Rehabilitation of Ghadir Sewage Treatment Plant and Khaldeh, Naameh, Damour & Jnah Sewage Lifting Stations

TECHNICAL SPECIFICATIONS DOCUMENTS

February 2015

Technical Specifications

Section –I- General Specifications

1. Definitions:

Architect and Engineer: also referred to as Design Architect or Engineer means the individual or organization

who furnished the design, which includes but not limited to the construction drawings and technical

specifications.

The “project implementer” means UN Habitat.

The “Funding Agency” means the organization, entity, or persons who have entered into a contract or agreement

with UN Habitat to achieve a development objective. UN Habitat is responsible to manage the funding provided

by the Funding Agency.

The “Supervising engineer”, or Engineer’s representative, means the person whose services have been engaged

by UN Habitat to technically monitor and administer the subcontract as provided therein, as will be notified in

writing to the contractor or stated in the Contract Data of the subcontract.

The “Owner” means the individual or organization that will own, use and be responsible for operations and

maintenance of the completed work, Beirut and Mount Lebanon Water Establishment (BMLWE).

The “contractor” means the person or corporate body whose bid to carry out the work has been accepted by the

project implementer who in this case is UN Habitat.

2. Location:

Project is located in the Beirut & Mount Lebanon premises, Ghadir Sewage Treatment Plant is located in the

Southern Suburbs of Beirut- Ouzai region, Sultan Ibrahim lifting station is in Jnah, the other Lifting stations are

located in Damour, Khaldeh & Naameh respectively on the seaside of each municipality.

3. General requirements:

Prior to any works; Contractor must obtain written approval from supervising engineer.

Approval must include proposed time table schedule submitted by Contractor, and approved by UN Habitat

WASH Engineer- Beirut Office.

Sign boards and visibility panels: (if applicable)

Contractor must provide visibility signs (sign boards) approved by the UN Habitat & BMLWE.

4. Method Statements and time table schedule:

The Contractor shall provide in a reasonably timely manner a method statement to the Supervising engineer

(Consultant) for any part of works upon request from the supervisor.

The Contractor shall also provide a detailed time table schedule on MS project or Primavera software, indicating

all the phases of the project, starting and ending dates and specific key times for any particular job and major

milestones to be achieved all along implementation period.

All schedules shall be in the English language and any system of dimensions (English or metric) shown shall be

consistent with that used in the subcontract.

An update of the schedule shall be provided, schedule of deliverables, showing the actual progress achieved on

each activity and the effect of the progress achieved on the timing of the remaining work, including any changes

to the sequence of the activities.

The contractor shall submit to the supervisor representative for approval an update schedule.

The supervisor approval of the schedule shall not alter the contractor’s obligation to perform within the period

of performance. The contractor may revise the schedule and submit it to the engineer again at any time. A

revised schedule shall show the effect of change orders, where applicable.

5. Safeguards to existing structures:

It shall be the Contractor’s responsibility to safeguard by means of temporary or permanent supports or

otherwise all existing installations, pumps cables, panels or other things which would be liable to suffer damage

if such precautionary measures were not taken.

6. Project Management:

The Contractor shall provide within his site organization a project management section to recommend and be

directly responsible to the Contractor’s Project Manager. The duties of the section shall include the following:

- Planning and program preparation particularly in relation to the requirements of the Employer and the public

authorities.

- Planning the execution of the works in a manner which minimizes disruption to the waste water system and

will permit the efficient and effective commissioning of the waste water system and their respective

components.

- Ensuring that adequate measures are taken to ensure the ongoing works.

- Continuous surveillance of progress and anticipation of factors likely to affect the timely performance of the

contract.

- Making proposal for modification to forward planning and to the program at an early stage in the light of

factors resulting from above.

- Continuous appraisal of the Contractor’s methods and routines particularly as to their effectiveness relating to

speed of execution and to their effect on the community and property.

- Forward planning for resource requirements taking due account of possible shortages and delays in the arrival

on site of materials, equipment, plant and personal and their mobilization for effective usage.

- Acquisition and process of up-to-date information for progress with the engineer. The preparation of monthly

progress reports including an update of the detailed program and cash flow forecast which shall include progress

pictures as directed by the Engineer.

7. Required standards:

Works covering the equipping of main water production facilities for the BMLWE water stations and the

distribution lines must conform to the technical specifications described later on in the tender documents.

Any reference to codes, specifications or standard means the latest edition or revision of above referenced codes

or standard.

Any work shall be manufactured (constructed), tested and installed in conformance to international standards, or

regulations applicable to such work.

The approval of “Supervisor” is a must prior to any work.

Any alternative proposal on required standards covering specifications, drawings and bill of quantities, must be

approved by “Supervisor”.

Proposed standards and codes governing this contract cover concrete, pumping units and all related accessories,

hydraulic works; steel works electrical works (cables & panels).

8. Silence of specifications:

The apparent silence of the specifications as to any detail, shall be considered as meaning “that only the best

general practice” is to be used.

In such case “Supervisor” will make the necessary and relevant interpretations covering such works.

9. Correspondence and records:

All correspondence between Contractor and “Supervisor” shall be made in English.

All records, sheets, drawings and documents shall be in English language.

Units:

The international system of metric units shall be used throughout this contract.

10. Intent of the contract:

The contract determines and specifies all the work conditions for the construction and completion of the

desired work.

Intent of contract is also the description of the work procedures in every detail enlisting all items related to:

The responsibilities and duties of the Contractor to furnish all the supplies, such as: labors material, equipment,

transportation in accordance with the plans, specifications and terms of the contract documents.

Submittal of shop drawings, (plans & sections) will be approved or returned for modifications within 8 days of

submittal.

11. Terms in the contract:

Expressions Like:

Contractor refers to the entity responsible for implementing the works.

“As shown”, “as indicate”, “as detailed” as terms of the same connotation, imply that the work should be done

according to the drawings and the related specifications.

“As approved”, “as directed”, “as required”, “as accepted” should mean and understood that the approval,

direction, requirement, permission, authorization, review or acceptance of the “Supervisor” is intended.

“Provide”, that be understood to mean “complete in place”, “that is”, “furnish and install”.

“Equal” or “equivalent” means that material or equipment will be acceptable when composed of parts or equal

quality, or equal workmanship and finish, designed and constructed to perform or accomplish the desired result

as efficiently as the named brand, pattern, grade, class or model.

12. Quality control:

Contractor is responsible for his own quality control and shall provide competent personal for supervising his

works, taking and preparing samples and for carrying out all necessary required tasks including rehabilitation,

concrete construction & casting, painting, installation of valves, installation of new toilets, providing equipment

and carrying out all necessary tests during work implementation.

13. Reporting:

Contractor in coordination with “Supervisor” will prepare and submit a detailed measurement of works that are

completed within the month frame.

Measurements are according to B.O.Q items and any addition in works greater than what is mentioned within

the B.O.Q must be within an approved work Comparison Table.

All materials that must be brought on site must be supplied in suitable containers and in appropriate batch sizes

for the work to be undertaken.

Information to be provided:

- Storage instructions.

- The manufacturer’s name.

- Shelf life and dates of manufacture.

- Material identification.

- Batch reference number.

- Net weight.

- Mixing instructions.

- Any warnings or precautions concerning the contents and their safe use;

Add to this that Contractor shall supply with each consignment of proprietary material delivered to the site,

certificate furnished by the manufacturer including:

- The manufacturer’s name and address;

- Material identification;

- Batch reference numbers, size of each batch and the number of containers in the consignment;

- Date of manufacture;

14. Refusal of delivered materials:

In case delivered articles or materials are found unsound or of poor quality, such items will not be used and must

be removed from site, and replaced by materials pre-inspected and approved by “Supervisor”.

15. Quality of supplied materials and of workmanship:

The materials and work man ship shall be the best of their respective kinds to the approval of the “Supervisor”.

The words “to the approval of Supervisor” shall be deemed to be included in the description of all materials and

workmanship for the due execution of works.

16. Approval on materials:

All proposed and supplied sources of materials, construction requirements and proposed standards should be

deemed to the “Supervisor’s” approval, the “Supervisor’s” has to approve and agree upon any standard or

method of manufacture or specification whether to maintain or change these items.

In other words, nothing related to the constructions or works, or the choice of standard materials in terms of

quality (and liability or validity) should be carried out or obtained without the ultimate approval of the

“Supervisor”.

Samples of materials shall be submitted to the “Supervisor” for approval, materials supplied must confirm to the

quality of the samples that have been approved by the “Supervisor”.

17. Damages to properties:

Any damage occurring in the course or progress of work shall be rearranged on Contractor’s expenses in

cooperation with the owners of any underground or overhead utility lines.

The damage resulting in terms of considerable expense or inconvenience shall be managed before the

continuation of work.

18. Starting out of works – Submittal of shop drawings:

Upon receiving clearance to start works, Contractor will submit to the “Supervisor’s” approval, detailed

drawings and data sheets required to start works.

Coordination will be made between “Supervisor” and Contractor, so as to agree on basic information

supplementary to that shown on submitted drawings like concrete renovation areas, gate shop drawings details,

toilets drawings and pipes’ connections…

Supplementary information will be submitted on draft drawings, sketches or in writing.

The Contractor shall submit to the “Supervisor” shop drawings that shall satisfactorily establish actual details of

manufactured or fabricated items and of works to be executed.

Shop drawings shall clarify and amplify the design drawings and other design requirements and shall,

incorporate minor changes in design or construction as may be necessary to suit the requirements of the work.

By submitting shop drawings, the Contractor thereby admits that he has determined and verified all dimensions

in relations to existing works, as well as with regards to future works on site.

Accuracy of information submitted by Contractor is under his strict responsibility and any discrepancies, errors

or omissions in supplied drawings must be corrected and then re-approved by “Supervisor”.

The Contractor shall submit final as-built record drawings to the “Supervisor” for his review by the specified

date.

After review and approval by the “Supervisor” of the final as-built drawings, the Contractor shall within 7 days

thereof, produce a final set of “as-built drawings” and submit to the “Supervisor”, one computerized disk copy

and 2 printed copies.

In case there are no changes with proposed design drawings, the contractor must obtain of the approval of

“Supervisor” prior to commence works.

19. Miscellaneous works on site:

While working on site, Contractor must keep the site as clean as possible by removing wastes, debris and other

materials to approved dumping locations.

At the end of works, Contractor shall clean the site to restore it to its initial condition, to the exception of works

he has completed.

On all occasions works shall be properly flagged.

20. Insurance:

Contractor must insure his staff and materials against incident and theft, and must also insure his site against any

incident that might occur to his works on site.

Insurance must cover the whole period of works on site.

21. Site demobilization:

Upon completion of works and after getting the approval of “Supervisor”, Contractor will proceed to the

removal of all equipment from site.

Contractor must clean the site and remove all remaining debris, materials in excess, temporary structures.

Section-II- Particular Specifications

Technical specifications for Mechanical, Electrical & Civil Works All equipment furnished under this section shall be fabricated and assembled in proper operating conditions in

full conformity with drawings, specifications, engineering data, instructions and recommendations of the

equipment manufacturer unless exceptions are noted by the Engineer.

1. Electrical Works:

Contractor will supply and apply the following:

- Ghadir:

* PLC (programmable logic controller) system to operate the pumps.

*Automatic Control Panel to control an electrical motor of 3 phases 50Hz, 380 Volts, 292 kVA or 250

kW.

a. VFD (Variable frequency drive) should be made in Europe and granted for one year

minimum.

b. Maximum Continuous current 481A.

c. Maximum transient current for 60s: 577 A.

* Air Blower: Hibon or Aerzen or any equivalent having the following specifications:

a. 0.4 bar.

b. 960 m3/hr (18 kW).

c. Complete accessories and water proofing and air filters.

* Ultrasonic flow meter system to measure the influent flow.

* Supply and Apply lighting Sodium System- 250W- For Pillars as noted in the Bill of Quantities.

- Jnah:

*Automatic Control Panel to control an electrical motor of 3 phases 50Hz, 380 Volts, 292 kVA or 250

kW.

a. VFD (Variable frequency drive) should be made in Europe and granted for one year

minimum.

b. Maximum Continuous current 481A.

c. Maximum transient current for 60s: 577 A.

* Ultrasonic flow meter system to measure the influent flow.

2. Mechanical Works:

Contractor shall apply the following:

- Ghadir:

* Rehabilitate the mechanical inlet gate; 1.5 m width.

* Screws and nuts (36 mm) are to be replaced similar to the existing ones.

* All bearings should be rehabilitated.

* Maintenance of Basins Valves (2x1m) with all the related components.

* Maintenance of Screws for 600, 700, 900 & 1500mm Valves as noted in the Bill of Quantities.

- Naameh:

* Supply and Apply industrial fan- 60x60 cm with all its accessories: This item includes, making the

proper wall openings, insertion of the fans inside an aluminium closet from above and below, re-

instate the situation as it was, clean all debris and damages.

- Damour:

* Supply and Install Butterfly Valve:

a. DN 500mm.

b. Chrome Axe, 4.5 meters height to maneuver from top.

c. All related accessories from fixation to the ground or the basin’s walls and test it to the

approval of the engineer.

All other mechanical works are mentioned in the Bill of Quantities.

3. Civil Works:

QUALITY ASSURANCE

A. Codes and Standards: Comply with the applicable requirements of the following codes

and standards:

1. ACI - American Concrete Institute.

315 Manual of Standard Practice for Detailing

Reinforced Concrete Structures.

318 Building Code Requirements for Reinforced

Concrete.

2. CRSI - Concrete Reinforcing Steel Institute.

Manual of Standard Practice.

3. ASTM - American Society for Testing and Materials.

A 82 Specification for Cold-Drawn Steel Wire for

Concrete Reinforcement.

A 185 Specifications for Welded Steel Wire Fabric for

Concrete Reinforcement.

A 496 Specification for Deformed Steel Wire for

Concrete Reinforcement.

A 497 Specification for Welded Deformed Steel Wire

Fabric for Concrete Reinforcement.

A 615 Specification for Deformed and Plain Billet-Steel

Bars for Concrete Reinforcement.

SUBMITTALS

A. Mill Certificates: Submit steel producer's certificates of mill tests for reinforcing steel

for each consignment of steel brought on site.

B. Shop Drawings: Submit shop drawings for fabrication, bending, and placement of

concrete reinforcement. Include special reinforcement required at openings through

concrete structures.

PRODUCT DELIVERY, STORAGE AND HANDLING

A. Deliver reinforcement to the project site bundled, tagged and marked. Use metal

tags indicating bar size, lengths and other information corresponding to markings shown

on placement diagrams.

B. Store concrete reinforcement materials at the site off the ground and in covered storage

shed to prevent damage, rust and accumulation of dirt or deleterious material and take

extra precautions to prevent contamination of reinforcement by chlorides in the

atmosphere, by condensation and humidity.

MATERIALS

A. Reinforcing Bars: Provide Grade 460/425 to BS 4449 or Grade 60 to ASTM A 615

deformed bars, unless otherwise indicated or specified.

B. Steel Wire: BS 4482 or ASTM A 82 and A 496 as indicated.

C. Supports for Reinforcement: Bolsters, chairs, spacers and other devices for spacing,

supporting and fastening reinforcement in place:

1. Use wire bar type or precast concrete type supports, unless otherwise indicated.

Do not use wood, brick, and other unacceptable materials.

2. For slabs on grade and underground concrete members use corrosion resistant

supports to BS 729. Where wetted base materials will not support legs use

corrosion resistant horizontal runners.

3. For exposed concrete surfaces where legs of supports are in contact with forms,

provide supports with legs which are hot-dip galvanized, or plastic protected, or

stainless steel supports type 316.

4. Over waterproof membranes if any use precast concrete block bar supports to

prevent penetration of the membrane.

FABRICATION

A. General: Shop-fabricate reinforcing bars to conform to required shapes and dimensions,

with fabrication tolerances complying with BS 4466. In case of fabricating errors, do

not re-bend or straighten reinforcement in a manner that will injure or weaken the

material.

B. Unacceptable Materials: Reinforcement with any of the following defects will not be

permitted in the work:

1. Bar lengths, depths and bends exceeding specified fabrication tolerances.

2. Bend or kinks not indicated on drawings or approved shop drawings.

3. Bars with reduced cross-section due to excessive rusting or other cause.

4. Bars with surfaces having rust, rust scale or loose mill scale or contaminated

with dirt, earth, plaints, oils or other deleterious cause.

C. The Contractor shall prepare and submit in duplicate to the Engineer at least two weeks

in advance of placement bar schedules showing cutting and bending details of the reinforcement

shown on the drawings.

INSPECTION

The Contractor shall examine the substrate and the conditions under which reinforcement for

concrete shall be performed and correct any unsatisfactory conditions. Do not proceed with the

work until unsatisfactory conditions have been corrected in a manner acceptable to the Engineer.

INSTALLATION

A. Comply with the specified codes and standards, and Concrete Reinforcing Institute

recommended practice for "Placing Reinforcing Bars", for details and methods of

reinforcement placement and supports, and as herein specified.

B. At time concrete is placed, metal reinforcement shall be free from mud, oil or other

non-metallic coatings that adversely affect bonding capacity.

C. Accurately position, support, and secure reinforcement against displacement by

formwork construction, or concrete placement operations. Locate and support

reinforcing by chairs, runners, bolsters, spacers and hangers, as required.

D. Place reinforcement to obtain the minimum coverage for concrete protection. Arrange,

space, and securely tie bars and bar supports together with 16 gages (1.6 mm) annealed

wire to hold reinforcement accurately in position during concrete placement operations.

Set wire ties so that ends are directed away from exposed concrete surfaces.

E. Install welded wire fabric in as long lengths as practicable. Lap adjoining pieces as

indicated but at least 300 mm including one full mesh for deformed wire fabric, and

two full meshes with 50 mm overlap for plain wire fabric, and lace splices with 16

gage (1.6 mm) annealed wire. Offset end laps in adjacent widths to prevent

continuous laps.

F. Provide sufficient numbers of supports and of strength to carry reinforcement. Do not

place reinforcing bars more than 50 mm beyond the last leg of any continuous bar

support. Do not use supports as bases for runways for concrete conveying equipment

and similar construction loads.

G. Splices: Provide reinforcement splices by lapping ends, placing bars in contact, and

tightly wire tying. Comply with requirements on drawings for location and lap of splices

or, if no requirements are shown or indicated, with ACI 318 for minimum lap of spliced

bars.

H. Protect reinforcement when not being worked and until placement of concrete by

covering with polythene or similar impermeable sheeting.

WORK UNDER THIS CONTRACT

A. Without restricting the generality of the foregoing, the civil works covered under these

sections of the Specifications shall include the supply and installation of the following:

1. Supply and Apply Reinforced Concrete to pour a slab of 3m x 1.1m x 15 cm having a

compressive strength of 35 MPA.

a. The slab should support the screws. Screw’s Bases should be carefully implanted

within the slab.

b. The slab is solid; reinforcement should be presented by contractor to the approval

of the engineer with all calculation notes and standards used to the design.

c. Contractor should include supporting beams in his design to the approval of the

engineer.

d. If applicable, slab should be incorporated with existing walls or any rigid

adjacent wall/ column. Contractor should (1) Drill a 10cm minimum hole with a

diameter larger than the rebar used, (2) clean the hole from debris using an air

blower or equivalent, (3) pour epoxy to the extents of the hole, (4) insert bar, (5)

clean the excess of epoxy popped out due to the rebar insertion.

e. Beams and Columns should be coated with a protective coat for protection versus

waste water aggressive environment. Coat should be approved by the engineer

and thickness not to be less than 1cm.

2. Rehabilitate the bridge steel by grinding and painting them with sea air resistant

paint.

a. Grinding should be done by a metal wire brush/ Sand Blasted.

b. Primary surface should become clean of all existing paint.

c. Fix or treat deteriorated or rusted areas.

d. Base coat to be applied to the whole surface.

e. Paint is to be applied after making sure that the Base coat is dry, paint should

have a minimum thickness of 400 microns- Sea air resistant paint- Color to be

approved by engineer.

Figure 1: Steel Bridges- Actual Conditions

3. Rehabilitate the steel gutters by grinding and painting them with sea air resistant

paint.

Ditto as item 2.

Figure 2: Steel Gutters- Actual Situation

4. Remove all manhole covers then Supply and Apply PVC covers instead that can

withstand 200 kg/m2.

Figure 3: Manhole Covers and Part of Deteriorated Slabs

5. Rehabilitate and treat the cracked concrete with special materials to fill the cracks.

a. Curing material should be certified and according to the standards.

b. Cracked concrete should be removed.

c. Rusted reinforcement should be:

- Removed if section is totally damaged.

- Re-instated: Brushed with a wire metal brush, Painted with epoxy.

Reinforcement is judged to removal or re-instatement as directed by the engineer.

d. Special grout (bonding agent between old and new concrete).

e. Concrete mix design should be presented to the approval of the engineer before

any casting process.

6. Painting of the storage area with a grey paint.

a. Old paint should be removed- a clean and smooth surface should be handled to

the approval of the engineer.

b. Putty coat should be placed in deteriorated areas.

c. Base coat is then applied.

d. Grey emulsion paint is then applied on the final surface.

Figure 4: Part of deteriorated paint- And existing Shutter

7. Remove and replace an electrical door or shutter (3mx4m) with its motor and control

button.

a. Old Shutter is to be removed and Metal case to be renovated or removed.

b. New Shutter is to be placed based on a method statement presented by the

contractor and approved by the engineer.

c. Shutter to be tested under the engineer’s supervision and to his satisfaction.

d. Shutter should be painted with Sea Air resistant paint to the approval of the

engineer.

8. Supply and apply aluminum closets for the kitchen above and below the sink with

new sink of 1.2m length and all accessories. Aluminum Closets from Above and

below (length 120cm).

9. Replace the broken glass with new one of 6 mm thickness.

10. Supply and apply a steel gate at the main entrance made of two parts 7.85m x 2.4m

movable over a steel rail and driven by an electrical motor and controlled from the

guard room and the other part will be manual driven.

a. Contractor should inspect the location of the existing fence.

b. Contractor should propose a method statement prior to the fence installation.

c. Engineer should approve all propositions and method statements.

11. Supply a steel bin for the grits having a volume of 1.5 m3- Diesel.

a. Steel bins or Dumper. Technical data sheets should be presented by Contractor

before any purchase.

b. Engineer should approve the type- the brand and the model.

c. Drive type 4x4- Max. Speed 25/28 km/h- Min. Turning Radius 36%.

d. Second Hand Types can be accepted by Engineer, a full mechanical report should

be attested for this kind of vehicles.

12. Supply and apply Penstock Valve of Stainless Steel- 316L. 102x102 cm.

a. Technical Data sheet should be presented by Contractor and approved by the

engineer.

b. Long axe of 5m should be incorporated in the valve to be able to maneuver it

from the top of the basin.

Figure 5: Standard Penstock detail with a long maneuver axe

13. Supply and Apply a guided support I-Beam d= 50cm to hold the mobile winch.

a. I-Beam should be fixed on the ceiling of the stations with exact fixation devices

to the approval of the engineer.

b. I-beam should be coated with anti-corrosion paint or epoxy.

c. I-beam should abide the ASTM A992 and to have a grade not less than 50000 psi.

14. Supply and apply Aluminium stairs as required in the bill of quantities.

15. Bathrooms and Kitchenette’s to be designed as per the drawings attached and the bill

of quantities and all material to be approved by the engineer.

16. Supply and Apply Stainless Steel Screens as defined and determined in the bill of

quantities.

17. Supply and Apply Proper Metal Collar for the 90 degrees elbows of the 300mm dia.

Pipes connected to the main pumps. Collars are to withstand the vibration caused by

the pumps. These collars are to be attached by proper stainless steel (tripod) and

attached to the existing slabs and walls. Special Roll Bolts and Base Plates to be used.

Contractor shall present a full datasheet of all material to be used. Engineer to

supervise/ approve material properties before any installation.

18. All other items are well developed in the Bill of Quantities.

CONCRETE

Concrete will be used for valves chambers and pipe anchoring. Concrete must have a minimum compressive

strength of 350 kg/cm2 at 28 days.

­ Composition:

Concrete shall be composed of cement, sand, broken rock or gravel, and water all well mixed and brought to the

proper consistency. In case of adverse weather conditions (freezing temperature),

powdered admixture shall be added to decrease concrete curing period.

The exact proportions, in which these materials are to be used for different parts of the work, shall be as

determined from time to time during the progress of the work and as analysis and tests are made of samples of

the aggregates and the resulting concrete.

The m3 of concrete shall be composed as follows:

- Gravel as per required specification with maximum gravel size of 20 mm.

- Sand free from organic materials (marine sand is strictly forbidden)

- The individual mixes will be based upon securing concrete having suitable workability, density,

impermeability, and required strength, without the use of an excessive amount of cement.

- Such means and equipment as are required shall be provided to accurately determine and control the relative

amounts of the various materials, including water and each individual size of aggregate entering the concrete.

- All batches of concrete shall be proportioned on the basis of integral sacks of cement, unless the cement is

weighed, and the amount of each individual size of aggregate entering each batch of concrete shall be

determined by direct weighing.

- The amount of water shall be determined by direct weighing or volumetric measurement.

- The amount of water used shall be changed as required to secure concrete of proper consistency and to adjust

for any variation in moisture content of the aggregate as it enters the mixer, provided that a water cement ratio

of 0.60, by weight, shall not at any time exceeded.

- Contractor is responsible for the design of concrete and shall take the approval of “Supervisor” for the mix

proportions.

The proportion of cement, aggregates and water shall be determined in accordance with (2, 3&4) BS 5328.

- Cylinders of concrete must be put on site (minimum 3 for each cast), and crushing tests will be made at day 7

& day 28.

- The quantity of water entering any batch of concrete shall be just sufficient, with a normal mixing period, to

produce concrete of the required consistency.

- Excessive over mixing, requiring additions of water to preserve the required concrete consistency will not be

permitted.

- Uniformity in concrete consistency from batch to batch will be required.

- Slump tests will be made in accordance with the Tentative Method of Test for Consistency of Portland‐Cement Concrete (A.S.T.M. Designation: D13832T of the American Society for Testing Materials.

­ Cement:

Cement for concrete shall comply with the Standard Specifications for Portland cement, and shall be C‐S 42,5

according to the Lebanese norm, also the heat of hydration of cement measured by the method of “ Bouteille

isolante” defined by “ Centre d’Etudes et de Recherches de l’industrie des liants hydraulique” shall not

exceed 70 calories / gram of cement at t= 7 days

Cement delivered in bulk shall not be used.

The quality of the Portland cement shall be equivalent to AASHTO M85, type I, II, III or V.

Cement will be delivered in bags of 50 kg each.

­ Aggregate – Sand:

Sand for concrete and grout may be obtained from natural deposits or may be made by crushing suitable rock.

The sand particles shall be hard, dense, durable, uncoated, nonorganic rock fragments that will pass a 6mm

square or a 8mm round opening.

It must be free from injurious amounts of dust, lumps, soft or flaky particles, shale, alkali, organic matter, loam,

mica, or other deleterious substances.

The sand as it is used in the concrete must be so graded that concrete of the required workability, density, and

strength can be made without the use of an excess of water or cement.

The sand for concrete shall have a fineness modulus of not less than

2.75 Nor more than 3.25, unless approval is given to use sand not meeting this requirement.

17.4­ Broken Rock and Gravel:

The broken rock or gravel for concrete must be hard, dense, durable, uncoated rock fragments free from

injurious amounts of soft friable, thin, elongated, or laminated pieces, alkali, organic, or other deleterious

matter.

It shall be so graded that concrete of the required workability, density, and strength can be made without the use

of an excess of sand, water, or cement.

The suitability of the broken rock or gravel will be determined with the aid of tests made in accordance with the

standard practices.

Any crushing, blending, screening, washing, or other operation on the broken rock or gravel required to meet

these specifications shall be done by the Contractor, and the cost thereof shall be included in the unit prices bid

in the schedule for the items of work in which the broken rock or gravel is used.

The broken rock or gravel shall be washed unless specific authority is given to use unwashed broken rock or

gravel.

The broken rock or gravel shall all pass through a screen having 7 cm square or 8 cm round openings and shall

be retained on a screen having 0.7 cm square or 0.8 cm round openings.

It shall also be separated into three intermediate sizes by screens having 2 cm square or 2.25 cm round openings

and 4 cm square or

4.5cm round openings.

Screens having openings of other sizes or shapes may be used, provided that equivalent results, as determined

by test, are obtained.

The relative amounts of each size of broken rock or gravel to be used in each mix of concrete and in all parts

of the work will be based on securing concrete having the required workability, density, impermeability,

strength, and economy, without the use of an excess of sand, water, or cement, and using, insofar as practicable,

the entire yield of suitable material from the natural deposits from which the broken rock or gravel is obtained.

For concrete used in structural parts of chambers the maximum size of particles shall not exceed 2 cm. For other

uses of concrete the maximum size can go up to 3 cm.

­ storing of cement:

Cement bags will be stock piled on site and must be protected from any damage occurring by climatic

conditions.

Cement must be transported to the mixer in its original sacks. Each batch shall contain the full amount of

cement for the batch. In case cement is placed in contact with the aggregates it must be mixed within 60 minutes

or it will be rejected.

­ sampling of concrete:

Preparation of concrete will be under contactor’s responsibility.

Approval of “Supervisor” on mix proportions must be obtained at least one week prior to the beginning of

concrete work.

Mixing proportions of cement, aggregates and water must be done in accordance with BS 5328.

Concrete must have a minimum compressive strength of 250 kg/cm2 at 28 days.

For each cast a minimum of two cylinders must be taken and stored in adequate places as specified by

“Supervisor”.

Cylinders on site will be stored in a locked place and key will be put at the disposal of “Supervisor”.

­ stockpiling of aggregates:

Batching site must have an adequate size to allow the stockpiling of materials.

Approved materials must be in sufficient quantities so work can be implemented without interruption.

All aggregates will be stored (stockpiled) before use in order to prevent segregation of material and to provide

uniform conditions for proportioning mixing control, thus obtaining a uniform concrete.

In any case stockpiling of aggregates must be approved by “Supervisor” and every precaution must be taken to

prevent segregation like not making layers above 1.5 m and in case additional layer is brought to site it is

forbidden to cone down new layer above old one.

Also aggregates must be protected against contamination from water diverted from site or from water pumped

during dewatering of ponds.

If instructed by “Supervisor”, aggregate stockpiles will be sprinkled with water 12 hours before use and this in

order to maintain moisture content in the aggregates equivalent to the water absorption value of the aggregates

as determined by AASHTO T84 & 85.

­ Ready mix concrete:

Ready mix concrete can be used specially for main boosting unit valve chambers.

­ Steel for concrete reinforcement:

All steel bars used for concrete reinforcement shall conform to the requirements of AASHTO M31 grade 60.

Contractor must submit a certificate of origin for steel used on site.

For each lot of billet steel certificate must include identification of process used in the manufacturing of steel.

Steel bars shall be tagged by the manufacturer and tag must show manufacturer’s test number and lot number

that identify the material.

­ Reinforcement of steel bars:

All reinforcement bars shall be free detrimental dirt, mill scale, rust, paint, grease, oil or other foreign substance,

fins or tears. The Contractor will not be required to remove slight rusting which discolors the metal, but he shall

remove all loose mill scale and scales rust.

Brushing to clean blue metal will not be required.

Supports, metal supports, approved by the “Supervisor”, shall be provided and used to retain the reinforcement

at proper distances from the forms. Supports under horizontal bars slabs shall be spaced at not more than eighty

(80) diameters of the bar.

All reinforcement shall be so rigidly supported and fastened that displacement will not occur during

construction. Reinforcing steel shall be inspected in place and must be approved by the “Supervisor” before any

concrete is deposited.

Reinforcing steel shall be stored above the ground on plate forms, skids, or other supports. It shall be stored in

such a manner and adequately marked to facilitate inspection and checking.

When placed in the work, the reinforcing steel shall be free from dirt, detrimental scale, paint, oil or other

foreign substance.

All cutting and bending of reinforcement bars shall be done by competent workmen and with equipment

approved by the “Supervisor”.

All reinforcement bars shall be cut and bent in an onsite fabrication shop. Bent bar reinforcement shall be cold

bent to the shapes shown on the plan, and unless otherwise provided on the plans or by written authorization of

the “Supervisor”, bends shall conform to the following requirements:

D= 6d for five (5) millimeter through twenty two (22) millimeter bar sizes.

D= 8d for twenty four (24) millimeter through twenty eight (28) millimeter bar sizes.

D= 10d for thirty (30) millimeter and over bar sizes.

Where:

D= minimum pin diameter around which a bar may be bent d= bar diameter.

All reinforcing steel shall be accurately placed and, during the placing of concrete, firmly held by approved

supports in the position shown on the plans.

Reinforcing bars shall be securely fastened together; reinforcement placed in any member shall be inspected and

approved before any concrete is placed.

Laying or driving bars into the concrete after placement will not be permitted.

All horizontal reinforcement shall be supported on metal supports or spacers as approved by the “Supervisor”.

The use of small stones or wood blocks for supporting reinforcement will not be permitted.

The reinforcement shall be held securely in place at the proper position and spacing as indicated on the plans by

the use of wire ties at bar intersections and tying to the supports and spacers.

The adequacy of the supports and ties to secure the reinforcement properly shall be subject to the approval of the

“Supervisor”.

­ Falsework & Formwork

Construction of concrete structure requires proper implementation of various jobs needed to complete works.

Work consist in furnishing and placing Portland cement concrete for structures in accordance with the

specifications and conformity with the lines, grades and dimensions of drawings and plans.

Falsework

Where needed and whenever asked, Contractor must submit detailed plans for falsework.

Falsework design must provide rigidity to with stand and support loads without excessive settlement or

deformation.

Falsework columns shall be mounted on wood or metal bases when it cannot be supported on rock, shale or

thick deposits of other compact material in their natural bed.

In no case, and unless it is on foundation footing, falsework will not be supported on any part of the structure.

Spacing of false work columns in the general framing must be approved by “Supervisor”.

Falsework and centering shall be designed and constructed to support the total anticipated loads with a

deflection not to exceed two one thousandths (0.002) of the falsework span.

The Contractor shall submit calculations to support this requirement for all spans over 3 meters and other spans

if requested by the “Supervisor”.

The Contractor shall provide means for accurately measuring settlement in false work during placement of

concrete and shall provide a competent staff (Forman of skilled labor) to observe to observe and correct the

settlement.

Timber used in falsework must be composed of sand wood in good condition and free from defects that might

weaken its strength.

Note:

In designing forms, concrete will be regarded as a liquid having a weight of 2,400 kg per m3, and not less than

1,400 kg per m3 shall be assured for horizontal pressure.

Formwork

Forms must be rigid to withstand pressure of concrete or any other incidental loads that occurs during

construction including vibrations.

It must be mortar tight and free from opening, it shall be designed to permit easy removal without injury to the

concrete.

Form lining material shall not bulge, wrap or blister, nor shall it stain the concrete. Form lining shall be used in

the largest practicable panels to minimize joints.

The joints in the lining shall be tight and smoothly cut.

Forms shall be maintained after erection to eliminate warping and shrinkage. They shall be checked for

dimensions and condition immediately prior to the placement of concrete.

Metal forms may be used and are subject to the same requirements and approvals specified for wood forms.

The inside of all forms shall be oiled with light, clear, paraffin base oil that will not discolor or otherwise injure

the surface of the concrete.

The oiling shall be done where possible after the completion of the forms and prior to placement or

reinforcement.

The width and thickness of the lumber, the size and spacing of studs and Wales shall be determined with due

regard to the nature of the work and shall be sufficient to ensure rigidity of the forms and to prevent distortion

due to the pressure of the concrete.

All curved surfaces shall be formed with approved plywood or steel.

When the Contractor instructed by the “Supervisor” shall submit formwork drawings and calculations to the

“Supervisor” in advance of the concreting.

Formwork shall be of such accuracy, strength and rigidity as to carry the weight and pressure from the concrete

to be placed on or against it.

Formwork shall be sufficiently tight without plugging to prevent loss of grout during the vibration of the

concrete.

Faces of formwork shall be clean, free from projecting nails adhering grout and other imperfections or defects.

Formwork shall be treated with approved mold oil before positioning.

Formwork shall be such as to allow for its removal without damaging the concrete and in the case of suspend

floors for the removal of the beam sides and slab sophist without disturbing the beam bottom boards and their

props.

Before concreting, the areas which are intended to receive the concrete shall be cleaned by jetting with

compressed air and all water extraneous material removed.

Where timber is used for formwork it shall be properly cured free from warp straight, clean and free from loose

snots.

Tolerance

Unless otherwise indicated on the drawings, the tolerances of the finished concrete with respect to the

dimensions shown on the drawings shall not exceed the limits set out in the following table. Formwork shall be

constructed to ensure completed work within the following tolerance limits:

Departure from established alignment: 0.5 cm

Departure from established grade: 0.5 cm

Variations from plumb or specified batter in lines and surfaces of columns, piers and walls: 0.5 cm in 3 meters,

if exposed

0.5 cm in 3 meters, if backfill

0.5 cm in 3 meters, if exposed

Variations from level or indicated grade in slabs, beams etc...:

0.5 cm in 3 meters, if backfill

Variation in cross sectional dimension of columns, piers, slabs, walls, beams: ‐ 0.5 cm + 0.5 cm

Variation in slab thickness: ‐ 0.5 cm + 0.5 cm

Footing: plan dimensions: ‐ 0.5 cm + 0.5 cm

Eccentricity: 2 percent of footing width, not exceeding 5 cm

Reduction in thickness: 2 percent of specified thickness

Immediately after the removal of the forms, all fins caused by form joints and other projections shall be

removed and all pockets cleaned and filled with a cement mortar composed of one part by volume of Portland

cement and two parts sand. Sufficient white Portland cement shall be mixed with the cement in the mortar, so

that when dry, the color will match the surrounding concrete.

- Painting

All painting (internal and external surfaces) shall be applied in conformity with the manufacturer’s

recommendations.

All interior paints for Ghadir Treatment Plant will be covered by washable Latex – Based paints.

Paints shall be washable, of a perfect solidity and shall allow a flawless application.

Surfaces that must be painted shall first be cleaned, and sand papered before the application of the first coat of

sealer.

A second sanding shall be followed by the application of a primer coat.

Finally two (2) paint coats shall be applied in conformity with the colors and samples approved by the engineer.

For exterior surfaces a plastic paint ready to use under the form of a unctuous thixotropic paste will be used; it

shall be composed of vinyl maleate resins or water, the painting must adhere perfectly and be totally waterproof

and offering a perfect resistance to chemical agents, heat and fire.

Before any commencement of application of the paint, contractor must make sure that all surfaces are clean,

without grease and dustless.

The contractor shall apply a primer coat (undercoat) acting as a surface regulator and then will apply two coats

using an alxeolroll.

Application must be in thick layer and must be starting from down toward upper zones.

The product must be applied in important quantities but not spread.

- Tiling

Tiling will be used for floors and walls of the bathrooms as instructed by the supervising engineer.

The contractor must take all necessary measures to ensure complete protection for tiling works and this until the

taking over.

Cement mortar for wall tiles and skirting’s shall be composed from one part of Portland cement and three parts

of sand (Volumetric dosage)

Cement used must conform to B.S.12 and sand must be clean free from dint, clay particles and other impurities.

For wall tiling contractor must use a white ceramic enameled tiles 20cmx20cm, and skirting 10x20cm.

Ceramic tiles must be of a first grade quality and have to be resistant to acids, bases, grease and hydrocarbons.

They must be tested under a 400kg/cm2 load during manufacture.

For floor tiling, contractor must use concrete tiles not less than 3 cm, or cement mosaic tiles 20x20cm.

Mosaic tiles shall be of local manufacture and shall consist of two layers:

A wearing layer of 7 mm minimum thickness

A base layer constituted of a mixture of sand and cement proportioned at 350 Kg of cement (7 bags) for 1 m3 of

sand.

The minimum thickness of the tiles shall be 200 mm, and must be highly resistant to abrasion.

- Surface finishing

Surface finishing of works shall be in strict accordance with the General Technical specification and shall

include the protection of materials and the surface treatment.

Exposed surfaces shall have no unevenness, burrs, or metal run-out. Salient angles and projecting parts shall be

rounded off. Welds shall be carefully ground. Screws shall be inserted and then painted. Accessible bolts shall

be covered. Element showing appearance or assembly defects shall be rejected. It is expressly forbidden to

cover and hide these defects.

- Protection of metals against corrosion

No metal part shall be accepted on site unless previously protected against corrosion.

Elements shall be in factory protected according to relevant applicable standards. Unprotected iron parts shall be

painted after removal of calamine, rust, and oil, with a rust proof zinc chromate paint, 60 microns thick,

compatible with the top coat specified in the relevant section (or eventually with two coats of red lead).

Immediately after installation, any painted surface showing imperfections due to impacts or handling shall be

wire brushed and repainted.

- ALUMINIUM WORK

Contractor must provide aluminium stairs:

Aluminium shall be new, free of defects. The aluminium shapes used for stairs shall be of the extruded “solid”

or “hollow” type with the main web having a minimum thickness of 2mm. The supplier shall be submitted for

approval.

All aluminium parts shall be anodized.

The anodic protection shall meet the requirements of B.S. 1615 or B.S. 3987. The color of anodizing shall be in

accordance with samples approved by the Engineer.

Aluminium alloy shall be 50 AGE, anodized over 18 microns, satin silvery color or any color as specified.

The Employer may require all necessary tests to be conducted in an approved laboratory to ensure the

conformity of the aluminium with the requirements.

Aluminium shall have the following mechanical characteristics:

Elastic limit at 0.2% 15 kg/mm2

Breaking load 20 kg/mm2

Modulus of elasticity 5.700 kg/mm2.

- WATER PROOFING, INSULATION of Concrete Beams & Columns

The provisions of this division shall apply to the:

Concrete Beams and the Columns to be implemented prior for pipes’ joints fixation.

The provisions here below shall apply to the materials, products and execution procedures concerning the

waterproofing of the reservoir roof covers and the building roof terraces.

Waterproofing approved membranes will be one layer of 4mm minimum thickness (minimum 4.7 kg/m2 with

protection):

- Plastomeric (Atactic Polypropylene = APP)

The assembly of manufactured sheets will be by torch welding.

These membranes will generally be self-protected from the factory (mineral self-protection).