the different grades of steel shall be provided in accordance with
BS 4360.
Except in the case of special plate with through thickness properties guaranteed by
the manufacturer all plates and sections 40mm or over in thickness shall be
ultrasonically tested for laminations and shall meet the requirements of grade L4 of BS
5996. The Engineer may specify that other plates be ultrasonically tested and unless
otherwise specified they shall meet the requirements of grade L4 of BS 5996.
Dimensional tolerances of (i) rolled sections shall comply with BS 4, BS 4848 and (ii)
plates and flats shall comply with BS 4360.
Electrodes for metal arc welding shall comply with the requirements of BS EN 4910.
Ordinary bolts and nuts shall comply with BS 3692, BS 4190.
Unless otherwise agreed with the Engineer ordinary bolts and nuts shall be grade 8.8.
High strength friction grip bolts, nuts and washers shall comply with BS 4395 Part 1.
2.4.2
Certification
Two copies of manufacturers test certificates and mill certification verifying that the
materials comply with the relevant British Standards or approved equivalent standards
shall be submitted to the Engineer for all structural steel, bolting materials and welding
consumables.
2.4.3
Drawings
For all structural steelwork the Contractor shall prepare the necessary arrangement
drawings and shop drawings for fabrication and shall be fully responsible for checking
the accuracy of these drawings. The general arrangement drawings shall be to such a
scale that identifying numbers for each member are clearly shown. Shop drawings
shall indicate all connections, welds, fabrication details, identifying mark numbers and
other pertinent data. Four weeks in advance of fabrication three copies of checked
shop drawings and connection design calculations shall be submitted to the Engineer
for approval. Such approval shall not relieve the Contractor of the responsibility for the
accurate detailing and fabrication of members and for proper assembly at the time of
erection.
2.4.4
Inspection
The Contractor shall afford all facilities for the inspection of the work at all stages by
the Employer at the fabrication works.
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2.4.5
180
Fabrication
Construction and fabrication shall be in accordance with the requirements of BS 5950
or similar approved standard.
The fabrication and workmanship shall be to the best modern practices and shall
comply to the requirements of BS 5950 Part 2 or similar approved. Only qualified
fabricators shall be engaged for the work.
All measurement shall be made by a steel tape related to a standard tape, which has
been certified to be correct at 200C. The tape and the steel to be measured shall be at
the same temperature and proper precautions shall be taken to tension the tape
correctly.
All plates, bars and sections shall be flat, straight and free from twist within the
tolerances specified in the relevant approved standard, unless more stringent
tolerances are specified. Any flattening or straightening necessary to achieve the
required tolerances or to satisfy fit-up requirements shall be carried out before any
other work is done on that item. Flattening or straightening shall be done by approved
mechanical means and shall be carried -out such as not to deface or weaken the
material.
Steel may be sawn, sheared, cropped or machine flame cut. Sheared member shall
be free from distortion.
The Contractor shall carry out procedure trials for machine flame cutting; such
procedures shall be to the approval of the Engineer. Where it is impractical to use
machine flame cutting, the use of hand cutting shall be subject to the approval of the
Engineer, who may require dressing or other treatment of the cut edges, depending on
the details of the joint or member.
Where notches are necessary they shall have smooth radial internal corners,
produced by drilling holes not less than 20mm diameter before cutting the rest of the
notch or by carefully controlled flame cutting.
All burrs left by sawing, cropping or shearing shall be removed before fabrication or
assembly. All sharp arises shall be removed by light grinding.
The Contractor shall inform the Engineer of members on which he will be using
shearing or flame cutting and in cases where steel so cut is specified as being subject
to dynamic or fatigue loading or liable to brittle fracture, the sheared or flame cut
edges shall be machined to a depth to be agreed by the Engineer.
The ends of compression members at splices, caps or bases dependent on contact for
the transmission of compressive stress shall be prepared so that butting faces fully
satisfy the design requirements. Base and cap plates and other bearing surfaces shall
also be prepared to the same standard. For parts -to be machined at least 3mm in
excess of the finished size or thickness shall be allowed for machining.
The ends of all members shall be truly square, where required.
Members shall be adequately supported in both the vertical and horizontal planes
during cutting or machining to ensure that the prepared ends are square to the axis of
the member.
All plates 25mm thick and over which are to be connected using H.S.F.G. fasteners
shall be checked for "bowing" or "ripple": if these defects are present they shall be
eliminated before despatch to site.
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In H.S.F.G. connections all surfaces, which have been machined, shall be grit blasted
in such a way as to provide the design slip factor.
The ends of fitted plates and stiffeners shall be accurately sawn or sheared and
ground to fit tightly between the flanges or parts to be stiffened. The maximum gap
shall not exceed 0.25 mm.
Any structural connection shall be either welded or bolted and no mixed connections
shall be allowed. Drainage holes shall be provided in members where water could
collect during and after erection.
To facilitate grouting, holes shall be provided in stanchion bases for the escape of air.
2.4.6
Holes
Holing shall be in accordance with BS 5950 Part 2 or equivalent approve standard.
Holes for friction grip bolts shall be in accordance with BS 4604 Part 1 or equivalent
approved standard.
All burrs and rags shall be removed.
All holes shall preferably be drilled but punching of holes in accordance with
procedures to the satisfaction of the Engineer shall be permitted. Circular holes for
bolts and rivets shall not be flame cut.
Slotted holes shall either be punched in one operation or else formed by punching or
drilling two round holes and completed by high quality flame cutting and dressing to
ensure that the bolt can travel the full length of the slot freely.
Holes through more than one thickness of material in built-up sections shall, where
possible, be drilled after the members are assembled and tightly clamped or bolted
together. Punching may be permitted before assembly, providing the holes are
punched 2mm less than the required diameter and reamed after assembly to the full
diameter.
Holes in members built up by welding shall be drilled after welding has been
completed.
2.4.7
Welding
Metal arc welding of steel to BS 4360 shall be in accordance with the requirements of
BS 5135 or other equivalent approved standard.
All welders shall be suitably qualified and experienced for the work on which they are
employed and shall have satisfied the relevant requirements of BS EN 287-1 or BS
4872 Part 1 as appropriate. The Contractor shall provide to the Engineer valid
certification that all welders working on the Contract have passed the appropriate test.
The Engineer and Employer reserve the right to have any welding operator tested at
any time.
Welding shall be carried out under the supervision of a competent and experienced
welding superior. The Contractor shall keep records to enable all main welds, in
particular butt welds, to be identified with the welder responsible for production. Such
records shall be made available to Engineer, immediately on demand.
Fillet welds shall be continuous to form a complete seal where two members join.
All butt welds shall be complete penetration butt welds. Full throat thickness at the
ends of main butt welds shall be obtained by the use of run on/run off pieces on either
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Bolting
The use of bolts, including permissible stresses, size and pitch of bolts shall comply
with the requirements of BS 5950 or equivalent standard.
All bolts, nuts, and washers other than H.S.F.G. bolts shall comply with the
requirements of Grade 8.8 to BS 3692. Ordinary bolts shall be provided with a washer
under the nut, unless otherwise agreed. Washers shall be tapered or otherwise
suitably shaped to give nuts and heads of bolts a satisfactory bearing. The threaded
portion of bolts shall be outside the parts bolted together and the ends shall protrude
by not less than 2 full threads through the nut after tightening.
H.S.F.G. bolts shall be used for site connections as shown on the drawings and in
accordance with B5 4604 or equivalent approved standard. Only one system of
H.S.F.G fastening shall be used in the Works.
Particular attention shall be directed to the correct sequence of tightening bolts in
large connections. Bolts provided with load indicating devices shall be tightened in
accordance with the manufacturer's instructions using power-operated spanners,
equipped with torque limiters. H.S.F.G. bolts shall not be used as service or temporary
bolts or in any connections bolted in the fabricator's yard. Any H.S.F.G. bolts, which
have to be loosened, shall in no circumstances be re-used.
2.4.9
2.4.10
Erection
Steelwork erection shall be in accordance with BS 5950 or equivalent approved
standard.
Erection of steelwork shall be carried out in a safe manner in accordance with all
relevant Safety, Health and Welfare legislation and taking account of the
recommendations of BS 5531 or equivalent approved standard.
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The steelwork erector shall employ on erection only such persons as are skilled and
experienced in steelwork erection. A competent Engineer shall supervise them on the
site.
Steelwork in course of erection shall be securely bolted or otherwise connected
together and if necessary provided with temporary bracing or effectively anchored
steel guy ropes to resist all dead loads, loads due to erection equipment and the
operation thereof and all lateral loads including wind. Temporary bracing and guy
ropes shall be left in position and maintained for as long as is necessary to ensure the
safety of the structure.
Each part of the structure shall be aligned as soon as practicable after it has been
erected.
No permanent bolting or welding shall be carried out until as much of the structure as
will be stiffened thereby has been brought into correct alignment. No straining into
position will be allowed after the permanent connections have been made.
The Contractor shall be responsible for the correct alignment and level of all steelwork
and for the accurate plumbing of stanchions. The alignment, level and plumb of the
steelwork shall be in accordance with the following tolerances unless superseded by
more stringent tolerances dictated by installation and operation e.g. overhead
maintenance cranes.
(i)
Position
+5mm
Level
+ 3 mm
(iii)
+5mm
2.4.11
+ l5mm
Inspection
Contract Price shall be deemed to include for providing the necessary access ladders
and facilities therefore and attendance on Engineers staff
engaged in inspection work.
2.4.12
Protective Coatings
2.4.12.1 General
All structural steel work shall have approved corrosion protection systems applied to
give a life to first maintenance of 20 years (minimum). Corrosion protection systems
shall be appropriate for the environmental conditions.
The Tenderer shall include in the Technical Schedules its proposed corrosion
protection system and procedures for structural steelwork, for the different
environments.
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2.4.12.2 Materials
Paints used shall be of the best quality suitable for tropical use and of a proprietary
brand approved by the Engineer. The Contractor shall forward technical data sheets
for all materials to the Engineer. These technical data shall give product information as
listed in Appendix A to this Specification. All paint products and thinners shall be
delivered to the place of application in sealed containers, clearly labelled, identifying
the manufacturer, formulation, colour, batch number, date of manufacture, shelf life,
pot life, mixing instructions and method of use.
Paints shall only be thinned in accordance with the manufacturer's instructions. All
products shall be stored in properly ventilated and temperature controlled premises in
accordance with the manufactures instruction. When the shelf life limit is reached the
materials shall be removed from the place of application and discarded. Products shall
be stored in such a manner that the material stored longest will be used first.
Products, which have livered, gelled or deteriorated in any way during storage, shall
not be used. Materials, which can be restored to normal consistency by stirring, will be
accepted, provided that they have not exceeded the recommended shelf life.
Immediately prior to application products shall be thoroughly stirred with a power
mixer for a time sufficient to thoroughly remix the constituents, except where this
would be contrary to the manufacturer's instructions (for example with thixotropic
paints). If the product is a two-pack system then the manufacturer's instructions shall
be strictly adhered to in respect of mixing and the maximum length of time the material
may be in the pot before application. Under no circumstances may materials be used
after the recommended pot life has elapsed.
2.4.12.3 Working Conditions/Safety
It shall be the responsibility of the Contractor to ensure that all relevant statutory
legislation is complied with and that all precautions required to avoid risk to health and
safety are carried out in the application of protective coatings, painting and all
associated activities.
2.4.12.4 Surface Preparation
All surfaces to be coated shall be free of scale, rust, grease, oil, dust and other
deleterious materials. Steelwork shall be blast cleaned to remove all miliscale and
other contamination to BS 70710. The surface finish shall be to visual standard SA 21/2
in accordance with SIS 055900.
The abrasive used during blast cleaning shall be steel, malleable iron or chilled iron
shot of a grading suitable to give maximum surface amplitude of 100 microns.
Abrasive shall be selected in accordance with BS 2451 and BS 7079 Table 2. Sand
blasting shall not be used.
All surface defects likely to be detrimental to the protective system such as cracks,
surface laminations and deep pitting, shall be removed in accordance with BS 4360.
Fabrication surface defects such as fins at saw cuts and burrs shall be similarly
removed.
All dirt and debris shall be removed from surfaces after blasting, by vacuum
cleaner, airline or brush. If residues are trapped in the paint the affected area
shall be re-blasted and recoated.
All shop weld areas and shop bolted or riveted connections shall be blast cleaned to
the same standard as adjacent steel. All weld slag and spatter shall be removed.
Blast cleaned surfaces shall be over coated within four hours of the start of cleaning,
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and the steel shall not be exposed out of doors during this period.
2.4.12.5 Connections using H.S.F.G Bolts
Under no circumstances shall the friction contact surfaces be painted, greased etc.
Friction contact surfaces shall have an approved robust masking material securely
applied before the application of any priming, painting coats.
Prior to erection all friction surfaces shall be thoroughly cleared with an approved
solvent and shot blasted to give the design slip factor.
2.4. 12.6 Structural Steelwork Components Encased in Concrete
Steelwork to be encased in concrete and other surfaces in contact with concrete shall
be unpainted. Such surfaces shall be cleared to remove oil, grease and chemicals,
which may be adhering to the surfaces. The surfaces shall be blast cleaned or wire
brushed to remove loose mill scale, rust and dust particles.
2.4.12.7 Painting Procedures
Before the work commences the Contractor shall supply the Engineer with samples, if
required, of all paints for testing by an approved testing laboratory and painting shall
not commence until paints have been approved.
During the course of the Contract the Engineer shall have the power to take samples
from paint in use on any part of the job for testing by an approved testing laboratory.
Paint shall be stored in a lock-up store where the temperature shall be between 50C
and 300C. Any storage conditions specified by the manufacturer shall be observed,
and all materials shall be used as delivered and within 12 months from date of
manufacture.
All paint shall be applied in accordance with the manufacturer's instructions and to the
Engineer's approval. Paint may be applied by brush, roller, or airless spray equipment,
provided the specified dry film thickness of the coating system is obtained and the
manufacturer's instructions are observed.
Spraying equipment shall be so designed and operated as to achieve a coat of
specified minimum thickness and free from surface defects especially craters,
pinholes, ravelling, sagging, dry patches, etc., with an even and uniform appearance
and complete adhesion. The Engineer may require to witness a demonstration of the
proposed procedures before work commences.
The dry film thickness shall be checked by the use of an approved thickness tester.
Where practicable, tracer coats shall be used in priming coats and undercoats. The
convention and specification for the various coats shall be agreed before painting
commences and shall comply with the paint manufacturer's recommendations.
The build up of paint in boltholes shall be avoided by good painting practice.
The surface shall be dry immediately before primer or coating is applied and shall be
protected from moisture for as long as it is necessary for the coating to harden, set or
cure to such an extent that it can be wetted without adverse effect.
If heating or ventilation is employed by the Contractor to secure suitable conditions to
allow work to proceed, care shall be taken to ensure that treatment of a local surface
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The humidity in the vicinity of the surfaces is such that condensation could
readily occur on the surfaces either immediately, before or during application or
when the humidity could have a detrimental effect on the work or when the
relative humidity is above 90%.
(2)
The wet paint film could be damaged by wind-blown sand or dust; and
(3)
Conditions obtain which in the opinion of the Engineer are detrimental to good
workmanship.
2.4.12.8 Painting
Except for galvanised surfaces all steelwork shall be blast cleaned to BS 4232 (1967),
second quality finish with amplitude not exceeding 50 microns.
Before priming, surface defects such as cracks, surface laminations, deep pitting, fins
at saw cuts, burrs, sharp edges, etc, shall be removed. Where extensive grinding has
been necessary the dressed areas shall be re-blasted to remove all rust and provide
an adequate paint key.
The required paint treatment is:
(i)
Within one hour of blast cleaning all surfaces shall be primed with one coat of
two-component epoxy/polyamide primer containing zinc phosphate with solids
by column and specific gravity or not less than 48% and 1.3 respectively, to a
dry film thickness of 50 microns.
After priming if any abrasive particles are found under or embedded in the paint
film the affected area shall be re-blasted and re-primed. After priming, rough
surfaces shall be filled with approved two component filler and rubbed down to a
smooth finish. The affected area shall be re-primed if necessary.
A two-component polyamide cured epoxy high build intermediate coat with a solids by
volume and specific gravity of not less than 55% and 1.3 respectively, shall then be
applied to a dry film thickness of 80 microns.
Finally two coats of two-component epoxy/polyamide enamel finishing paint with high
resistance to impact and abrasion with solids by volume and specific gravity of not
less than 40% and 1.0, respectively, shall be applied to a dry film thickness per coat of
40 microns.
2.4.12.9 Galvanising
All galvanising shall be carried out by the hot dip process and shall conform to
729 or equivalent approved standard.
BS
Attention shall be paid to the detail design of members in accordance with BS 44710.
Adequate provision for filling, venting and draining shall be made for assemblies
fabricated from hollow sections. Vent holes shall be suitably plugged after galvanising.
All surface defects in the steel including cracks, surface laminations, laps and folds
shall be removed in accordance with BS 4360. All drilling, cutting, welding, forming
and final fabrications of unit members and assemblies shall be completed before the
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structures are galvanised. The surface of the steelwork to be galvanised shall be free
from welding slag, paint, oil, grease and similar contaminants.
The minimum average coating weight shall be as specified in Table 1 of BS 7210.
Structural steel items shall be initially grit blasted to BS 7079, second quality (SA
2.5).
On removal from the galvanising bath the resultant coating shall be smooth,
continuous, free from gross surface imperfections such as bare spots, lumps, blisters
and inclusions of flux, ash or dross.
During off-loading and erection the use of nylon slings shall be employed. Galvanised
work, which is to be stored in works or on site shall be stacked so as to provide
adequate ventilation to all surfaces to avoid wet storage staining (white rust). Any
areas of the galvanised coating damaged in any way shall be repaired by:
(i)
Cleaning the area of any weld slag and thoroughly wire brushing to give a clean
surface.
(ii)
The application of two coats of zinc-rich paint, or the application of low melting
point zinc alloy repair rod or powder to the damaged area, which shall be heated
to 3000C.
After fixing, bolt heads and nuts shall receive two coats of zinc-rich paint. In
connections where galvanic corrosion may occur, suitable isolating membranes to the
approval of the Engineer shall be used.
2.4.12.10 Bolts Nuts and Washers
Bolts, nuts and washers shall be hot dip galvanized, and subsequently centrifuged, in
accordance with BS 7210. Nuts shall be tapped oversize such that after galvanizing
the nut can be hand turned on the bolt for the full depth of the nut.
The bolt manufacturer shall carry out galvanizing of high strength friction grip
(H.S.F.G) bolts nuts and washers.
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APPENDIX A
(Paint system proposed)
The Contractor shall submit the data requested on the sheet following for the Project Managers
approval. Failure to submit the data in full will result in delay in obtaining approval for the paint
system proposed.
Information to be included in Contractor's submission for approval of any paint system.
1.
Scope of use
2.
Type of product
3.
4.
5.
Pot life
6.
Method of application
7.
Covering capacity
8.
9.
Drying time
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2.5
WATER SUPPLY
2.5.1
Quality
189
All materials and equipment to be incorporated into the finished work shall be new,
undamaged, free of defects, and fully operational as applicable. No damaged,
defective or inoperable materials or equipment shall be installed or allowed to remain
in the finished work if discovered after installation.
Where required by the specifications or when requested by the Engineer, the
Contractor shall submit certified test results showing that the materials to be
incorporated into the work meet the Specification requirements. Certifications or test
results so required by the Specifications shall be submitted prior to installation of the
materials into the work.
2.5.2
2.5.3
BS 1972
B5 3505, BS 4346
2.5.4
BS 534
BS 5163
Excavation
Trenches for water mains shall be excavated in accordance with the provisions of
Section 1 of this Specification.
2.5.5
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Testing
All pipes and fittings shall be tested at the works before dispatch to ensure compliance
with this Specification and, after laying and jointing, the main shall be carefully filled
with water so as to expel all air and then tested under pressure appropriate to the
class of pipe in accordance with BS 8301.
2.5.7
Backfilling
When the permission of the Engineer has been obtained the trench shall be carefully
backfilled in accordance with this Specification.
2.5.8
Cleaning
Before the main is placed in service, it shall be thoroughly flushed with clean water to
the approval of the Engineer.
2.5.9
Anchor Blocks
Anchor blocks comprising Grade C concrete shall be provided at bends where
required, or as directed by the Engineer. They shall be so located as not to impair the
flexibility of joints, where affording adequate restraint to the pipe.
2.6.
DRAINAGE WORKS
2.6.1
General
The Contractor shall be fully responsible for the design and installation of all drainage
systems. All drainage work and discharge quality shall be in accordance with national
and local statutory requirements of Ghana.
The Contractor shall be responsible at all times during the construction and up to the
end of the Maintenance Period for ensuring that all drainage work is kept in working
condition at all times.
All pipes shall be cleaned inside and tested for soundness and inspected for defects
before being laid. Any defective, damaged or unsound pipes shall be rejected. Pipes
shall be laid true to design gradients and in straight lines. Each pipe shall bear evenly
on the prepared bedding material, for the full length of the barrel. The bedding material
shall be in accordance with the design requirements and the pipe manufacturers
instruction.
2.6.2
2.6.2.1
BS3656,
BS65
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BS5911
BS5911
BS437
BS7
BS65
BS65
BS65
BS5911
BS5911
BS5481
BS5480
BS4660
BS2760
All pipes and fittings shall be checked for soundness before laying. Pipes shall be
delivered, handled and stored in accordance with manufacturers' recommendations
or, in the absence of any recommendations, in such a manner as to protect them from
damage, distortion or deterioration.
The use of pipes and fittings containing asbestos shall be subject to the Engineer's
written approval, and shall comply with all relevant safety regulations.
2.6.2.2
Excavation
All excavation for pipe trenches shall be in accordance with this Specification.
Excavations for sewers, drains, gullies and manholes shall be carried out to the lines
and levels shown on the drawings.
The Contractor shall maintain pipe trenches pumped out, protected with safety
barriers and well supported where necessary and shall not open up trenches and
leave them to fill with water without the written permission of the Engineer.
Where solid rock is encountered at invert level it shall be removed to a depth of
150mm below the bottom of the pipes and replaced with 150mm of compacted
granular fill to the approval of the Engineer.
2.6.2.3
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2.6.2.6
(a)
(b)
Exterior wrappings shall be shop applied. The pipe shall be cleaned, primed
and wrapped as per the manufacturer's recommendations. Wrap shall be
heavy-duty, self-adhesive PVC or Polyethylene backed carrier strips and
applied to a minimum thickness of 1 .78mm
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2.6.3
Rainwater Goods
2.6.3.1
Materials
193
Gutters, down pipes and fittings shall be in accordance with the following standards:
Aluminium rainwater goods
BS 2997
BS569
BS 460
BS 4576
BS 1091
Rainwater goods
BS 1431
Erection
Gutters, down pipes and fittings shall be erected in accordance with BS 6367.
During erection, care shall be taken to ensure that no damage is caused to existing
buildings and structures. The Contractor shall ensure that his work does not interfere
with other building work, which may be proceeding during erection of rainwater goods.
2.6.3.3
Protection
Steel and iron shall be protected from corrosion in accordance with BS 5493. Any
protective coatings, which may have been damaged before or during erection, shall be
made good immediately.
2.6.3.4
2.7.
MASONRY
2.7.1
General
Masonry shall preferably be constructed of locally manufactured brick/block units
which shall comply with the requirements BS 3921 and BS 6073 or other equivalent of
BS 3921 and BS 6073 or other equivalent standard approved by the Engineer.
Trial panels of all masonry types included in the works shall be constructed by the
Contractor for approval by the Engineer. These trial panels shall be erected prior to
building construction on site: The costs associated with all trial panels shall be
deemed included in the Tender.
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2.7.2
Materials
2.7.2.1
Bricks
194
Clay bricks shall be in accordance with BS 3921 calcium silicate bricks shall be in
accordance with BS 187; concrete-building bricks shall be in accordance with BS
6073.
Facing bricks shall be to the dimensions of standard common bricks and shall be
supplied by a manufacturer approved in writing by the Engineer. The bricks are to be
first quality and of uniform size and selected so as to give a slight mottled effect in
colour on the finished wall.
2.7.2.2
Blocks
Concrete building blocks shall be in accordance with BS 6073. Concrete blocks and
bricks shall be from an approved manufacturer whose products shall be examined
and approved by the Engineer before work commences.
2.7.2.3
Mortar
The mortar shall be composed of cement, lime and sand in the ratios of 1:1/2:4 giving
a minimum compressive strength at 28 days of 14N/mm2.
Sand shall be clean sharp natural sand, well graded and entirely free from loam,
clay, dust or organic matter.
Water and cement shall comply with this Specification.
Lime shall be high calcium containing not less than 90% by weight of calcium oxide.
Plasticisers shall be free from calcium chloride or similar salts and shall be to the
Engineer's approval.
2.7.2.4
Sand
Sand shall be clean sharp river sand or pit sand, well graded and entirely free from
loam, clay, dust or organic matter.
(a)
The clay/silt content shall not exceed 3% by weight.
(b)
2.7.2.5
The chloride and sulphate contents shall not exceed the limits given in
Clause on aggregates for concrete.
Plasticiser
Plasticisers shall be free from calcium chloride or similar salts.
2.7.2.6
Colour Agents
Colouring agents when used in mortar shall be in accordance with BS 1014 and
shall not exceed 10% by mass of the cement in the mortar.
2.7.2.7
Pre-Mixed Mortars
Shall comply with the general requirements for materials and mix proportions shall
be as given in this Specification.
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2.7.2.8
195
Damp-Proof Courses
Flexible damp-proof course materials shall comply with BS 743 where applicable
and shall be:
(i)
(ii)
(iii)
2.7.2.9
Bonding Ties
Bonding ties shall be expanded metal strips or woven mesh.
2.7.2.10
Wall Ties
Wall ties shall comply with BS 1243 and shall be hot-dip galvanised steel or stainless
steel as specified.
2.7.2.11
2.7.3
Workmanship
2.7.3.1
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2.7.3.2
196
Mortar
Mortar generally shall be machine mixed, mixed dry and then water added until the
correct consistency and uniform distribution of materials is obtained. It shall be made
in small quantities only. All mortar shall be used within half an hour of the addition of
water to the dry mix and any mortar, which has begun to set, shall not be used.
Before mixing a fresh series of batches, the mixer drum shall be thoroughly cleaned.
Hand mixing shall be done on a clean watertight platform, first dry and then with
added water until the correct consistency and uniform distribution of materials is
obtained. Mortars shall be used within 35 minutes of the addition of water; any mortar
not then used shall be discarded.
2.7.3.3
Masonry
All masonry delivered to Site shall be unloaded by hand and carefully stacked and
protected from rain, frost and inclement weather all to the satisfaction of the Engineer.
Masonry shall be stored on the Site on a drained surface clear from the ground and
located away from roadways and mixing sites to avoid splashing with mud, lime or
cement.
Masonry shall be adequately wetted prior to use. Masonry with one frog only shall be
laid frog uppermost and shall be fully and carefully bedded, all joints being filled and
flushed with mortar.
No joint shall exceed 10mm thickness. Every third course of masonry shall be truly
levelled and laid accurately by line and kept true and square, the whole of the
masonry being properly bonded together. The masonry shall be carried up uniformly
and no part of the work raised more than 900mm above another unless approved by
the Engineer.
At the commencement of each day's work the receiving beds shall be brushed to
remove all loose particles or debris and well wetted before laying proceeds. The tops
of walls shall be adequately protected during construction against the effects of
inclement weather and to prevent water entering the walls.
Concentrated loads shall not be applied for at least 3 days after building masonry
walls or columns.
Staining: Grout or mortar or soil shall be prevented from staining the face of masonry
to be left exposed. Remove immediately grout or mortar in contact with such
masonry. Protect base of walls from rain-splashed mud and mortar splatter by means
of coverings spread on ground and over wall surface.
Sills, ledges and projections shall be protected from droppings of mortar.
2.7.3.4
Joints
All joints between bricks/blocks shall be as specified and shall be solidly filled to a
general thickness of l0mm. All cross-joints shall be filled by well buttering the end of
the brick/block and then pushing it into position against its neighbour.
2.7.3.5
Pointed Joints
Joints on external walls, which are to be pointed, shall be raked out 20mm deep as
the work proceeds.
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197
Outer surfaces of external walls are to be pointed in a cement mortar with a weather
struck joint or other specified joint. The colour of this pointing shall first be determined
and approved by the Engineer from a number of samples of pointing, each sample to
cover an area of about one square metre. Joints between facing brick/block and
precast concrete units shall be treated in a like manner.
As an alternative to raking and pointing, the wall may be constructed with mortar to
the colour required and to the strength required for that location. Where such
coloured mortar is used, the joint is finished to the specified design.
2.7.3.6
Fairfaced Joints
Where a fairfaced finish is specified, the joints shall be rubbed with a rounded tool to
give a concave finish to the mortar. This must be done when the mortar has stiffened
sufficiently for working. The finished joint shall be smooth with the mortar making
good contact with both masonry units.
A fairfaced finish may be required in walling of fairfaced blocks or of standard blocks.
All such blockwork shall be left free of excess mortar or droppings.
2.7.3.7
2.7.3.8
Flush Joints
Unless otherwise specified, joints on all other walls are to be neatly struck flush, as
the work proceeds and care shall be taken to ensure that there is no raggedness and
that no mortar encroaches upon the faces of the blocks or bricks. The surfaces of
walls, which are to be painted, are to be cleaned down thoroughly and left clean for
the painters.
The face of all masonry and precast concrete products shall be left clean.
2.7.3.9
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198
All steel and aluminium surfaces, which are to be built against or embedded in
masonry, shall be cleaned and given two coats of bituminous paint. The coating shall
be of uniform thickness without voids. Metal surfaces not embedded or in contact
with the masonry shall be protected against soiling by the bituminous paint.
2.7.3.12 Caulking
All joints of exterior masonry at the perimeter of door, window and louver frames shall
be not less than 10mm nor more than 12mm wide, shall be raked out and cleaned to
a minimum uniform depth of 20mm and shall be filled with caulking compound forced
into place with a pressure gun and the face of joint neatly finished.
2.7.3.13 Weep Holes
Weep holes shall be provided over thru-wall flashing in wall, at bottom of quall and
elsewhere as required for proper drainage. Weep holes shall be spaced at 600mm
centres, and shall be formed with plastic tubing extending into the cavity and left in
place.
2.7.3.14 Connection of New Work
When starting masonry work after work has been stopped for the night or other
reasons, the exposed bearing surface of the masonry shall be cleaned with a wire
brush, all loose mortar removed to obtain the best possible bond between new work
and the previously installed work.
2.7.3.15 Connecting to Existing Masonry
Where new masonry work must be connected to existing masonry work, the
Contractor shall remove all existing masonry so noted, shall do all cutting and fitting
of the existing work as required to make satisfactory connections and complete the
work in a finished and workmanlike manner. In general, the connection of new
masonry work to existing work shall be made by cutting and toothing in such a
manner that no through continuous vertical mortar joint is made and the new work is
thoroughly anchored into the existing work.
2.7.3.16 Cutting and Patching
The Contractor shall leave out or cut all chases and openings shown or as required
for the installation of the work of other trades, and make tight around same if required.
Only masons shall perform cutting and patching of masonry. Masons shall build in or
cut out all rebates for flashing as shown or evidently required. Cutting and raking shall
be avoided as far as possible by co-operation with the trades involved.
2.7.3.17 Adverse Weather Conditions
No masonry work shall be performed when the ambient temperature is below 50C
(400C F) or above 400C (1040F), or is likely to fall below the minimum or rise above
the maximum during the 24 hour period after laying, unless the approval of the
Manager is received and adequate protection is provided. At temperature below 50C
(400F), adequate equipment shall be provided for heating the materials and
completed masonry.
Temperature of air on both sides of the wall shall be maintained at 50C-(400F)
minimum. Temperature of the separate materials, including mixing water, when
placed in the mixer shall not exceed 600C (1400F). When the mortar is being used, it
shall have a temperature above 100C (500F) and the mortar shall be maintained at
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199
this temperature until it has been placed in the masonry. No masonry units having a
film of water on their surfaces shall be laid in the work.
2.7.3.18 Protection of Work
Top of new work shall be covered with suitable waterproof covering, turned down at
the edges and held in place by plank or other suitable means when work is topped.
The staging plank next to the walls shall be turned back from the face of the masonry
work when work is stopped, to prevent spattering and staining of masonry in the
event of rain. The Contractor shall protect all sills and projecting members with
suitable and sufficient boxing as a protection against mortar dropping and damage.
Bases of walls shall be protected from soil staining by covering adjacent soil.
2.7.3.19 Cleaning and Repairs
All masonry shall be cleaned and defects repaired as follows before acceptance of
the work.
Masonry shall be cleaned with trisodium phosphate and detergent, 0.24 litres of each
to each 3.9 litres of water. Before cleaning, all dirt, excess loose mortar shall be
scraped or brushed off and masonry saturated with clean water. The cleaning
solution shall be scrubbed on with still brushes as required and rinsed off thoroughly
with clean water until all mortar, dirt and cleaning solutions are removed.
As the cleaning progresses, all joints shall be examined for cracks, holes and
imperfect pointing. Defective joints shall be cut out and pointing repaired.
Sandblasting or use of commercial cleaners shall be used only with approval and only
after a test demonstration, of the suitability of the method, are acceptable to the
Engineer.
2.7.3.20 Inspection
Erected steelwork will be inspected by the Engineer and the tender price shall be
deemed to include for providing the necessary access ladders, facilities and
attendance of the Engineer when engaged in inspection work.
2.8
2.8.1
Materials
2.8.1.1
Structural Timber
Timber grading for structural use shall comply with BS 4978 and BS 5756 and shall
be used in accordance with the recommendations contained in BS 4169, BS 6446
and BSEN 26891.
2.8.1.2
Carpentry Timber
Non-structural carpentry timber shall comply with BS 1186 and shall be properly
seasoned and shall be sawn square, straight and true and shall be free from the
following:
Splits, ring shakes, soft pith; checks exceeding 300mm long or 1.5mm wide or one
half thickness of timber in depth; knots exceeding 38mm diameter or one half the
width of the surface; decayed or dead knots unless cut out and plugged; pitch
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200
Joinery Timber
Joinery timber shall be sound, well conditioned, properly seasoned to suit the
particular use and free from the defects listed under carpentry timber.
Softwood and hardwood joinery timbers shall comply with BS 1186.
2.8.1.4
Manufactured Boards
a) Blockboard shall comply with BS 3444, Grade 2.
b) Chipboard shall be resin-bonded wood chipboard complying with BS 56610.
c) Fibre building boards shall comply with BS 1142.
d) Plywood generally shall comply with BS 6566. Those from sources not included
in BS 6566 shall be subject to the Engineer's approval and shall be of equivalent
grades of veneer and types of bonding. External quality plywood shall have
Grade 2 veneer with WBP bonding and internal quality plywood shall have
Grade 2 veneer with MR bonding.
2.8.1.5
Asbestos Cement
Asbestos Cement sheets shall be fully compressed sheets complying with BS 690.
Sheets shall be sized to suit the location in which they are to be used.
2.8.1.6
2.8.1.7
Polystyrene Boards
Expanded polystyrene boards shall comply with BS 3837, Grade SD, Type A cut
boards.
2.8.1.8
Suitable Timbers
Unless otherwise specified or approved by the Engineer, timber shall be used in the
locations as follows:
Location
Timber
Teak
Teak
Teak
Teak
Teak
Teak
Teak
Teak
19mm Thick Blockboard
Hardwood lipped all round
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2.8.1.9
201
Pressure Impregnation
Preservative for timber shall be pressure or immersion impregnation complying with
BS 1282. The Contractor shall treat cut ends and notches, etc. made on Site with a
brush-applied preservative recommended by the manufacturer.
2.8.1.10
Fixing
Nails shall comply with BS 1202, screws with BS 1210, bolts with BS 916 and timber
connectors with BS 15710.
2.8.1.11
Building Paper
Waterproof building paper shall comply with BS 1521, Class Al.
2.8.1.12
Priming
Priming paint shall comply with BS 5082 or BS 5358.
2.8.1.13
Storage
Timber shall be stored under cover clear of the ground and protected form
dampness.
2.8.2
Workmanship
2.8.2.1
General
a) The term 'plugging' shall mean the provision and fixing of hardwood or approved
proprietary plugs or, at the contractor's option fixing by means of a cartridge
operated rivet gun or other approved mechanical means.
b) The term 'selected' shall be deemed to include keeping the material so described
clean for staining, varnishing or any similar finish.
c) Framed work shall be properly morticed and tenoned, wedged, glued and
crimped together and dowelled where necessary. The use of nails for fixing or
framing any items of joinery will not be permitted. Sprigs may be used for glazing
beads only.
d) All mouldings shall be worked true to details and all joinery shall be dressed and
sand papered.
e) The surface of all joinery work shall be wrought and finished so that the plane
marks do not show.
f) All nailing to joinery shall be done with fine wire nails and concealed as possible.
All framed joints to joinery in timber 32mm thick and upwards to be double
morticed and tenoned except where otherwise described.
g) The Contractor shall allow for:
i)
Priming all joinery with a coat of priming paint either before leaving the works or
within three days of delivery on to Site. All cut ends, mortices and tenons, etc. to
both internal and external joinery to be primed before fixing.
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202
Skirtings
Skirtings shall be fixed to timber grounds plugged to concrete or blockwork.
Nailing through plaster will not be permitted.
2.8.2.3
Jointing
a) All necessary morticing, tenoning, grooving, matching, tongueing, housing,
rebating and all other necessary for correct jointing shall be executed in a first
class manner.
b) Where joints are not specifically indicated, they shall be the recognised forms of
joints for each position. The joints shall be made so as to comply with BS 1186.
2.8.2.4
Veneering
Veneering shall be carried out in an approved manner and to the satisfaction of the
Engineer.
2.8.2.5
Inspection
Facilities shall be given to the Engineer to inspect all work in progress in the shop
and on Site.
2.8.2.6
2.9.
METALWORK
2.9.1
Crane Rails
Crane rails shall comply with BS 105 Light and Heavy Bridge Type Railway Rails or
be to other approved profile and shall also comply with the general requirements of
BS 11 - Flat Bottom Railway Rails. Rails shall be cold straightened and free from
twist. They shall be substantially free from pitting, laminations and other defects.
The supplier in accordance with these standards shall furnish manufacturers test
certificates.
Insofar as they are not over-ruled by this Clause, crane rails shall conform to the
requirements of Clause 2.4 herein. Rails shall receive the same protective paint
treatment as specified in Clause 2.4.
After erection of the crane girders the rails shall be accurately aligned on the girders
and fixed in position using proprietary expansion type clips approved by the
Engineer. The clips shall be bolted down with high tensile bolts tightened in
accordance with the manufacturers specification. Crane rails shall be aligned within
the tolerances set out in:
Federation European de la Manutention
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Section 1:
203
Location of rail joints shall be shown on the Contractor's drawings and shall be
positioned to avoid joints in crane girders and be located between pairs of clips.
2.9.2
Chequer Plate
Chequer Plate flooring shall be galvanised raised pattern, self-draining type to BS
4360 Class 43A.
2.9.3
Hand railing
Hand railing shall consist of galvanised tubular steel standards and tubular steel
railing and bevelled where necessary. Blisters or uneven portion of welds shall be
ground off. The tubing shall be in accordance with BS 1387 or BS 1775.
2.9.4
Inspection
Facilities shall be given to the Engineer to inspect all work in progress in the shop
and on Site.
2.9.5
2.9.6
2.9.7
Ironmongery
(a)
Hinges shall be housed into the door or windows and the frames.
(b)
All locks catches, etc. shall be properly cleaned tested and oiled and all keys
shall be clearly labelled.
Materials
(a)
Steel
Structural steel shall comply with the requirements of this Specification for structural
steel.
(b)
Galvanising
Nuts and bolts, etc. shall comply with BS 4190 and BS 1494 and shall
have ISO metric thread complying with BS 3643.
(ii)
Stainless steel bolts are to be set bolts and shall comply with BS
4190. The stainless steel for bolts, nuts and washers shall comply
with BS 970, quality EN 58 AM.
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(iii)
(d)
204
Aluminium
(i)
Mill finish.
Matt anodised.
Brush anodised.
Chequer Plate
See Structural Steelwork Section of the Specification.
2.9.8
Design
The doors shall be designed to withstand the wind forces of the area in
accordance with CP3, Chapter V, Part 2. The basic wind speed for the Site is
given in the General Requirements Section of this Specification.
(a)
Laths
(b)
2.10.
BOUNDARY WORKS
2.10.1
General
A minimum clearance of 3.0m shall be maintained throughout the site between the
innermost face of the boundary works and any structure above ground within the
substation boundary.
Adequate provision shall be made by means of uPVC pipes or openings
approximately 1 metre below finished ground level to allow the ultimate development
of the outgoing feeder cables of all voltages and the associated pilot cables to pass
through the boundary works. uPVC pipes which pass under the boundary
foundations and perimeter drain shall be encased in a concrete duct bank to the
approval of the Engineer.
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2.10.2
Fencing
2.10.2.1
General
205
Chain link fencing, gates and gateposts shall be in accordance with BS 1722, Part 1,
1972 and Supplement 1, 1974 unless otherwise specified herein.
Security chain link fence, gates and gateposts shall be in accordance with BS 1722,
Part 10, 1972 unless otherwise specified herein.
2.10.2.2
Materials
(i)
(ii)
Wire
The plastic coated wire for the fencing mesh, line wire, straining wire and tying
wire shall be in accordance with BS 4102, Grade A. Minimum diameter of wire
core shall be 3.5mm. Ultimate tensile strength shall be 250N/mm2. Wire shall
be galvanised in accordance with BS 443.
Framing and Gates
All framing and gates shall consist of structural steel sections. Sections shall be
in accordance with BS 4848 or BS 4. Circular Hollow Section (CHS) for
gateposts shall be sealed top and bottom by means of welded steel plates of
same thickness as the CHS. All sections shall be hot dip galvanised in
accordance with BS 7210.
(iii)
Vinyl Coating
Chain link fence mesh shall have a vinyl coating of not less than 0.5mm. Colour
of coating shall be dark green.
(iv)
Concrete
Concrete shall be in accordance with this Specification.
2.10.2.3
Erection
Fences shall be erected without sudden steps of changes in level. If the existing
ground is uneven, it shall be levelled to a uniform slope prior to fence erection.
2.10.2.4
General Levelling
Fences shall be erected without sudden steps of changes in level. If the existing
ground is uneven, it shall be levelled to a uniform slope prior to fence erection.
2.11
2.11.1
Classification
The complete installation shall comply with a standard approved by the Local
Authority and/or any Wiring Codes that are mandatory in the country of the
installation. Where no codes exist, the lighting system shall be in accordance with
IEC 598.
This Specification covers electric light fittings, cables, switches, contractors, L.V.
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206
transformers, socket outlets and accessories and all other plants necessary for the
completion of all lighting systems indoor and outdoor and all sockets and power
supplies required within the building.
2.11.2
Design
2.11.2.1
Requirements
The lighting installation shall be designed to give adequate illumination levels for the
respective area of the station. The installation shall also meet the limiting glare index
as set out by the approved Code.
All outdoor lighting shall be controlled by photo-electric cells and contactors shall be
suitably located. Provision shall be made for over riding remote control from the
control room. Lighting of all rooms shall be locally controlled. All outlets, terminals,
cables, boxes etc. shall be adequately rated for the load they are supplying. A
reasonable number (15%) of spare outlets shall be provided on distribution boards
for unforeseen loads.
A system of 415V 3-phase 40A sockets of approved type shall be provided indoor
and outdoor at suitable locations. These sockets shall be suitable for welding sets
and other heavy-current transportable equipment.
2.11.2.2
Coding Systems
The Contractor shall when preparing drawings showing the respective designs use a
code to identify each lighting fitting and socket outlet.
2.11.2.3
Cables
Cables shall be PVC, PVC/PVC or SWR (steel wire reinforced) depending on
application and shall be manufactured and tested to the requirements of the
appropriate standard.
Flexible type cables for pendant cords and final connections to fixed apparatus shall
be butyl or silicone rubber isolated and sheathed, manufactured and tested in
accordance with the requirements of the appropriate Code or Standard.
2.11.2.4
Cables Terminations
Termination for SWR cables shall be comprised of compression type glands with
armour and bonding clamps to meet the requirements of the appropriate Code of
Standard.
Terminations for PVC/PVE insulated and rubber insulated cables shall be comprised
of compression type glands where the function of the gland is to secure the outer
sheath of the cable, in accordance with the requirements of the appropriate Code of
Regulation. A watertight seal shall be provided between the outer sheet and the
gland.
2.11.2.5
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2.11.2.6
207
Cable Trays
Cable trays, where required to be supplied as part of the Contract supply, shall be
perforated galvanised sheet type.
2.11.2.7
Trunking
PVC trunking is preferred and shall be supplied in lengths suitable for erection in the
areas concerned. Alternatively, trunking manufactured from good quality hot dip
galvanised mild steel sheet not less than 1.22mm thick for sizes up to 100mm wide
and not less than 1.63mm thick for size up to 150mm wide will be permitted.
2.11.2.8
Lighting Fittings
Lighting fittings for interior and exterior use shall be manufactured and tested in
accordance with the appropriate Code of Standard and together with all components
shall be suitable for service and operation in the climate stated.
The lamp casing shall be resistant to corrosion and shall be of type IP65 enclosure.
All lights shall be suitable for an ambient temperature of 450C. Particular importance
is attached to easy services and low maintenance requirements.
Outdoor fittings shall be completely weather proof. Fluorescent luminaries shall have
dispersive reflectors. The fittings shall be furnished with high-pressure sodium
discharge lamps for flood lighting and low-pressure sodium discharge lamps for road
lighting. They shall be constructed of vitreous enamelled steel or equivalent.
The outdoor lighting systems shall be fed through sub-distribution boards at suitable
locations.
2.11.2.9
Switches
Switches shall be rated for 6 Amp and shall be provided with an earth terminal.
Switches for use in areas designated for surface installation shall be quick-makequick-break fixed grid industrial types mounted in galvanised malleable iron boxes
with protected dolly and arranged where necessary for multigang switching.
Switches for use in areas designated for flush installation shall be micro-break types
fixed to white plastic cover plates and mounted in PVC flush-type box.
Switches or Switch/Socket outlet combinations shall be mounted approximately 1.20
metres above finished floor level.
Live (L)
Neutral (N)
208
:
:
brown or red
blue or white
Location of all lighting fittings and sockets throughout the site, showing the
different types of equipment used.
Location of sub-boards and what fittings are sockets are fed from each board.
Location of masts etc. and route of underground cables to sub boards.
Location of emergency lights at exits etc.
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